Project Phoenix Buggy *FOR SALE!*: The Beast from the East

[OverkillZJ]

Project Phoenix Buggy: The Beast from the East

Some of you might remember a couple of years ago when I decided to revive my rusty Jeep into a nice and capable vehicle, with the goal of making it to Grand Slam West 2004.
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There was a massive thread on NAGCA: http://www.nagca.com/forum/viewtopic.php?t=12581

It’s contents have been copied to MallCrawlin as well (hella faster server), more or less as an archive: http://www.mallcrawlin.com/forum/showthread.php?t=3992
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I also put together a video of that years crazy trip, which can be downloaded (or $5 for the DVD.)

RIGHT CLICK, SAVE AS!

High Resolution – (320 MB) http://www.bigassjeep.com/video/phoenix2004webhigh.wmv
Low Resolution – (96 MB) http://www.bigassjeep.com/video/phoenix2004weblow.wmv

And the last video is the most recent video of us beginning the buggy build. It’ll probably be the last video for awhile until the project is done, and tested. Then will come the best video yet!

Anyway, RIGHT CLICK, SAVE AS! (35 MB) http://www.bigassjeep.com/video/phoenixteaserweb.wmv
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So That should bring you up to speed. The Jeep really did better than I imagined and I abused it as it was meant to be abused. I took it to Moab for GSW in 2004 and 2005, as well as a few weeks of other wheeling out west both years. Of course it was amused back east too. I kept breaking it and fixing it.

After abusing it that much, and flexing it (not to mention jumping it) so many times without a cage, it took its toll on the unibody. When it got to the point where I could no longer really open or close the doors without effort, as well as blowing up 2 more ball joints and yet another locker in the front HP30, I decided that enough is enough. I’ve grown accustomed to the type of wheeling which a full bodied ZJ can only survive so many times. My Jeep was well past that “so many times” mark. I felt like I had 3 options: sell it for next to nothing, part it out and get the already destroyed frame hauled off and crushed, or build it into a BUGGY. Being obsessed with offroading, and being rather attached to my ZJ, I chose to buggy it, and build it big to the point where I shouldn’t really have to worry about breaking things so much.

So here’s the plan:

-gut it
-cut it up almost down to the frame rails
-Build a full roll cage (you’ll see details on plans for that later)
-ditch the weak driveline to go with
-14 bolt rear w/ Detroit locker and disc brakes (4.56)
-HP60 front from a 79F350 with 35 inners, outers, drive flanges, ARB (4.56)
-Full Hydro
-e350 master cylinder
-Stak 3 speed tcase
-Corbeau suspension seats
-Waterproof sound system
-41.5” Irok
-Either driveline brake, or line lock (more likely skid steer) on the rear brake line
-Radiator and tranny cooler moved to rear / upper cage



I’m sure some of the plan will change throughout the project, but that’s the starting point anyway. I have some talented help, mainly Steve (blackbox renegade) who’s a certified welder and all round likes working on crap as much as I do; and Dave (DMG) who’s a REAL mechanic and good with gears and driveline while I just like to pretend.



First, a few pictures or how it looked in Moab just a few months earlier.









And the darn thing even got a few shots in an issue of 4 Wheel Drive and Sport Utility Magazine. Here’s a link to one of the pics: http://4wdandsportutility.com/freestuff/05104wd_moab_02_1280.jpg


So let’s get to it. Day 1: begin parting it out and cutting it. There was a whole lot of shock factor. There’s a video of this day here: (right click save as) http://www.bigassjeep.com/video/phoenixteaserweb.wmv


































































I consider this thread “chapter 2” of Project Phoenix. It’s the same vehicle (well, kind of) – just the next phase!

I’ll keep updating as things happen.

[TrojanMan]

looking good :beerchug:

[OverkillZJ]

Here’s the second day of cutting it up. We were hoping to get the front end and back cut down to the frame rails, but Steve felt like crap, I wasn’t motivated, Heidi didn’t know what to do, and Dave was just amused watching us be stupid for a lot of it.

We still got some done, and got to brain storm a little bit.





























Ya, I’m cheap enough to save the 50 cents of washer fluid from the reservoir we removed from the ZJ…






SO MANY FREAKING WIRES TO DEAL WITH! In one wiring harness, there’s speaker wires, light wires, tail light wires, FUEL PUMP WIRES, etc. It’s going to be a huge project just figuring out what I need.

I always thought the radiator and fan shroud could be removed while the fan was still installed, I just didn’t think it involved cutting the front crossmember off! That’s the only cutting we did all day, the rest was taking apart the engine compartment and the rest of the interior, except the dash.


This is where we just sat there saying… Now what?

[OverkillZJ]

I picked up my new rear axle today. This was a score! Military surplus... It’s a 67.5” wide 14 bolt, STOCK from GM with 4.56 gears, a Detroit locker, Disc brakes, etc. As is, stock from GM. Definitely a rare find.

This thing is 495 pounds as packaged, and 450 pounds out of the crate. I took it out myself too, I was a little too anxious.






Here you can see what was stamped on the box: GM Rear axle destined for the US Military. I think my buggy is a better use!


Here’s after I got it all unpackaged. Steve and I area going all the way up to Buffalo New York tomorrow morning (bright and freaking early) to pick up a pair of 60’s, but the trailer I’m using is SCARY when unloaded. We’re leaving the 14 bolt on it for dead weight.


Here’s after practicing backing up with a trailer, A LOT, haha. I got it about .5” from the tree.



Now time for bed, need to leave here at 7am tomorrow to ALMOST get there on time.

[Kraqa]

your very darring to chop the from cross member with the motor in there. thos frame rails are WEEEEEK. i woudl bolt the stock rad support back in ther eto hold them from seperating. at least till youget the motor out of there.

[OverkillZJ]

Meh, oops.

[zj95]

whos wk?

[OverkillZJ]

Originally Posted by zj95

whos wk?

Dads. Traded him my lil' Corolla for a few days, I DEFINATELY got the better end of this deal.

It came with a corporate gas card too, makes moving axles around cost me ahemmm NOTHING.

[zj95]

sweet

[ogdak]

Wauw, this is gonna be a interesting thread again.

[Kraqa]

WOW Who's the handsome devil in the passenger seat?

[Elliott]

only bitches ride bitch seat

[Kraqa]

what does that make you riding in the back seat then?

[TrojanMan]

Originally Posted by Kraqa

what does that make you riding in the back seat then?

bitch who takes it in the back

[deadman]

Nice score on the 14b!

[cmarley]

Overkill I am new to this site but want to know what you are going to do with the lift you currently have under the zj when you full buggy it? consider selling it...?

[OverkillZJ]

Only going to be selling the springs and maybe front track bar. The LA's stay!

[ATL ZJ]

I like the Evan Williams tranny shifter...

How much support does the stock xmember really provide?

[OverkillZJ]

Originally Posted by ATL ZJ

I like the Evan Williams tranny shifter...

How much support does the stock xmember really provide?

LOL @ the tranny shifter.

I don't know how much support the stock xmember really provides up front, I think that Kraqa was just worried about the frame rails spreading under the weight... But I'd argue that it's the engine that kept them in place (tieing both sides together).

I put it back in for good measure anyway, can't hurt, right?

[ZJake]

Originally Posted by deadman

Nice score on the 14b!

x2. where'd you find that setup and at what price? Boyce Equipment? 14b is what I'd like to do also .

[OverkillZJ]

Originally Posted by ZJake

x2. where'd you find that setup and at what price? Boyce Equipment? 14b is what I'd like to do also .

Came across ebay seller whitejeeprubicon - it's an offroad shop in TN. I think they might have one left.

he was asking $1,299 but let's say that he'll come down a lil'

I dont' even know if he knows the history of these, fromthe looks of the auction he might not know what he has.

http://cgi.ebay.com/ebaymotors/ws/eB...ayphotohosting

1986 military overstock.

[ATL ZJ]

That's a lot for a 14b .. even if he came down to half price. I guess it is new and has a locker in it though.. but still, wow.

[BigDaveZJ]

Originally Posted by ATL ZJ

That's a lot for a 14b .. even if he came down to half price. I guess it is new and has a locker in it though.. but still, wow.

4.56's, detroit, and disc brakes, BRAND NEW, and it's a lot???

[OverkillZJ]

Originally Posted by ATL ZJ

That's a lot for a 14b .. even if he came down to half price. I guess it is new and has a locker in it though.. but still, wow.

What kind of weed are you smoking and can you please send me some?

Price out what it costs to build a 14 bolt. An old rusty 14 bolt you need to clean up yourself and replace all bearings, seals, probably install new gears, odds are hunt down a detroit, not to mention fab up brackets, or buy brackets for a disc break conversion. Guess what the price comes out to? About that ebay auction. No, more. Plus labor.

That's a lot of work I don't have to do now. Not to mention the gears were set at the factory, and still have the gear marking compund on them.

Shipped, in it's original GM crate, perfect and new. you're saying half of $1200 is still too much? Dude, GIMME SOME OF THAT WEED!

[ATL ZJ]

It's going under a buggy. Drums will provide more than enough braking power for that light pile of tube. I know you can find 60s with 4.56s, and even as low as 5.13 if I am not mistaken, that came in them stock. The same *should* be true for the 14bolt, or at least close.. And you aren't going to be daily driving something on 41.5s, so why go with a Detroit? Might as well just spool it, or even weld the carrier. More predictable on the trail, and you aren't going to be driving it to soccer practice anyways. Even if it needs a rebuild kit, those can be had for the 14b for $152.. But I wouldn't really mess with that unless those were clearly bad. And as for the bright and shiny housing, well you're going to have to grind off a lot of that pretty paint to add brackets and most likely a truss. I'd rather be knocking off rust and dirt with a wire wheel than semi-gloss. Maybe I'm just a broke college student, but snagging a 14bolt for $85 at my local junkyard and doing it the simple way just seems a little more attractive.

Continually lowering my standards,
Cam