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XJ Build (with a haircut)
11-18-2009, 10:20 PM,
#1
XJ Build (with a haircut)
Ok guy's I decided to leave my JK alone for a while and build an XJ rig.

The Plan:
- 42" tires
- 9" rear -8-bolt pattern
- '609' front with 8-bolt pattern
- 4 seats and a Heater......
- 3-link front
- 4-link rear
- full hydro steer.
- full interior rollcage
- exo-cage also...
- 4L / aw-4 / np231doubler
- 14"-16" travel (goal) coilover shocks.
**** 'PLAN' subject to change in a heartbeat.....due to lack of parts,cash,rum.....******

found this jeep on kijji.... $500.00
[Image: jeepdevin_09015800x600.jpg]
[Image: jeepdevin_09014800x600.jpg]

Then let the 'CUTTING' begin........
[Image: jeepdevin_09016800x600.jpg]
[Image: jeepdevin_09018800x600.jpg]
[Image: jeepdevin_09020800x600.jpg]
[Image: jeepdevin_09021800x600.jpg]

now i see why i got it for 500 bucks........'Holy cancer batman!'
[Image: IMGA0150640x480.jpg]
[Image: IMGA0149640x480.jpg]
[Image: IMGA0148640x480.jpg]

Well needless to say i was very disappointed with it, but the drive train was in very good shape.
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11-18-2009, 10:41 PM,
#2
Re: XJ Build (with a haircut)
soooo then i found this for $500.00 at a pick-a-part, and was able to drive it home Lol

[Image: IMGA0158640x480.jpg]
[Image: IMGA0161640x480.jpg]
[Image: IMGA0162640x480.jpg]

Look familier? 8)
we sent the white on to the farm for cold storage of the drivetrain....

and then i started to give this one a haircut also.

[Image: IMGA0173640x480.jpg]
[Image: IMGA0172640x480.jpg]
[Image: IMGA0179640x480.jpg]
[Image: jeep_01062800x600.jpg]
[Image: jeep_01063800x600.jpg]

This one was WAY better shape... (the frame was actually 'attached' to the body.....LMAO!)

[Image: IMGA0166640x480.jpg]
VS
[Image: IMGA0148640x480.jpg]
rotted semi replaced floor.......ewwww!
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11-18-2009, 11:43 PM,
#3
Re: XJ Build (with a haircut)
ahh to be young and energetic again!! Cry Looking good, can't wait to see your dreams fullfilled. Keep us posted. TNT Fairview pulled a couple of wrecks out of the bush today. Too bad they weren't "projectable junkers" Price was right :!: :!:
95 Suzuki Sidekick, 4" lift on 32"s. Spooled Rear. Superwinch. Choose a road wisely!! Wide the road that leads to destruction and many will choose it. Narrow the road that leads to life, but few will find it. Math.7:13-14
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11-19-2009, 12:50 AM,
#4
Re: XJ Build (with a haircut)
Looks awesome Trent !!!

(When are we supposed to get our diffs?)
PITBULL TIRES: http://pitbulltires.com/

Bilstein Shocks

PSC Steering

Poly Performance

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11-19-2009, 08:19 AM,
#5
Re: XJ Build (with a haircut)
All you XJ enthusiasts are a weird bunch Mrgreen :wink:

Looks much better than the first attempt [Image: thumbsup2.gif]
Colin Paulovich
TNT Orange
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11-19-2009, 09:18 AM,
#6
Re: XJ Build (with a haircut)
Brings back to when I cut the top on mine. I still remember making the first major cut and asking myself "WTF am I doing!!". Mrgreen Can't wait to see it take shape.
2008 JKU, 3.5" lift, LT37x12.50x17 ProComp Xtreme MT, 17" ProComp 5129 wheels, Core 44 front 4.88 ARB, rear 4.88 Detroit, Smitty XRC bumpers, Smitty 8K X20 winch
Bobbed Scrambler buggy, LM7/4L60E/NP241, Mog9s, 42" Rockers on Allied beadlocks, 16" Radflos, 116" WB
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11-19-2009, 09:33 AM,
#7
Re: XJ Build (with a haircut)
Cool build.

Dmonkey

2003 WJ for groceries, 2005 LJ Rubicon for family wheeling, 2015 Power Wagon for making money, 1989 MJ for working on, 20xx Ultra 4 buggy for dreaming and leaning on.
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11-19-2009, 09:43 AM,
#8
Re: XJ Build (with a haircut)
ok, while waiting for my tubing my bender showed up. I didnt get many pics of putting it together.
but i looked at some of the kits out there for hydralic conversions and decided to try it on my own.

Material list:
1- pro-tools 105 bender.
1- snowplow 12" hyd ram
1- air/hyd foot pedal pump
2- 12" springs
some 1/4" plate and alm 3/4" sleeving i had laying around.

The bender was packaged very nicely, all spray foam filled boxes.
the instructions were ok. for someone who likes to read, and understands what they are reading... :oops:

[Image: IMGA0143640x480.jpg]

Check out the price on the ram... what a score 75% off of 29 bucks....total 7.00 yehaa!
the air over hyd pump was around 200 bucks, cant remember exactly.
a few misc fittings and a hose and i was ready to start.

[Image: IMGA0145640x480.jpg]

i cut some flat bar to hold the cylinder, a couple of sleeves to center it. and a piece of 2"x2" square tubing in the middle to support it also.
i then used the stock mounting bolts to attach the ram end to the bender. the ram had the perfect hole through it for mounting.
a few spacers to center the ram side.

[Image: IMGA0147640x480.jpg]

then a couple of fender washers cut in half and tacked for the springs to attach to.
the springs return the ram to the closed position. the ram is only a one way hyd cylinder.

[Image: IMGA0144640x480.jpg]

and the completed unit.

the bender works awesome, barley slows down on 2" 0.120 wall DOM tubing.
i am very happy with the results.
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11-19-2009, 01:38 PM,
#9
Re: XJ Build (with a haircut)
Nice, I have that bender too, is the foot pump from princess auto too?
90 Blazer TBI 350/NV 4500/203/205 D60/14 Bt /Chromoly/Rockmonstrer Beadlocks/ 41.5" Rockers / Hydro-assist........
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11-19-2009, 05:32 PM,
#10
Re: XJ Build (with a haircut)
yes, i have an extra cylinder. feel free to come over and take a look at my setup.. wouldnt take us long to convert yours. i also have a 1.250,1.750 dies if you need one of those sizes.
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11-19-2009, 06:50 PM,
#11
Re: XJ Build (with a haircut)
Greg. did you move back to GP or just wishing you still live here??? Mrgreen

Dmonkey

2003 WJ for groceries, 2005 LJ Rubicon for family wheeling, 2015 Power Wagon for making money, 1989 MJ for working on, 20xx Ultra 4 buggy for dreaming and leaning on.
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11-19-2009, 07:55 PM,
#12
Re: XJ Build (with a haircut)
well , got my tubing home...........time to bend Evil

[Image: IMGA0175640x480.jpg]

well i had to dream up a way to build a full cage inside the XJ????
Not sure how well this will work but here we go..

[Image: jeep_01064800x600.jpg]
[Image: jeep_01066800x600.jpg]

First stick of pipe...

[Image: jeep_01067800x600.jpg]
[Image: jeep_01068800x600.jpg]
Then 'yj_and_corey' and leon came over to drink my beer.... they said they were helping......Big Grin
Here is my main cage hoop. 2"x0.120 DOM bender bent this like butter....
[Image: jeep_01072800x600.jpg]
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11-20-2009, 09:06 PM,
#13
Re: XJ Build (with a haircut)
I thought i had such a good idea sinking the cage hoop into the stock piller, but..... how the hell do you get it in in one piece?
you don't!
you end up cutting it and sleeving a 12" piece of 1.75x.120 wall inside it and roset/plug welding it up... :wink:

[Image: jeep_01075800x600.jpg]
[Image: jeep_01076800x600.jpg]

well i got some more of the cage done this week, paying work has been slow...lol

[Image: jeep_01080800x600.jpg]
[Image: jeep_02001640x480.jpg]
[Image: jeep_02003640x480.jpg]
ya before i hear it........ i redid some of my welds better..... dam cramped space... :oops:

[Image: jeep_02009640x480.jpg]
[Image: jeep_02011640x480.jpg]
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11-20-2009, 09:12 PM,
#14
Re: XJ Build (with a haircut)
Looks amazing Trent - good work!
PITBULL TIRES: http://pitbulltires.com/

Bilstein Shocks

PSC Steering

Poly Performance

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11-20-2009, 09:17 PM,
#15
Re: XJ Build (with a haircut)
Then i spent the whole day today trying to plate the frame...
I got one side almost done......

[Image: jeep_02012640x480.jpg]
[Image: jeep_02013640x480.jpg]
Wow grinding/wire wheel on that under coating sucks big time......

Test fit:
[Image: jeep_02015640x480.jpg]
out side welded... oh i used 3/16 plate for the re-enforcments to the frame.
[Image: jeep_02017640x480.jpg]
Inside the frame.... just need to cap it now.
[Image: jeep_02016640x480.jpg]

thats all for this week.....now to take the JK out wheeling this weekend......for some relax time....
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11-20-2009, 10:05 PM,
#16
Re: XJ Build (with a haircut)
Looks good. Wish I knew you where plating the unibody, I still have the templates from when I did mine. ( or did i chuck them 3 days ago when I moved the last bit of the shop?)

Looks like you didn't need them anyways. :wink:

Dmonkey

2003 WJ for groceries, 2005 LJ Rubicon for family wheeling, 2015 Power Wagon for making money, 1989 MJ for working on, 20xx Ultra 4 buggy for dreaming and leaning on.
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11-21-2009, 12:08 AM,
#17
Re: XJ Build (with a haircut)
:wink: That would have made it tooo easy..... Twisted
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11-24-2009, 04:56 PM,
#18
Re: XJ Build (with a haircut)
Gotta great build goin there. Givin me lotsa hope and dreams i never even imagined.
I may yet take the sawzal to mine.
"Great minds discuss ideas; Average minds discuss events; Small minds discuss people."
Eleanor "Roosevelt"
RR
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11-29-2009, 04:02 PM,
#19
Re: XJ Build (with a haircut)
well i didnt get too much done this week. work has picked up, but i did get a few things figured out.

I would also like to say at this time most of what i am doing to this xj is a acumulation of ideas i have seen on this
board. Thank you.

Here we go... I cut another 2 inches from my rocker panels to get a bit more angle and clearence on my boat sides.

[Image: IMG_1682640x480.jpg]

Then cut slots in th floorboards for my angle supports from the rock slider to the frame. my roll cage will also tie into these cross supports.

[Image: IMG_1677480x640.jpg]
[Image: IMG_1683640x480.jpg]
[Image: IMG_1678640x480.jpg]
i will weld the cage into these supports for the final tie in point to the frame.
[Image: IMG_1679640x480.jpg]
[Image: IMG_1680640x480.jpg]
underside.....
[Image: IMG_1687640x480.jpg]
i will then sheet the underside with 3/16 plate for the sliders...
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11-29-2009, 04:19 PM,
#20
Re: XJ Build (with a haircut)
I then got to thinking how i could tie the rear tube frame into the existing frame for strenth, this is what i came up with.

Let me know if you think this will work good or if i am over building it.

When i plated the frame i counter sunk the end cap about an 1.5"

My thoughts were i needed something stronger than just a butt weld for the pipe.
so i will butt weld the pipe first here.
[Image: IMG_1674640x480.jpg]

Then slide this piece over the pipe and weld it again while tieing in the rest of the cap to the frame plating.

[Image: IMG_1675640x480.jpg]
[Image: IMG_1676640x480.jpg]
I am thinking this should be strong enough now.... 8)

also on a side note i found a dana 300 last week also... so now i have almost all my parts for my 231/300 twin stick doubler.......

[Image: IMG_1681640x480.jpg]

Yehaaa!!!!!
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