CJ Hellcat Swap – Full Custom Build Sheet

Overview

Complete custom-built CJ chassis with full frame reinforcement, Hellcat (TRX-based) powertrain integration, and one-off fabrication throughout. No aspect of the vehicle was left untouched—this is a ground-up engineered build designed for strength, articulation, and high-performance off-road capability.

Chassis & Frame

• Full frame reinforcement:
  • 1/4” plate (front 1/3 of chassis)
  • 3/16” plate (rear section)
  • Fully boxed, plated, and welded (inside, outside, top, and bottom)
• Frame corrected and squared:
  • Rear section cut, notched, and re-graphed
• Custom crossmembers:
  • Transmission crossmember
  • Front structural crossmember (Hellcat support)
  • Rear fuel cell support crossmember
• Custom front frame modification:
  • Driver-side frame section cut and rebuilt for steering box mount
  • Fully sleeved and welded

Powertrain

• TRX / Hellcat powertrain swap
• Engine and transmission fully centered in chassis
• Custom fabricated:
  • Engine mounts (frame + engine side)
  • Transmission mount
• Atlas transfer case with custom linkage and levers
• Custom driveshafts (front and rear)

Suspension

• Custom 4-link/control arm system (all links welded and reinforced)
• King 2.0 coilovers (12” travel, all four corners)
• Custom shock mounts (front and rear)
• Custom bump stop mounts:
  • Plated frame-side mounts
  • Reinforced axle-side mounts
• Custom front sway bar:
  • RockJock torsion bar setup

Axles & Drivetrain

• Dynatrac:
  • Dana 60 (front)
  • Dana 80 (rear)
• 5.13 gearing (approx.)
• Electronic lockers (front & rear)
• Axles disassembled, powder coated, and reassembled

Steering System

• PSC full hydraulic assist system:
  • Steering box
  • Pump
  • Cooler
  • Custom AN hydraulic lines
• Custom fabricated:
  • Pitman arm (clearance optimized)
  • Drag link (full articulation clearance)
  • Track bar and mount
  • Tie rods
• PSC ram mounts fabricated and welded
• Custom steering column with heim-supported center mount

Braking System

• CJ brake booster conversion
• Corvette master cylinder
• Fully custom brake system:
  • 3/16” hard lines (front to rear)
  • Braided stainless soft lines at all pivot points
• Extended brake pedal and custom gas pedal mount

Cooling & Air Systems

• Custom Mattson radiator (integrated trans cooler)
• Custom intercooler system (Dakota Customs)
• Fully custom plumbing:
  • Intercooler piping
  • Radiator hoses (cut to fit)
• Engine oil cooler + custom lines
• PSC steering cooler (mounted in grille)
• Custom mounts for:
  • Coolant surge tank
  • Intercooler water pump
  • PSC reservoir

Fuel System

• Fuel cell (custom mounted to rear bumper)
• Custom fuel system:
  • -8 AN feed lines
  • -6 AN return lines
  • Inline fuel filter
• Aeromotive fuel regulator and pumps
• Custom fuel pressure regulator mount
• Custom fuel filler neck and vent system
• Custom fuel level sender (wired + programmed)

Electrical System

• Complete rewire using Painless Wiring kit
• Deutsch connectors at steering column
• Systems wired and integrated:
  • Engine & transmission harness (Mopar)
  • PCS transmission control module
  • Dakota Digital cluster (programmed)
  • Dakota  PCM & tuning
  • Switch-Pros 12 switch panel
• Custom aluminum enclosure for wiring harness
• Battery system:
  • Optima RedTop battery
  • Custom cables and grounds
  • Battery cutoff switch
  • Bulkhead fittings for isolation
• All auxiliary systems wired:
  • Fuel pump
  • Fans
  • Intercooler pump
  • A/C clutch
  • Lighting (full vehicle)

HVAC

• Jeep Air A/C & heating system (custom fitted)
• Fully custom A/C lines
• Modified compressor fittings for clearance
• Bulkhead fittings through firewall
• Charged with R134a

Interior

• Custom CJ dash (fully cut and modified)
• Dakota Digital gauge cluster
• Custom center console (Fiberwerx base)
• Atlas transfer case shifters integrated
• Custom interior:
  • Front and rear seats
  • Door cards
• Custom steering column (Ididit with multifunction switch)
• Dome lights (Baja Designs) with custom door switches
• Interior lighting installed
• Rearview mirror + side mirrors
• Seat belts (custom mounts)

Exterior

• GenRight components (modified):
  • Fenders
  • Rock sliders
  • Front and rear bumpers
  • Body guard panels
• Custom front bumper:
  • Integrated skid plate (steering protection)
• Warn 12K winch (synthetic rope) with 1” steel mounting plate
• Custom mounts for Baja Designs LP6 headlights
• Front grille:
  • Mounted with radiator, intercooler, condenser
  • Integrated blinkers
• Tail section:
  • GenRight taillights (wired)
  • Custom fuel cell integration
• Doors, tailgate, hood mounted and aligned
• New seals, trim, and hardware (stainless throughout)
• Windshield:
  • New seals
  • Wiper motor and linkages

Wheels & Tires

• Method Race beadlock wheels
• 40” Nitto Trail Grapplers

Exhaust

• Fully custom exhaust system professionally built by MagnaFlow at HQ
• Full heat wrap and under-cab heat shielding

Fabrication & Cage

• Full roll cage (GenRight modified)
• Custom tie-in plates (bolted + welded)
• Additional structural reinforcement throughout chassis

Final Assembly & Finishing

• Full disassembly for powder coating:
  • Frame, cage, axles, suspension, bumpers, sliders, etc.
• Complete reassembly of:
  • Chassis
  • Suspension
  • Powertrain
• Fluids filled:
  • Engine oil
  • Transmission fluid (8-speed)
  • Gear oil
  • Transfer case fluid
  • Brake fluid
  • Mopar coolant
  • PSC hydraulic fluid
• 4-wheel alignment completed
• Dyno and tuning completed
• Spring rates calculated (documented)

Summary

This CJ build is a fully engineered, Hellcat-powered custom chassis with extensive fabrication, reinforcement, and system integration. Every major system—chassis, suspension, steering, drivetrain, electrical, and interior—has been custom designed, built, and refined for durability and high performance.