What you are about to read is an adventure that was undertaken with little prior experience or knowledge. Caution: sharp learning curve ahead!
During late summer 2006, my goal was to own a Jeep Wrangler (YJ). A friend had a 1991 Wrangler, which I thoroughly enjoyed driving and working on (my friend had little mechanical knowledge at the time, so I helped him out where I could). Within a year of him taking posession of his YJ, it was sold. In early October 2006, my goal was realized through an eBay auction. (Note: Avoid International Auto Exchange, Inc. in the Scranton, Pennsylvania area. eBay ID: neautoauction. Even though they're a legal auto dealership, they're quite shady. Buyer beware!)
What I had obtained, unknown at the time of the auction, was a Jeep that was previously owned by a marina... a SALTwater marina. Adding to that, it was also registered in Scranton, PA. What luck! Winter in Scranton brings with it A LOT of road salt. Those two facts combined equates to a bad situation for metal, a primer for mass rusting of unprotected parts. This lead to the name chosen for this adventure: Project Salt.
When I picked up the Wrangler the state inspection was valid through the end of February 2007. Between October and February I did little to the YJ when compared to after the inspection's expiration. Some of what was done included replacing all shock absorbers; changing the air filter (it was coated with engine oil); changing the valve cover gasket and cleaning the valve cover interior; replacing the worn-out tires; replacing the stock glove box with a Tuffy brand glove box; painting the front and rear bumpers; some engine degreasing; and repairing the fuel sending unit (sort of). Unfortunately, I didn't take any pictures of the above-mentioned activities.
With the purchase of the Wrangler I decided on a 90-day warranty, for an extra fee, of course. Close to the end of that 90-day period the Jeep went to an inspection station to see how badly it would fail the PA state inspection. Boy, did it ever fail! Here's a rundown of what wouldn't pass:
Body Mounts: the bottom half of most of the bushings were gone... completely gone
Frame / Chassis: holes due to rust and corrosion; the 2nd rear crossmember (above fuel tank) needed replaced
Brake Lines: the hard lines were rusted and could soon break through
Rear Brakes: the wheel cylinders needed replaced, as well as the hardware
Front Brakes: the rotors needed replaced (never did replace them as they were still in good condition)
Parking Brake: not working, needed to replace cables
Shock Towers: the front left side had a small hole; the rear right side needed replaced
Exhaust: muffler and tailpipe needed replaced
Steering: front axle u-joints needed replaced
Drive Shafts: u-joints needed replaced
Suspension Stops / Axle Snubbers: the factory stops had corroded away long before I took ownership and were non-existant. These were never replaced due to adding a lift kit.
How did this Wrangler ever passed the 2006 inspection? My guess is that it was inspected at the marina's vehicle maintenance shop. Why I kept driving it after the failed inspection still puzzles me.
After being told to get rid of the Wrangler before the inspection would expire, I actually thought about letting it go. But then I remembered why I bought it... for experience in repairing a vehicle, and to own a Jeep Wrangler. So I kept it. In March 2007 I was in need of a place to dismantle and repair the YJ. I found a local storage shed facility that had an owner that was willing to accomodate me. At that point, I had a 10' x 30' storage unit to work on Project Salt. My plan was to have Project Salt out of the storage unit by the end of May. After delays with weather, helping other people with various projects, and my sister's wedding, I was out of the storage unit on July 4, 2007.
Click on the links below to read about and see the tear-down and rebuild of Project Salt. Stay tuned, as updates and further improvements are sure to come!
