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Jeep TJ-6 (cut a 98 tj and added 15")

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18K views 26 replies 9 participants last post by  Pat/Rick  
#1 ·
Jeep TJ-6 (cut a 98 tj and added 15")

Hello my name is Ziptie (Jason). I use my jeep as a woods access tool not just a wheeler. I am an avid elk hunter and fisherman. I also have a wife, small boy and a dog. The TJ is just too small for my needs at this point in my life. It has become a struggle to take the family into the woods. This need for more space has inspired my TJ-6 build. I am building up my TJ and stretching it out to fit a LJ top. I will have a LJ tub with the rear overhang of a TJ.

The TJ stats:
98 TJ sport, 4.0, 5 speed, SYE, D30 open, D44 Detroit, geared to 4.56, 33’s, 3.5” lift, winch, CB, hard & soft top.
This set up has worked well for many years but it is time for the jeep to grow with the family.

The TJ-6 build plan is to improve the size and ability. Keep the center of gravity low and able to drive at 65 MPH all day.
The TJ-6 stats (in addition to TJ stats):
Stretch- LJ soft top, TJ rear overhang, I will be using the back of a LJ tub and Poison Spyder custom corners
Tires- BFG AT’s in 35x12.50-15 (got used in a trade), I just want to try out AT’s 
Axles- upgrade the front D30 to a Rubi D44 and lock it
Gearing- axles stay at 4.56, but add a NWF Black Box with 2.72:1 low
T-case Skid- I will build a flat skid and also raise the engine 1”.
Lift- use my 3.5” and add 1” of body
Wheels- Spyderlock beadlocks in 15x9
Gas tank- raise existing tank 1”
 
#3 ·
Re: Jeep TJ-6 (cut a 98 tj and added 15")

Removing the TJ tub.
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I found a wrecked LJ tub in a bone yard, the back was still good. I have been storing this thing and dreaming of this day for 8 months. I will be using the floor, rails, and modifying the wheel wells for added storage. The rear will also be trimmed up to TJ spec’s.
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Front D44 upgrade:
I found a Rubi D44 housing in a add for $400. I had it geared to 4.56 w/ a lockright, and installed some G2 shafts. I do not plan on going bigger than a 35 with this jeep, so this axle should be all I need.
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#6 ·
Re: Jeep TJ-6 (cut a 98 tj and added 15")

Going to be one of a kind.. lot's of work and talent going into this project.. awesome so far.. I know the BFG/ATs are popular.. most here swiching to the Pro Comp AT's they are severe weather rated .. the run them year round
 
#8 ·
Re: Jeep TJ-6 (cut a 98 tj and added 15")

My 14 year old cousin came over to help out. This was his first time with a welder and a plasma cutter. He did great! Maybe he will start looking at getting a jeep for his first rig…..

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Mounting the LJ tub:
We prepped the LJ tub for welding to the TJ tub. We installed the tub then mounted it to the frame. Checked it all out and started welding it up.
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At the point on the floor that the TJ & LJ tubs meet we added some supports.
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#9 ·
Re: Jeep TJ-6 (cut a 98 tj and added 15")

Maximizing the added room:
The plan is to get the most room out of the stretch as we can. We decided that the stock LJ wheel wells could be improved, this is what we did.
Used- 18 ga. Sheet metal, 3/16 x 3”, 1/2x1/2”


Made a frame for the sheet metal, and tied the corner to the tub support with 3/16th
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We graded the floor 1/4” so water would not puddle in the corner.
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The passenger side is the same.
 
#11 ·
Re: Jeep TJ-6 (cut a 98 tj and added 15")

I checked to make sure things were all still working together and installed some bumpers. The bumpers are to hold the upper passenger side of the tailgate tightly shut and stop the swing out from hitting the tail gate when open. I used the factory ones and just trimmed them a bit.
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Added the rear cage, I used bars from a LJ.
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#12 ·
Re: Jeep TJ-6 (cut a 98 tj and added 15")

Building the flat skid.
I used ¼” plate with ½” spacers off the bottom of the frame. I then used “C” chanell for the cross and added plate to the bottom to stiffen and protect the needed holes. I also used “C” cannel for the Black Box mounting point.

FYI- It took me 3 to 4 times the amount of time I had planned to build this skid and install the Black box and set up the shifters.

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#18 ·
Re: Jeep TJ-6 (cut a 98 tj and added 15")

Started up the cage upgrades. Used some PSC parts and 1.75x.120 DOM. It is all just tacked in at this point. I still have to beef up the rear before pulling and painting the cage. I do not have a bender or notcher but I am happy so far.

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#20 ·
Re: Jeep TJ-6 (cut a 98 tj and added 15")

That stuff gets my heart pounding... That is an outstanding rig you put together there.. Always wanted a Jeep, and was shopping for one a few years ago but found this first and couldn't resist! A 65 Chevy K-20 4x4 with a 283, all stock and completely original. All it needed was to be driven! ;D
 

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#22 ·
Re: Jeep TJ-6 (cut a 98 tj and added 15")

Nice job! Got any pics? ;D
 
#24 ·
Re: Jeep TJ-6 (cut a 98 tj and added 15")

Great job on the build, Zip. I'm a Jeeper myself, and although I spent a grewat deal of time with recreational wheeling, I'm moving more to a hunting/utility application.
Here's my specs.
1999 TJ, red with tan soft top
2.5 4 cyl, 5 speed
OEM limited slip in the rear and Lok-Rite in the front
4" Rough Country X Series lift
4.56 gears 31x10.50 all terrains
Ramsey 8K winch
48" Hi-Lift jack & assorted straps and shackles for recovery.
I used to run 32x10.50 Swamper TSL Radials, but switched to all terains for comfort and longevity. I've also ran 32x1.50 Cooper STT's and will most likely buy another set when the A/T's wear out. The Swampers were top notch off-road, but they don't last long on the road and will beat you to death.
GH1 :)