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 Customs 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 leather interior:
Front and rear seats
Door cards
Custom steering column (Ididit with multifunction switch)
Steering wheel installed
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 linkage installed
Wheels & Tires
Method Race beadlock wheels
40” Nitto Trail Grapplers
Exhaust
Fully custom exhaust system by MagnaFlow
Full heat wrap and under-cab heat shielding
Fabrication & Cage
Full roll cage (GenRight modified)
1.75” DOM tubing
Cage tied into frame at A, B, and C pillars
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)
Additional Notes
Custom intake tube fabricated
Custom battery tray and PDC mount
New hardware throughout vehicle
Nutserts installed for hardtop mounting
License plate mount and lighting installed
Door straps and finishing components installed
Price: $95,000
More info: Click here to see original eBay auction and get more information (Affiliate link)
Seller's other items: ret164497 (Affiliate link)
Location: Murrieta, California, United States
