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View Full Version : My REAL Jeep pickup build up, Project Comanche


Nutbar
01-14-2010, 03:36 AM
Well I figured I should finally start a build thread since I have a few pics now.

This is my 87 Comanche short box pickup, I have had it for a few years now. It was my daily driver for quite a while till the frt end fell apart, hence the start of a new build on it. I bought it with a 3 in lift and 31s, it was a 4.0L, 5 spd, and dana 44 rear end. I did a quick mickey moused 8 in lift on it (but we won't talk about that other than to say it was a showcase of what NOT to do) and 33s and I drove it for a little while. Then it got a power plant refit, I swapped in EVERYTHING from the doors foward from a 92 Cherokee Ltd. It got loaded, LOL, 92 4.0L HO engine, auto tranny, full time part time transfercase, and almost every interior option that was available for the XJs (some options that were not even available for the Comanche from the factory), also 4.10 gears, and a Detroit Locker for the rear. I drove it like this for years and started collecting parts to do a real diff swap in the frt. Then the OE frt diff started falling apart and the truck got to the point that it was unsafe to drive and I didn't want to waste any money repairing the pile of crap that is the Dana 30. So here we are . . .

The new build at the moment is some diffs and suspension swap in the old girl. I have a pair of 88 Wagoneer Dana 44 axles and a Rubicon Express long arm suspension set to install.

The shop . . .
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The Comanche . . .
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The old parts . . .
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The new parts . . .
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The belly pan . . .
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Starting the frt diff mock up . . .
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Installing high steer arms . . .
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Changing Rubicon Express's game plan (making it Mikey tuff, LOL) . . .

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That's it for now more progress pix to come . . . and the test flogging:D

D-Ass
01-14-2010, 04:21 AM
[36] you know what i say all ready [cheers]

yoda thrills
01-14-2010, 06:25 AM
looks good, i can tell this ones gonna be a gooder, keep up the good werk

F150HULK
01-14-2010, 08:14 AM
Keep it comming Mikey!!!! Looks awsome! [36]

Always broke
01-14-2010, 08:32 AM
Now this is a lesson on how it should be done!!!!

hilltoptoy
01-14-2010, 08:44 AM
Sweet truck .

UU
01-14-2010, 09:34 AM
nice pics

lincoln locked
01-14-2010, 09:59 AM
wow now thats beefy looks like you will be romping in that unit

crazylike
01-14-2010, 09:59 AM
looking pretty solid nice welds :)

Tunabomber
01-14-2010, 10:23 AM
lookin good mikey

keep us posted dude [cheers]



any plans for the box.....maybe a bob job for better tree fitting

vajayjay
01-14-2010, 10:26 AM
I'm liking this

Keep it up[cheers]

'Balmer
01-14-2010, 10:58 AM
Great work man!!! Very impressive fabbing and welding. Looks like you've got the same axle and bracket combo that I have. I wasn't happy with the truss either but I don't have the room to do one like yours so I'm looking for "low-profile" options. The question I have for you is this: When you welded your truss on, did you weld to the cast housing with your mig or did you switch over to stick with nickel rod? I keep hearing that you need to weld with a nickel rod if your welding mild steel to cast. I've seen this on several fabrication forums as well as 4x4 sites. If you used your mig, did you have to make any adjustments when you welded to the cast section? I'm a fairly novice welder when it comes to electric... I'm super old fashioned and actually learned how to weld on a gas set-up, so any tips would be helpful. Again great work on your build! Looks like it's going to be one serious rig! Friggin awesome shop too - I'm jelous!

C-Dog
01-14-2010, 11:11 AM
Now this is a lesson on how it should be done!!!!


Couldnt have said it better my self man Mikey that looks killer man its definaltey going to be a kick ass rig for what u r building it for i really like the work u do there is time and lots of thought that goes into it

[36] [36] [36] [36] [36] [36] [36] [36]
[cheers]

MuddyWheeler
01-14-2010, 12:06 PM
Sweet!!!:D

atoyot
01-14-2010, 12:33 PM
nice ....

REZ
01-14-2010, 12:40 PM
great fab work

Nutbar
01-14-2010, 01:15 PM
lookin good mikey

keep us posted dude [cheers]
any plans for the box.....maybe a bob job for better tree fitting

The only plans for the box is replacing the rotted out one with one I found that is super nice shape. This truck is my daily driver/parts getter/camping rig, it is already a short box (6 ft box on a jeep) and I have a canopy for it to go camping with if I bob the box I won't be able to sleep comfortably in it any more. What I do plan on doing with it is some rock sliders and some exo work, since I know it will get wheeled after all this is me, and my driving skills:D should get me around any vehicle size/length issues.


Great work man!!! Very impressive fabbing and welding. Looks like you've got the same axle and bracket combo that I have. I wasn't happy with the truss either but I don't have the room to do one like yours so I'm looking for "low-profile" options. The question I have for you is this: When you welded your truss on, did you weld to the cast housing with your mig or did you switch over to stick with nickel rod? I keep hearing that you need to weld with a nickel rod if your welding mild steel to cast. I've seen this on several fabrication forums as well as 4x4 sites. If you used your mig, did you have to make any adjustments when you welded to the cast section? I'm a fairly novice welder when it comes to electric... I'm super old fashioned and actually learned how to weld on a gas set-up, so any tips would be helpful. Again great work on your build! Looks like it's going to be one serious rig! Friggin awesome shop too - I'm jelous!

Most of the dana housings and knuckles are forged steel not cast iron, so welding to them is not a complicated process. I used the mig to weld the truss on you don't need any special filler rod/wire as it is steel you are welding. The only thing you have to watch is depending on the thicknesses of the pieces you are welding you want to do some preheating and post heating to prevent stress risers in the forging do to temperature differences. When I welded that truss on I used the torch to warm up the housing and truss before I welded it and as I was welding it and kept it warming it up afterwards to slow the cooling as I didn't have any insulation to wrap it in.

Also when I welded the truss to the pumpkin I had a pinion and carrier bolted in the housing so the housing was "pre stressed" and everything was flexed to where it wants to sit. This is done to prevent any extra stress on the housing when reinstalling the gears and carrier do to the heat warpage from the welding.

DIRTDIGGLER
01-14-2010, 01:20 PM
Good job,sweet shop,going to be a very nice rig [cheers]

Explorer guy418
01-14-2010, 03:19 PM
nice shop man... :D awesome work.

SHITTY
01-14-2010, 04:20 PM
sweet build keep the pics coming . i want your shop

bakelite
01-14-2010, 04:41 PM
Beautiful work Mikey, love the Comanches [36] I had one a few years ago and enjoyed the hell out of it. NICE build buddy [cheers]

BeerBaron666
01-14-2010, 04:44 PM
Looking good Mikey[36][cheers]

Arnee
01-14-2010, 07:07 PM
looks awesome mikey. if you need a quick hand at anytime, grab my number from bryson i'm not far away to lend a hand

yoda thrills
01-14-2010, 11:37 PM
hey Mikey, when can Dustin and my self com chek out your new set up, guess theres no more shops nights due to the fact that you moved eh?
either way, u never fail to impress me man [cheers]

Happypants
01-15-2010, 12:00 AM
Looking good mikey, my original plan was to do up a manchee, slice the back frame off and tube it all but was having troubles finding on in good/satisfactory condition, keep us updated man, looks wicked,

Troy
01-15-2010, 12:51 AM
nice clean organized shop

brackets look good

In The Zone
01-15-2010, 09:22 AM
Looks great Keep up the progress

harleyfatboy99ca
01-15-2010, 09:34 AM
Now this is a lesson on how it should be done!!!!
[iagree] keep up the good work[cheers]

Jeepnut
01-15-2010, 10:16 AM
sweet.....i want one[36]

J20
01-15-2010, 02:45 PM
nice werk Mikey

Nutbar
01-18-2010, 01:28 AM
couldn't get motivated this weekend so this is all I got done.

cleaned and painted the knuckles and high steer arms
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the finger was for the one who shamed me into adding a few speed holes
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Explorer guy418
01-18-2010, 08:34 PM
looks great dood

jonny6door
01-18-2010, 09:26 PM
i hope you used pre and post heat treatments welding to the pumpkin.

FKN MRK
01-18-2010, 10:22 PM
The only plans for the box is replacing the rotted out one with one I found that is super nice shape. This truck is my daily driver/parts getter/camping rig, it is already a short box (6 ft box on a jeep) and I have a canopy for it to go camping with if I bob the box I won't be able to sleep comfortably in it any more. What I do plan on doing with it is some rock sliders and some exo work, since I know it will get wheeled after all this is me, and my driving skills:D should get me around any vehicle size/length issues.




Most of the dana housings and knuckles are forged steel not cast iron, so welding to them is not a complicated process. I used the mig to weld the truss on you don't need any special filler rod/wire as it is steel you are welding. The only thing you have to watch is depending on the thicknesses of the pieces you are welding you want to do some preheating and post heating to prevent stress risers in the forging do to temperature differences. When I welded that truss on I used the torch to warm up the housing and truss before I welded it and as I was welding it and kept it warming it up afterwards to slow the cooling as I didn't have any insulation to wrap it in.

Also when I welded the truss to the pumpkin I had a pinion and carrier bolted in the housing so the housing was "pre stressed" and everything was flexed to where it wants to sit. This is done to prevent any extra stress on the housing when reinstalling the gears and carrier do to the heat warpage from the welding.

[cheers] :D

D-Ass
01-18-2010, 11:03 PM
couldn't get motivated this weekend so this is all I got done.

but you looked so fresh and clean;)

FZJ80
01-24-2010, 01:22 AM
Looks even better in person, very nice workmanship.

Evan the Blue
01-24-2010, 08:45 AM
Great work Mikey ... as always
I don't think I've ever seen the shop so clean
Keep us updated [cheers]

UU
01-24-2010, 08:50 AM
some of those speed holes look a little crooked to me


just sayin :dontknow:

Nutbar
01-24-2010, 09:40 AM
some of those speed holes look a little crooked to me


just sayin :dontknow:

[33] Asshole












































































:D

Always broke
01-24-2010, 10:43 AM
So are they gonna whistle at speed????

bakelite
01-24-2010, 01:16 PM
They are angled down at the front to act as a spoiler so Mikey don't wheelie so much at the mud drags. [36]

Apathy
01-24-2010, 01:59 PM
i'd be worried they fill up with mud and lead to corrosion.

Nutbar
01-24-2010, 03:30 PM
The mud in the Wendy's parking lot is pretty light and should slip right off the protective layer of Armor All and wax that everthing is gonna get, so I'm not worried:D

Tunabomber
01-24-2010, 03:32 PM
The mud in the Wendy's parking lot is pretty light and should slip right off the protective layer of Armor All and wax that everthing is gonna get, so I'm not worried:D



what he says is accurate

Nutbar
02-06-2010, 10:35 AM
Well it's been a little bit but here is some more pics. I ordered a couple new parts and now they're here.

I decided to try the new Yukon Gear Zip Locker, Yukons version of an ARB locker. Gonna try the Zip Locker in the frt diff and put my OX locker in the rear diff.

OOOOOOOO Shiney
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The Zip didn't require any bearing cap clearancing for the air line (at least on the D44 any way) like you have to do with an ARB
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I didn't care for their way of shimming the carrier. On the bearings that they used on the carrier, the bearing sticks out past the outside of the race so they have to use a thick spacer ring with the bearing and they give you some external side shims as well in the usuall .030, .010, .005, .003 thicknesses
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and as per Yukons instructions they want you to assemble the bearing, spacer, and shims in this order
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after several attempts to load the carrier into the housing and the shims not cooperating resulted in this
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so I went against Yukons instructions and wound up assembling the parts this way
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The seal ring side was no problem as the thick spacer and shims are sandwiched between the bearing and the seal ring
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all installed
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and a little paint
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TOYLESS
02-06-2010, 10:52 AM
Can I have the sticker & did you where your resparator....:D

theborges
02-06-2010, 02:26 PM
Dang that is looking sweet mike.

4skin
03-01-2010, 01:13 AM
nice fab work niceshop
is that a 64-65 chevell hidin in the corner???

Toyquad
03-01-2010, 08:29 AM
awesome work man!

UU
03-16-2010, 09:21 AM
is it done yet ???


[f]

Nutbar
03-16-2010, 03:01 PM
I finally spent some more time with the Comanche, got side tracked with The spudspudspudspudspud Run and some projects on the big CJ. So now back to the pickup and get some shit done.

I have done a little more work and have some pics to post just didn't feel like it last night, maybe tonight:dontknow:

Nutbar
03-17-2010, 12:28 AM
a couple'o'pics my lazy ass got to resizing . . . here ya go

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Moondog
03-17-2010, 12:31 AM
Looking good Mike[36]

Chopstick
03-17-2010, 01:03 AM
man that looks good,
nice shop

Happypants
03-17-2010, 08:45 AM
Looking good dood [36]

England
03-17-2010, 08:58 AM
Nice work Mike

Pudge
03-17-2010, 09:05 AM
dayammmm, looks pimptastic!! sexy wheels tooo

great work as usuall Mikey!!

aarong
03-17-2010, 09:30 AM
looks damn good

bakelite
03-17-2010, 09:52 AM
Looking awesome Mikey! [36]

regulate34
03-17-2010, 10:12 AM
wow that is quite the fab job man
looking extreamly tuff

Tinker
03-18-2010, 03:27 PM
Does it hurt knowing ur that good? Looks sweet Mikey!

MacGyver
03-19-2010, 12:25 AM
Very nice work :)

FZJ80
03-19-2010, 07:56 AM
Looks dam fine Mike, 35s?

Nutbar
03-19-2010, 11:40 AM
Yeah, those are some old school 35-12.50 bfg mud ta's

Used to be street rubber for the cj

Happypants
03-20-2010, 12:17 AM
Coils arnt bent or sideways or anything, quality workmanship mikey! Can't wait for ya to take it out and beat the piss out of it [36]

bcbugger
03-20-2010, 11:06 AM
sweet ass truck man[36]

dirka dave
03-20-2010, 07:57 PM
Done yet ?


:D

harleyfatboy99ca
03-21-2010, 09:22 AM
Nice work Mike[cheers]

UU
03-21-2010, 09:28 AM
:confused0006: one of the speed holes looks like it might be off by a 1/16th

atoyot
03-22-2010, 08:04 PM
nice work on the jeep bud!!!!!!

ouch!!!!!!!!!!
that positive Jeep talk kinda hurt a bit....

North49
03-22-2010, 09:22 PM
wow sweet rig! even if it is a jeep!