Most of the time, products are built around a vehicle. This time, a vehicle was built around a product. Frank Currie spied American Expedition Vehicles' Highline body kit for Jeep TJ Wranglers at its Moab debut three years ago. Plans for a Jeep buildup were instantly set in motion. AEV's kit includes a stamped-steel hood, stamped-steel front fenders, four fender flares (two front and two rear), and a pair of battery-tray supports. Although the Highline kit is topnotch in fit and finish, its appeal goes well beyond the aesthetic and firmly into the functional. The Highline body kit raises the front fender height and creates extra room beneath. Taller fenderwell cavities mean that larger tires will fit at much lower lift heights. Lower lift height means a lower center of gravity and greater ease of ingress and egress.
Frank's Highline TJ (left) is sitting on a set of 37-inch Goodyear tires. A stock-bodied TJ (right) sits on 35s. Which sits lower? Yes, the ground is level, and no, your eyes do not deceive you.
Before going further, a bit of background is in order. The Highline-equipped Wrangler on these pages is far from Frank's first Jeep. Instead, it's the latest in a series. Prior to building the Highline TJ, Frank put together a red, V8-powered TJ on 40-inch Goodyear MT/Rs called the Strangler. The concept behind the Strangler was to have "the ultimate all-around Jeep." It turns out that 40-inch tires make for tough going if daily driving and general trail riding are on the menu. As such, Frank decided that his Jeeping world was better off with two vehicles. The first would be built for trail riding and general exploring, and it would be street-driven. The second would be a hard-core rock buggy capable of taking on whatever series of obstacles could be thrown at it. The Highline TJ is the first on Frank's two-Jeep list.
Frank's blank TJ canvas appeared on a used-car lot in completely un-glorified form. It was a base model with a four-cylinder engine under the hood and a delectably low asking price. It couldn't have been more perfect, as the buildup plans called for nearly every major component to be replaced. Frank pulled his new prize into his home garage, and the transformation began.
Fitting the AEV Highline kit was the first order of business. The hood simply bolts in place of the stocker. The front fenders bolt in place using modified support brackets. Next, the AEV flares bolt to the Highline fenders and the stock rear body panels. Since 37-inch tires were destined for the TJ, Frank trimmed the rear body tub per AEV instructions for proper clearance. The resulting body configuration allows this TJ on 37s to sit 2 inches lower than a TJ with stock body panels on 35s. To put this further into perspective, Frank's TJ has a ride height equivalent to a stock TJ fitted with comparatively puny 32-inchers.
After the Highline kit was in place, the stock four-cylinder engine made a quick exit. In its place, Frank slung a Chevy LS1 plucked from a Camaro at a local salvage yard. A 4L60E transmission backs up the LS1, which feeds into the stock NP231 transfer case. The 231's weak points were addressed by fitting an Advance Adapters heavy-duty slip-yoke eliminator kit and a 2-Lo kit that allows low-range operation in two-wheel drive.
The LS1 fits well and runs even better. Frank positioned the engine as high as possible under the hood to allow as much upward suspension travel as possible. Highway fuel economy is about 16 mpg - very impressive for a 300hp engine pushing 37-inch tires. | 
David Castillo's fabrication talent created these custom headers. | 
The Currie High-Pinion front axle is based on a Ford 9-inch housing fitted with 1/2-ton end forgings and stock TJ knuckles and steering. Ground clearance is plentiful under the front driveshaft, which tucks neatly between the exhaust system and the oil pan. |