1997 Jeep Wrangler TJ - Armor Plating Install

Project Teal-J II, Intro
Project Teal-J II, Part 1
Project Teal-J II, Part 2
Project Teal-J II, Part 3
Project Teal-J II, Part 4
Project Teal-J II, Part 5
Project Teal-J II, Part 6
Project Teal-J II, Part 7
Project Teal-J II, Part 8
Project Teal-J II, Part 9
Project Teal-J II, Part 10
Project Teal-J II, Part 11
Project Teal-J II, Part 12
Project Teal-J II, Part 13
Project Teal-J II, Part 14

One thing that you usually learn the hard way after hitting the trail a few times is that your rig needs protection. Investing money in axles, lockers, suspension and tires is great, but if your rig comes back after a few trail runs looking like it had an encounter with a sledgehammer-wielding Mike Tyson, you will be a bit peeved. Not having the right armor often limits where you can go or where you want to go, without mangling your ride.

When it came to our '97 TJ, we did not want to limit where we could go. Plus, we knew that we would be hitting the trail--that's why we're doing this rebuild, after all--so it was time to add as much armor as we could to keep our Jeep from getting bashed. However, in keeping with the theme of our Project Teal-J II, all of our parts needed to bolt on easily and take no longer than a weekend to install.

We came across Poison Spyder Customs, which offers a wide range of armor for Jeeps, and we decided to utilize their Crusher Corners, Rocker Knockers and new tube fenders to protect the sides of our Wrangler. To protect the nose and tail of our project, we turned to Warn, whose new Rock Crawler bumpers look stout. We also selected the new Warn 9.5 XP winch to pull out our rig from the inevitable stuck. Follow along as we show you the highlights of our latest weekend wrench session.

TUBE FENDERS

The first step to installing the tube fenders from Poison Spyder Customs is to take the supplied stencil and lay it out on the stock fender.
The first step to installing the tube fenders from Poison Spyder Customs is to take the su
Now comes the fun part. We broke out our favorite tool, the Sawzall, and went to work. Basically, to install the Poison Spyder fenders, first you cut out everything except the part that is under the stencil.
Now comes the fun part. We broke out our favorite tool, the Sawzall, and went to work. Bas
The cut also needs to be continued down the inner fenderwell until the whole outer part of the fender can be removed.
The cut also needs to be continued down the inner fenderwell until the whole outer part of

After you're finished cutting, what is left of the fender should look like this.
Then the new tube fender basically slides over the fender and attaches to the existing bolt holes that the stock fender attached to. We found the best technique was to attach the four bolts in the fenderwell loosely, push the fender over until we could sneak a bolt in its front mounts, and then snug everything down. Once that was accomplished, the fit of the tube fenders was excellent.
Then the new tube fender basically slides over the fender and attaches to the existing bol
A look at the front of the tube fender shows that the stock turn signals no longer exist. We plan to put some CJ turn signals into the grille of the TJ to remain legal. Our new front tube fenders can now take a major beating.
A look at the front of the tube fender shows that the stock turn signals no longer exist.

THE ROCKER KNOCKERS

Installing the Rocker Knockers from Poison Spyder is fairly simple. The first step is to unbolt all the body mounts on one side of the Jeep and gently jack up the body until the rubber mounts and body-lift pucks (if you have a body lift--we do) can be removed.
Installing the Rocker Knockers from Poison Spyder is fairly simple. The first step is to u
After shaving 3/8 inch off the rubber body mounts and our 1-inch body-lift pucks, we reinstalled them. The Rocker Knockers then slide over them and sandwich between them and the body. After the Knockers are in place, make sure they are level, and then drill the holes needed to mount them into the body.
After shaving 3/8 inch off the rubber body mounts and our 1-inch body-lift pucks, we reins
The last step is to use the countersunk bolts to attach the Rocker Knocker to the Jeep. Since the Rocker Knockers are 3/16 inch thick and tie into the body mounts for even more strength, we no longer have to worry about damaging Teal-J's rockers.
The last step is to use the countersunk bolts to attach the Rocker Knocker to the Jeep. Si

THE CRUSHER CORNERS

The Crusher Corners are very simple to install. First we removed our taillights, license-plate holder, fender flares and fuel cap. Then we positioned the Crusher Corner into place and once it was level, we held it in place with C-clamps. Next we started drilling the holes needed to attach it to the body.
The Crusher Corners are very simple to install. First we removed our taillights, license-p
Once the countersunk bolts were used to attach the Crusher Corner to the body, we busted out a 4 ½-inch holesaw to cut a hole for the LED taillights. Poison Spyder also makes Crusher Corners for the stock taillights, but we decided to make the back of our TJ completely flat.
Once the countersunk bolts were used to attach the Crusher Corner to the body, we busted o
The LED taillights are a nice option, as there is no longer a big taillight hanging off the back of the Jeep waiting to get smashed. The stock fuel cap also goes back into place and the factory license-plate holder can also be used, but we decided that we didn't want it hanging off the back.
The LED taillights are a nice option, as there is no longer a big taillight hanging off th

ROCK CRAWLER BUMPERS AND 9.5XP WINCH

We used Warn's winch mount because it's a stout way to attach a winch to a TJ.
The Warn front bumper slides onto the frame, and the winch mount (with the winch already attached to it) can be placed on top of the bumper and frame. Then it is simply a matter of torquing down the bolts.
The Warn front bumper slides onto the frame, and the winch mount (with the winch already a
To pull our Jeep out of a serious stuck, we selected the new Warn 9.5XP winch. It is rated for 9,500 pounds of pulling power and features Warn's new high-output parallel series-wound winch motor, which makes a whopping 6 hp. It is built for extreme environments and extreme water resistance with full-face contact drum seals, motor and end-housing gaskets.
To pull our Jeep out of a serious stuck, we selected the new Warn 9.5XP winch. It is rated

A nice feature of the Warn Rock Crawler front bumper is it comes with these heavy-duty mounts that make for a perfect spot for Warn's shackles.
A nice feature of the Warn Rock Crawler front bumper is it comes with these heavy-duty mou
Bolting on the rear Rock Crawler bumper is fairly simple, but takes a bit of time because the bolts attach from the vehicle-side of the bumper. We found the best way was to loosen the gas-tank skidplate to allow for enough room for our hands.
Bolting on the rear Rock Crawler bumper is fairly simple, but takes a bit of time because
Once the rear bumper is bolted on, the tire-carrier portion of it can be attached. The maximum size supposedly is a 36-inch tire, but we think we might be able to sneak a 37-incher onto it. Now both the nose and rear of our TJ are protected with the stout Warn bumpers.
Once the rear bumper is bolted on, the tire-carrier portion of it can be attached. The max