This Backyard-Built Jeep Grand Cherokee ZJ Will Make Your Jaw Drop

When Chris Frazier from BackyardBeaters rolled his rebuilt Jeep Grand Cherokee ZJ out of the garage, he wasn’t just showing off another mild modification. This thing had been completely transformed from the ground up into a legitimate one-ton monster that makes most trail rigs look like grocery getters.

The transformation started with the axles, and that’s where things get serious. Up front, he swapped in a 1993 Ford high pinion Dana 60 - the ball joint version that he prefers over kingpins for maintenance and reliability. The whole setup runs an RTec truss that’s been heavily modified, paired with a PSC full hydro steering system that lets him turn those 42-inch tires with one finger even on dry pavement.

What really sets this build apart is the attention to detail in the drivetrain. Both axles got the ballistic fab shave kit treatment, gaining over an inch of ground clearance at the diff covers. That might not sound like much, but as Chris points out, that clearance is equivalent to running three inches more tire - the difference between crawling over an obstacle and getting hung up on it.

The rear end houses a GM 14-bolt that cost him all of $100 to start with. After adding a truss, shave kit, disc brake conversion, and 5.38 gears, he’s got a bombproof rear axle that can handle whatever punishment he throws at it. Both axles run welded diffs instead of expensive lockers, and Chris makes a compelling argument for the choice. After dealing with airline problems, compressor issues, and solenoid failures on his old ARB setup, he wanted something foolproof that would get him off the trail every time.

The suspension setup deserves its own discussion. Those 14-inch Fox 2.5 coilovers up front and 12-inch units in the rear aren’t just mounted straight up and down. The angled shock mounting gives him about 20 inches of wheel travel in the front, and the custom fabricated coilover mounts he built by hand look like they came from a high-end shop.

Chris runs 42-inch Interco IROCs on 17-inch Pro Comp steelies with TMI beadlocks, and he’s not shy about praising their performance. On his first snow run with the new setup, he couldn’t get the Jeep stuck no matter what ditch or obstacle he threw it at. The combination of one-ton strength and those massive tires changed the entire character of the rig.

The drivetrain transformation goes beyond just the axles. Chris swapped in a manual five-speed transmission paired with a two-speed Atlas transfer case with twin sticks. This setup completely changed how he wheels, giving him clutch control for momentum management and multiple gear ratios in low range. The Atlas with its 4-3 gearing lets him tiptoe through technical sections or bump up obstacles in higher gears.

Not everything about the build went perfectly. Chris admits he’s disappointed with his Yukon 35-spline hardcore hubs. While they’re strong and pretty, they won’t unlock with his welded front diff due to binding issues. He wishes he’d gone with simple drive flanges instead - cheaper, stronger, and fewer parts to break.

The weight gain from the one-ton axles is noticeable too. Chris can physically feel the difference in power, even with the improved gearing helping out. The steel 14-bolt especially adds significant mass compared to his old setup. He’s already planning modifications to address the weight issue, though he’s keeping those plans under wraps for now.

The steering system deserves special mention. After killing multiple power steering pumps early on, Chris redesigned the whole setup with a larger PSC reservoir, proper hose routing, and dual coolers to keep fluid temperatures in check. The full hydro system with custom dual-shear high-steer knuckles gives him the steering precision needed to place those 42s exactly where he wants them.

Safety and functionality improvements are scattered throughout the build. The roll cage got additional tubing down the center, fire extinguisher mounting, and extensive rear bracing. The brake system received a Dodge 1500 master cylinder and booster to properly push the one-ton brakes, though Chris admits they’re still not as strong as he’d like with those massive tires.

The onboard air system got simplified too. Without ARB lockers to run, he ditched the big air tank and went with a hard-wired Smittybilt compressor that rips through tire inflation duties. Sometimes simpler really is better.

Chris’s honesty about the build’s shortcomings makes this walkaround particularly valuable. He’s not trying to sell you on perfection - he’s sharing real-world experience with expensive modifications. The hub issues, weight concerns, and brake performance are the kind of details that help other builders make better decisions.

The fabrication work throughout the build is impressive for a backyard builder. From the custom coilover mounts to the modified crossmembers and extensive gusseting, Chris clearly understands how forces transfer through a chassis and reinforced accordingly. The three-link front suspension with its hidden track bar routing looks clean while maintaining full articulation.

This ZJ represents what happens when someone commits fully to a build rather than making incremental upgrades. Chris stripped it down to the body and cage, then rebuilt everything with one-ton components. The result is a rig that can handle punishment that would destroy most trail vehicles.

The manual transmission and Atlas combination really seems to be the highlight of the build for Chris. The control and versatility it provides changed his entire wheeling experience. Being able to work the clutch for momentum management and having multiple low-range gears transforms how you approach obstacles.

Future plans hint at more major changes coming, possibly addressing the weight concerns he mentioned. With tubing visible on his trailer and promises that we might not recognize the Jeep next time, it sounds like Chris isn’t done pushing boundaries with this build.

This kind of comprehensive rebuild shows what’s possible when you’re willing to do the work yourself and aren’t afraid to cut, weld, and modify everything to work together properly. The BackyardBeaters approach proves you don’t need a professional shop to build a serious wheeler - just commitment, skills, and the willingness to learn from mistakes.