Dave Seger of Fruita, Colorado,...
Dave Seger of Fruita, Colorado, built his '91 Jeep Wrangler YJ to be a fun trail-crawler, but it's also served as a test rig for the many bolt-on and build parts he sells at his 4x4 shop, Dave's Customs Unlimited (DCU).
Having the strongest frame of the short wheel-base, open-top Jeep lineup, the Wrangler YJ is a popular choice for project builds. As a result, there are lots of ways to build a Jeep Wrangler YJ and not a whole lot of ways to get it wrong. There are just a few ways, however, to get it absolutely dead-on correct. Dave Seger, owner of Dave's Customs Unlimited (DCU) in Fruita, Colorado, did just that with his LS-1-equipped, leaf-sprung front, and four-linked rear 1991 YJ.
Dave began his YJ build by stripping it to the frame and cutting off most of the factory frame brackets. Once the frame was clean Dave and the DCU crew began to determine placement of a Chevy LS-1 V-8 mated to a DCU-modified TF999 auto trans and an Atlas transfer case. A M.O.R.E. 1-inch body lift was used to raise the body so only minimal tunnel and firewall modifications were necessary.
With the drivetrain components located, DCU went on to hang the front and rear axles. A Dana 60 truck axle was acquired and set up with Dutchman Motosports chromoly axle shafts, Poly Performance drive flanges, 5.13 Sierra Gear & Axle ring-and-pinion, an Eaton Detroit Locker, and a DCU diff cover. The Dana 60 was hung from the frame using a DCU full-width axle kit and a set of Alcan Spring leaf spring packs. DCU front shock towers were welded to the frame rails and a set of RadFlo 12-inch-travel remote reservoir shocks were installed. For the rear, Dave cleaned and rebuilt a Dana 70 truck axle and installed 5.13 Sierra gears, a Detroit Locker, and Dutchman chromoly axle shafts, also adding DCU rear disc brake brackets and rear disc brakes. The Dana 70 was then set up beneath the YJ using a DCU four-link bracket kit along with DCU control arms and rod ends. DCU coil spring and bumpstop brackets and universal shock towers were welded to the frame and a set of coil springs and a set of RadFlo 14-inch-travel remote reservoir shocks were installed. With all in place the YJ received a set of 40-inch Goodyear MTR with Kevlar tires mounted on 17x9.5 Raceline Monster Diamond beadlock wheels.
While the frame, drivetrain, and suspension were coming together the DCU team also completed body work on the tub and installed a set of DCU Comp Corners body armor at the rear before applying multiple coats of blue paint and lining the interior of the tub. The tub was then placed back on the frame and a family-style rollcage was fabricated, along with seat mounts for the front and rear. DCU built a custom dash and steering column and installed a set of custom PRP race seats; buckets up front and a double-bucket in the rear. Crow harnesses secure all passengers.
A blue, paint-matched fiberglass hood and fender combo from Campbell Enterprises was installed over the LS-1, and a DCU stubby-style bumper and 9,000-pound Superwinch EPi9.0 winch wrapped with synthetic line was applied to the front of the YJ. An aluminum fuel tank was installed behind the rear seat and plumbed to the LS-1 V-8 using braided fuel line and aluminum AN fittings from Earl's Performance Plumbing. A-1 Muffler in Grand Junction, Colorado, routed the exhaust using 3-inch pipe to a Flowmaster muffler and exit point. To finish the build a DCU heavy-duty, dual-diaphragm power brake booster and high-pressure master cylinder were installed and hard brake lines and Kevlar brake hose from Crown Performance were routed.
Dave's YJ went under the knife for a frame-off restoration, and two months later he ended up with a trail-capable 'crawler constructed using primarily in-house parts. Whatever parts he didn't have on the shelf ready for sale at the time he created exclusively for the YJ build and now stocks at DCU. Built right, built tough. It's the YJ way. It's the right way.
Dave didn't just start bolting...
Dave didn't just start bolting and welding on parts to create his custom YJ. The project involved a frame-off resto that took two months to complete. Here the axles and suspension are mocked up along with the LS-1 engine, TF999 transmission, and Atlas transfer case.
Further along in the build...
Further along in the build Dave installed the tub and body components and armor, and also fabricated the roll cage. The fiberglass hood is from Campbell Enterprises.
Dave doesn't claim to have...
Dave doesn't claim to have a favorite mod that stands apart from any other. "The combination of everything — it works extremely well," he says. When you've created a capable 'crawler such as this, it's easy to be proud of it.
The Dana 60 front axle was...
The Dana 60 front axle was installed using a DCU full-width axle kit and hangs on Alcan Spring leaf packs with the center pins moved forward. The steering arrangement uses a PSC steering box, cooler, and cylinder-assist, along with a heavy-duty, Heim-equipped tie rod and drag link from DCU. The Dana 60 steering arms are also parts that DCU offers, as is the beefy Dana 60 diff cover.
The DCU Boat Side Rockers...
The DCU Boat Side Rockers are made from 3/16-inch steel and offer protection all the way to the frame rails. A M.O.R.E. 1-inch body lift is in place for extra tire clearance. You can also see the roll cage A-pillar frame tie-in, which rides on a urethane bushing. The flat center skid is a custom DCU unit. Don't forget the four-link brackets and coil spring mounts — also by DCU.
A custom roll cage was built...
A custom roll cage was built by DCU using 1 3/4-inch x 0.120-inch-wall DOM steel tubing; it's well gusseted and strong. Custom-embroidered PRP seats are mounted to the 'cage front and rear and are equipped with Crow harnesses. The interior of the tub is lined and the material extends over the panels for extra scratch protection. DCU's Comp Corners body armor panels secure to the tub with counter-sunk flush-mount stainless hardware.
The Dana 70 rear axle uses...
The Dana 70 rear axle uses a Dave's diff ring and cover that include an upper tab for the truss/four-link mount. The diff ring is machined from 3/4-inch steel and is welded to a 1/4-inch-thick skid plate. We really like how the Crown Performance kevlar brake lines stay snag- and rub-free being routed up the control arms. Also in view are the DCU coil spring and bump stop mounts and rear disc brake bracket kit.
A Dana 70 axle sits at the...
A Dana 70 axle sits at the rear of the YJ and is fit with a Detroit Locker, Dutchman chromoly axle shafts, and 5.13 Sierra Gear & Axle ring and pinion. The triangulated four-link rod ends secure to the top of the diff using a DCU universal four-link crossmember assembly/truss made from 1 3/4-inch x 0.250-inch-wall DOM tube. The Earl's Plumbing aluminum AN fitting used for the rear axle breather line is a nice touch.
A custom DCU flat skid pan...
A custom DCU flat skid pan protects an Atlas transfer case. Forward from the Atlas is a Torqueflite 999 auto transmission. The 999 is equipped with a full manual valve body and was highly-modified by Dave's Customs Unlimited using many heavy-duty racing internals. Tom Wood's 1350 driveshafts are in place front and rear.