Project Swiss Cheese, Project Slow Devil, Project Redwood, Project POStal — they are four legends that, against all odds, went from hopeless rustbuckets to road tripping kings and then beasts on the off-road trails of Moab, Utah. If I could pull those off, and if I could fix the unfixable Willys FC in Washington and Chrysler Valiant Ute in Australia and if I could get the $600 Chrysler minivan through Germany’s inspection, then surely this stripped-down Jeep Grand Cherokee ZJ that has sat abandoned in a Van Nuys, California parking lot for a year (and that sat abandoned for many years before that) should be no problem, right? Wrong. Here’s why my 2024 Moab Easter Jeep Safari build could be my hardest one yet.
I realize I’m the Boy Who Cried Wolf at this point when it comes to fixing cheap, dilapidated junkers given my history:
But trust me when I say: This time really is different.
Times Have Changed, And Wrenching Just Doesn’t Come Easy Anymore
It’s not about the project being the very hardest of any I’ve ever undertaken — I think that belongs to either the 1948 Willys Jeep (which needed significant engine and transmission work), the Postal Jeep (which needed a huge length of the frame welded back up, and also engine work), or Project Cactus (that Valiant Ute that needed pretty much everything). Still, this Jeep has never run under my ownership, it’s a complete mess inside, it has no driveshaft or exhaust, and frankly I know nothing about it, so it really is going to be tough even if I had time. But nowadays things have changed for me. I’m working hard to make this website, The Autopian, sustainable, and the precious time that I do have off I’m devoting to my girlfriend, whom I’ve somehow avoided scaring off for over 13 months now. I also find myself constantly sick — it’s a cold, it’s COVID, it’s the flu, it’s a sinus infection. It’s just a never ending illness shitstorm that really started when I got to California.
There just is no time for this Jeep project. And beyond that, my wrenching circumstances are far from ideal. No, I’m not living in a Toyota Land Cruiser down by the river and getting literal Trenchfoot, but I also don’t have a garage to work in, and that’s gonna be a first for any of my projects. Mind you, the arrangement isn’t bad: I’ve recently been granted this little space at the back of a parking lot — a space for which I am deeply grateful:
It’s covered, and reasonably flat, and I should be able to do some high-quality wrenching out there. I need to figure out how to store my tools in a secure way, and I’ll need to figure out what to do about lighting, but this is a solid arrangement — a little tougher than my usual setup, but solid. I’ve done tons of driveway wrenching in my day (often at below-zero temperatures) so I’m not too worried about this.
I’ll be able to make the space work, but whether I’ll have the time to fix this Jeep, especially given that I don’t have the Jeep contacts / friends I used to have in Michigan, I’m unsure. This project is one I’ll likely have to do entirely on my own. The last project I did the vast majority of work on was Project POStal, and that was nearly the death of me. And that was when I was single and didn’t have a site to keep afloat.
So this is going to be impossible even if it were a medium-difficulty build, but I suspect this will be more than that.
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The video above shows when I bought this Jeep back in 2021 for $350 out of a lumberyard in Virginia. The previous owner had snatched the manual transmission out of it, the exhaust was missing, the headliner was gone, and frankly — it had been stripped for parts. But the body looked decent, the rare manual transmission-ECU was there, and it was a factory-original manual ZJ that deserved to be saved from the crusher, especially since I knew of a second factory-original five-speed ZJ that had a transmission but was completely rotted out. Here you can see my friend Dustin and I wrenching on that rusty Jeep, removing parts:
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So I paid $350 for the 100% complete-but-rusty Jeep, and after Dustin and I pulled a bunch of parts off of it and jammed those parts into this red ZJ, I hauled the dead red machine from Michigan to California when I moved last year.
The more I look at the ZJ, the more I love it. Good size, reasonable weight, solid axles are flexy and durable, nice comfortable interior, decent ride, reliable, good visibility, and more handsome each day. (Also the fully loaded U-Haul is somehow doing 11 MPG @ 65mph!) pic.twitter.com/PFVl6GRuPl
— David Tracy (@davidntracy) February 13, 2023
It’s been sitting in my work parking lot ever since. Here are some pictures from earlier last year:
Here’s how it sits today:
At least the body remains reasonably rust-free:
So, what all do I need to do to this thing? Well, everything. Here’s a basic list off the top of my head.
PHASE 1: Essential Repairs
- Install shifter
- Install custom brake pedal that my friend made. Install new (longer) brake hoses that can handle a lift kit when I install one; bleed brakes.
- Replace the radiator, shroud, and coolant overflow bottle (I have spares of each in the Jeep). While the rad is out:
- Do the water pump and thermostat for good measure
- Find a power steering pump (there may be one in the Jeep, if not, it’s junkyard time) and install that
- Install serpentine belt
- Replace engine mounts (they’re cracked; I have new ones in the back of the Jeep)
- Install airbox and air intake tubing (install new air filter)
- Install new header panel, grille, headlights
- Hook up starter motor
- Change engine oil
- Install new 12-volt battery and try to crank the motor over with the spark plugs out. Reinstall new spark plugs, along with distributor and rotor. Maybe coil.
- Drop fuel tank and clean it out (I’m told the fuel system is bad; the Jeep hasn’t run in years). Replace fuel filter/hoses as necessary
- Try to fire up the engine
- If the engine runs well, good. Install new exhaust.
- Now it’s time to rummage among my driveshafts and try to find two that fit. If I have none, I’ll have a shop modify my shafts. Install those.
- Replace fluids in drivetrain. Then I’ll start driving the Jeep around, checking various systems.
PHASE 2: Lift, Skids, And More Off-Road Mods
- Install custom junkyard lift kit (about 3.5″). Maybe it makes sense to make the driveshafts AFTER installing the lift. We’ll see.
- Install all-terrain tires (31×10.50)
- Strip interior, disinfect, get rid of cat feces smell.
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- Install new seats and carpet and headliner from rusty Jeep. This will require me to weld a nut to a broken seat bolt and extract it (damn rust).
- Install skid plates for fuel tank, transfer case. Install rare rear tire carrier as part of the fuel tank skidplate installation process.
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PHASE 3: Underwater Breathing & Axle Beef
- Install snorkel
- Install new 3.73 axles, replacing the weak Dana 35 rear axle with a Dana 44 and swapping the Dana 30 up front for one with the right gears. (I have the Dana 44 (see above); I need to find a 3.73 Dana 30 at a junkyard)
- Find steel Jeep Liberty KJ steel 16″ wheels. Install 265 75R16 tires (these are 32s; they look better than 31s on the ZJ).
- Bolt up sway bar disconnects for improved articulation
There are probably a million things I’ve forgotten about. All I know is: This is daunting, and the only way to get through it is to follow a plan. Phase one is to just get the thing on the road. From there, I can worry about making it off-road worthy.
But the Easter Jeep Safari is at the end of March. Is three months enough time? I fear not. Especially since I’m doing this alone. Gulp.
you could probably save a bit of coin and/or time by finding a running and driving version in cali that already passes emissions and then use your parts jeep to make it special AKA manual with the funky spare tire carrier.
https://losangeles.craigslist.org/sfv/cto/d/studio-city-1997-jeep-grand-cherokee-zj/7704189487.html
This one is either a scam or the continued price drops indicate he is desperate, at any rate the v8 would mean better axles already but I am not sure if it would be easier or harder to swap the manual on tot he motor, or just regress to the inline six. it might be a difficult thing to pass emission with a different motor altogether.
Lol no such thing as “regressing” to the might high output 4.0
Sure, things are different now in your life, and I’m still stoked that your move West went so well for you!
I sincerely doubt your skills on the spanners have waned, you just need to get back into it and follow the process.
First step for me would be to empty the interior and make sure you have everything you need, since you’re likely to be going solo on most of this and any repeated trip to the shops or junkyards is just going to burn up time you don’t have.
Write up a comprehensive check list of what you need and get those parts organised into tubs/boxes!
From some comments below on CA emissions, it might be worth trying to locate a complete CA-emissions ZJ and find out if there was any differences so that box is ticked early.
We both know you can do it, like any gains at the gym it’s going to require dedicated time and consistency which will depend on your negotiating skills!
David, you can do it, but I suggest maybe crowd sourcing, has to be plenty of Autopians in Cali who would love to pitch in! I would if I lived close to you.
Came here to suggest this. Another Autopian meetup. A crowd could get phase 1 done in an hour.
I think that was his plan but I’m a cynic. He’s in hollywood. the producers motto is time and money. If you have enough of each then anything is possible. but he doesn’t have much of either
I don’t know about you, but if I were taking that Jeep off the beaten path, I’d definitely want to install a zebra zone-toughened windscreen and some anti-burst locks. Oh, and one of those little pine tree air fresheners.
find one in every car. you’ll see
The life of a repo man is always intense.
David Tracy Mad Libs
I have _____ days/weeks/months to repair this _____ for a trip to _____. I’m screwed.
Then David always succeeds like the A-Team. He loves it when a plan comes together. The success of Project Cactus proves anything is possible. Maybe you can import some of the Cactus Aussies for an assist.
Don’t let a crummy lift “upgrade” ruin your Jeep.
You know better.
If you’re “saving” it then you can easily run 235/75R15 on a ZJ with working stock suspension. Lift kits don’t tend to save Jeeps.
The ZJ needs a little pump-up to do some of the trails I like. Low sills, low front chin, big arse. But a little lift goes a long way.
There were a lot of places out west I couldn’t go in my Fleetwood. Big arse problems.
Did end up on an “off road” 4×4 road in Kings Canyon. It did fine.
Depends on what you’re doing with it. For something around town most of the time, don’t lift it. But he’s planning on actually bashing Moab with the thing, and a stock ZJ will not get very far rock crawling.
David you have the Wrangler that is fantastic for rock crawling. He doesn’t NEED it to be a crawler. so why not keep it closer to stock. If you are “restoring” if for the “grail” ness.
This is where I am confused. If you need a crawler, I get it. but he has the other jeep. if this is for yet another epic build like Project POSTAL or the CATCUTS project then that is fantastic but then why “complain” that your work at the Autopian is getting in the way. this is literally part of your work for the site. not trying to be a jerk I swore. But I agree with many here that this is an opportunity for your to source help from your many fans. But I don’t think its cool at this point to make it a negative thing about your workload here. We love your site and many like myself pay money to be here so we get that this is a job and its hard work but make the best out of it. I love cars and I wish more than anything that I could work here and make my passion my job and get paid for it instead of having to slave at a 9 to 5. You are living many of our dreams.
It’s not a negative thing, it just is what it is.
As always, at the outset of all of my projects, I lay out the obstacles in my way. This time, time is the largest one.
RE: living the passion. I spent 3 months professionally restoring old Alfas and Ferraris as I was thinking about changing career. I thought making a living out of my passion was a no brainer, but it’s not the same when you have to wrench to pay the bills. I’m back at a 9 to 5 that pays enough to allow my to enjoy wrenching on the side, which is preserving my automotive passion instead of rapidly eroding it.
So don’t blame DT if it’s sometimes still a job to him, and beware of living out of your passion, it’s not for everybody 🙂
So much this. A decade ago I was studying to become a Mechanical Engineer until I realized I preferred it to be more of a hobby than a job.
For me at least, an easy way to ruin something I enjoy is to do it repeatedly whether I feel like it or not and to make my financial well-being contingent on it.
Yup. That’s why I don’t fly nor go to air shows anymore. My first job killed that flame.
So not sure what the plans are now but this was originally supposed to be a long distance overlander with room for spare parts, sleeping inside, and camping gear and supplies. That’s why he’s modifying a ZJ instead of just driving the YJ.
If this is meant to be street driven and not towed everywhere, priority for Phase 1 should be getting it to pass smog. I had an old crappy ZJ pass smog, so it’s not impossible, but I wouldn’t throw money and parts onto a car that can’t pass.
There’s no critical structural repairs or proving road worthiness to the government. It’s practically halfway done already!
Believe in you, DT! If you need random reader assistance, i have airmiles to burn. And a low level of personal safety requirements.
That latter bit is key. I’m for it!
Time to check my work schedule- Texted my wife, all she has to say is “I want to go to the EJS!”
Dave that respiratory illness is an allergy to pollution called the crud. I had it for 14 months when I moved to CA. Get a good air purifier preferably one that ionizes.
Second, since when does a off-road vehicle need a headliner, back seats, etc? Stick to the necessary parts and save time and effort.
This is surprisingly probably true. Even with the C.A.R.B. doing it’s best to make the air better, I immediately get sinus issues when I have the unfortunate need to travel to California for work.
If my research is correct their is an inversion between the mountains and the coast. The air is blowing in from the ocean keeping the pollution over land and the mountains Block the heavier polluted air. So it just gets so thick you can not only see it but taste it.
I have to admit the surprisingly true comment kinda hurts. LOL
but I think David is in the valley protected by the mountains.
I thought he and the auto dealership were in LA.
The valley is LA. It gets confusing, there’s LA the city, which isn’t very big, then there’s LA county which is big, then there are cities that is in LA county that is incorporated and unincorporated.
The Valley is LA incorporated, the valley itself is made up from a number of cities.
Yeah I lived up in Eureka and then later in Santa Maria. It is weird I got the crud up in Eureka not a very polluted area but I remember it unhappily. So not too familiar with much south of Santa Rosa learned most from watching CHIPS
the valley is not LA, the santa monica mountains create “the valley” as in the san fernando valley where galpin is and I would think David lives near. maybe too much time at the girlfriends place in oh, santa monica? small price to pay
I would always get hit with the crud when I flew into Ontario Mills for work in and around Mira Loma.
I’m familiar with the valley. It’s actually the opposite; the mountains trap the smog and keep it in there. It only goes away when we get some crazy wind for a few days that finally blows it all out. Then it’s clear for a few days until it re-accumulates and goes back to normal.
As much as I deeply resent CARB for making engine modifications more frustrating and complicated, SoCal has a legitimate reason for having a separate set of standards for air quality. Whatever pollution is produced here gets concentrated and takes way longer to dissipate.
I know some older folks that told me that back in the 60s the smog was so bad that you couldn’t see the mountains 2 miles away from you.
You just explained why the smog check program exists in California. Smog sits over the main population areas thanks to topography.
Well I tried wasn’t sure of terms etc.
I figured it might be rust withdrawal.
Dear David,
It’s me, owner of Jeep. I’m here to tell you, if you show up to Jeep Safari in a Ford Bronco again. I will take away all your current Jeeps, and ban you from preserving/acquiring/ occupying or looking longer then 4 seconds at all future Jeeps. Get wrenching.
Your’s trail rated,
Seymour P. Jeep
Jeep was legit not happy about that. May have been why I didn’t get invited to the 2024 Wrangler debut!
Man, you skip dress code once and they disinvite you from their birthday party! tough crowd.
Should have just taped a Jeep badge on it. lol
“Ford? No! It’s the new Wrangler JM!”
My colorado zr2 is black with black bow ties. I plasti-sprayed the rest of the logos black. I bought toyota medallions and stuck them on. The fan boys think it is a Hilux…
Not sure who really got the worst of that (you not invited).
Maybe you can go to the Youtube’s OffRoad games by MORR?
After reading the list of just the critical items and looking over the photos, I concur…. you’re screwed.
Doesn’t matter if you get it road worthy, doubtful you can get it to the level of passing CA inspection and emissions…. You can always tow it to Moab with the i3…
What in CA inspection would be harder than New South Wales, other than emissions testing?
If it’s going back together with fresh brakes, suspension and the tyres aren’t old junk I don’t see why it couldn’t pass just like Project Cactus has gone through all inspections with flying colours.
California emissions are particularly tough. The motor might also be from a state without California emissions and therefore lack some crucial and operating smog equipment.
So you raid a junkyard ZJ for the components to pass the visual inspection if they’re different to what you’ve got and run a newer, more efficient catalytic converter and you’re mostly there?
it’s not the visual part that is tough usually, but certainly if the engine is running even a little bit close to the year’s numbers, then that is OK. tired engines with blow by caused by sitting a while can be tough to make come around for cheap though.
Any catalytic converter sold in California must be California certified. Looking at Magnaflow’s site, a CA certified universal cat for his Jeep is about $500 and a direct fit is nearly $1000.
If the entire vehicle is a 49-state model, then it’d be smogged in California as a 49-state model and any components present on a California-emissions model but missing from a 49-state model would not be required. You’re not required to “upgrade” it to California standards to register it in California.
that is interesting, I was not aware of that. I was told my 91 caprice was not able to be smogged in California because it was not a california car. Part of what saved me from a life in the high desert.
Whoever told you that was very uninformed or flat out lying. One of the things a smog tech has to enter in the computer is whether it’s a CA or 49-state emission car, and that dictates the tailpipe passing limits and the physical equipment that the smog tech is required to visually check for.
A guy I know recently had issues smogging his 49-state 1978 Lincoln Mark V. It has a 460ci engine which was not available in California (400 was the biggest in CA) and as such the emissions equipment is different. It got failed by a moron smog tech for this unfortunately and the owner eventually had to take it to a CA smog referee to get cleared up, but once there the referee had no problem smogging the car as a 49-state car with a 460 and fixed the records.
NEW JEEP WRENCHING CONTENT!!!! LETS GOOOOOOOOO!!!!!!!
:snf:
Our little rusty boy is growing up. Welcome to true adulthood, my friend.
You missed the most important thing to your current living situation. Passing smog in Cali.
See if you can do a crossover with MotortrendTV. Get hooked up with Roadkill Garage and “Don’t get it right. Just get it running.”
Freiburger and Dulcich would likely buy it afterwards to make it their own even.
Or Ian of Big Tire Garage. Or Fred Williams from Dirt Every Day is in Cali somewhere.
I will say having a relatively clean shell to start from is a major upgrade from previous projects. This project looks positively pleasant compared to the rustier ones before it. Sounds like DT needs to shine the Bat signal and get some wrenching help to get this done.
Yep. I fully agree. Having other people will make the job so much better. We are social creatures, so use it.
I don’t know a lot about Jeeps, but I know one thing for sure. Wrenching in the LA winter is much better than wrenching in the Detroit winter.
Another year, another impassioned plea to start with something less desperate. Maybe something on life support instead in need of a full lazarus.
But I want to save this rare gem!
You should, but maybe not for ejs
I need deadlines!
What are you doing posting here?!? Get your butt out into the parking lot!! Move! Move! Move!
It’s almost like a… Holy Grail.
Full Lazarus is the way to go, I love reviving cars
Don’t tell me you forgot to get that special gal a pink overall for Christmas.
At least you don’t have winter weather to deal with
You will NEVER get the smell of cat shit out DT. I once had a VW bus that had housed several cats for a time, before I got it. Even a power washer could not remove that stench, ever.
And as usual, this will be another half assed attempt to make a car out of a metal turd.
Maybe you could get your girlfriend to help?
Some things never change.
I haven’t tried it, but I keep seeing commercials for “Pooph” spray, which supposedly works for situations like this. $15 bottle may be worth a shot.
Enzyme cleaners do seem to be most effective. As a cat owner, I can say they work fairly well, but not well enough if it is fabric that has sat with the smell for an extended period.
FWIW a good shop wet/dry vacuum and hot water alone can do miracles. With just that I was able to remove an entire bloody regurgitated mouse mess that had absolutely soaked into my carpet AND pad to the point it is undetectable by sight, smell or ultraviolet light. Same with cat pee as long as its chased with a good enzyme cleaner.
On that note, not all enzyme cleaners are created equal. Look for ones that are bacterial based with live cultures. Those will colonize the stain and continue to eat at it, even multiplying until its completely eliminated, then (hopefully) go dormant until more “food” becomes available. IMO industrial grade ones are best.
Yogurt is always the answer.
I dunno, maybe? Given how awful sourdough starters start out I wouldn’t be surprised to find those stink eating bacteria in sourdough starter, yogurt and other unexpected places.
Ozone generator, like $50 on amazon. Crank it for a couple hours, come back the next day and repeat. Also, vinegar in a large surface area container does wonders on odors.
All this of course is removing the actual cat piss first. But between vinegar and the ozonator, you should de-stank it.
This is the correct answer. I’ve see (smelled) ozone machines take impossible smells out of cars many times, all without removing the interior at all.
I have an indoor cigar bar/man cave, and between the air filter for the particles, and ozonator for the smell, you’d never know.
Exactly. My cousin bought a 84 Accord that was owned by a 3 pack a day smoker. One hour with an ozone machine in it and there was no smoke smell anymore.
Careful with those. We used one to get the smoke smell out of pianos that had been in house fires. In a couple cases, 24 hours in a room with a generator degraded rubber stuff to an almost dried-clay state: touch it & it crumbles. Could be very bad for windshield & door seals. I know I lost a rubber valve cover gasket I had been warming on the window sill after shipping: for got about leaving it there, ozone generator ran all weekend, and it came apart when I picked it up
bmw warranty told me that the higher ozone levels in LA caused my timing belt to brake just outside the warranty. I ended up paying for the water pump, all else covered
Did you ask them why non BMW cars don’t have that problem?
The trick is to use it for a couple of hours max, and then just let it sit. Running constantly is not good.
I have revived several cars in worse condition than this. One of them was totally full of either racoon or cat poop. The smell was quite bad.
I vacuumed and scraped out as much as I could, then I pulled the carpet and power washed the snot out of it. Then I power washed the floors in the car.
Nothing will survive that treatment. That interior is as clean as it was when it left the factory.
Fabrics and foams can all be replaced. If its etched in to the paint or whatever, that can be sealed over with quality sealing primers if nothing else will get it out. Kilz is making some serious stuff, that while not officially an auto product, would likely work awesome to seal coat the interior of a vehicle before reinstalling carpet and seats etc. Totally doable if none of the ideas below worked out.
Do not underestimate the dark and awesome power of cat pee. I’ve heard all the stories of this product or that product working miracles. There is no one miracle product. The only thing that defeats cat urine odor is money. You have to money-whip it into submission.
The previous owners of a house I bought years ago had, unknown to me, kept a litter box in a seldom used bathroom. Their cat (ONE CAT!) apparently had terrible aim. I subsequently found out they brought in a heavy duty cleaning crew and deodorized the bathroom when they put it up for sale to cover up the scent. Two weeks after moving into the house, the smell returned like a punch in the face. After trying everything imaginable with the odor always coming back, I finally brought in a crime scene cleanup operation. The lead guy, who cleans up truly terrible things, said to me there’s nothing he can do. Cat urine that has dried and crystallized into any porous surface leaves only one option…
I had to actually demo the bathroom. Replaced the walls, the subfloor, sawed off the bottom two feet of the studs and replaced with new wood (because cat urine wicks up), painted every surface with coats of Kilz, new drywall, new tile, new everything. That, finally, got rid of the odor.
For your Jeep I’d do the following. All upholstery (including the seats themselves), carpet, foam, headliner, cloth (including seatbelts) has to go. Leave no soft surfaces! When only hard surfaces remain, clean the daylights out of it, then ozone machine (use a professional outfit, I’m sure Galpin has somebody they use) then paint any surface you can with Kilz.
The good news is that it’ll make a great article!
I got my current house for a huge bargain because of cat pee. Luckily it was concentrated in a few boards of the wood floors. We had those boards replaced and the rest of the floors refinished. The I remodeled the whole house to at least a livable state and moved in 3 months later. Cat pee can mean a bargain, but you’ll have a lot of sweat equity invested.
The headliner is already on its way back to its ancestors’ land
I mean, since this bit is part of the plan, he’s probably going to be okay…
I just have to say way to go on being so ambitious David but you don’t have to rush yourself too much…even if you miss the Jeep Safari there’s always next year. That is a lot of work and you’ve already got a lot going on. I’m sure you’ll get the majority of it though
This is proof that David had become such a seasoned rust belt wrencher that he is going through withdrawal from the reduction of oxidized iron and tetanus flowing through his veins
I was thinking that he previously spent most of his time alone or with a few specific people and now is exposed to a much larger population consistently, kind of like when a kid starts school and is sick all the time.
But, I like your answer better.
I think you’re right. I was in solitude A LOT in Michigan.
But maybe the rust thing is right, too.
Regardless of what it is that’s causing it, I really do hope you can get a reprieve from it and start to feel well more consistently soon!
Thank you!
My eldest was in preschool this year, kindergarten next year so I can commiserate. It’s brutal. She’s had a runny nose since February and everyone else has been sick on and off about every month.
Soon we will be invincible though *Mr Burns fingers*
Are you allowed to have MRIs at this point?
David is welcome to visit Maine and I can have him stand downwind of my flap wheel grinder as I touch it to pretty much any part under my Tacoma. Rust dust city. He can opt to NOT wear a dust mask if he needs the Fe203 back in his life.
Jeep kitten updates please, when you have a moment.
You can do this David. We’ve seen you take considerably sketchier vehicles to MOAB, and this time you don’t have to get there all the way from Troy.
That’s true. It IS a shorter drive…