The Re-Build of Kermit (97 XJ)

[matchframe]

On Friday 9 March my daughter was involved in a multi-vehicle accident just north of Huntsville, TX. Other than being sore from the airbags, she was not hurt thanks to the solid build of her XJ. She left the road at 65 mph and went through a ditch full of water which slowed her a lot before she hit the cables dividing the freeway. A post which hold up the cables stopped her.

When she saw her Jeep for the first time after the accident she almost broke down crying and asked if I could fix it. I told her I would do my best. Since I have worked on cars all of my life, I was not real sure if it could be fixed. After I got it home I became more optimistic so I started searching the Internet for forums about Jeeps. I am a moderator at DigitalCorvettes.com so I know the value of the knowledge in these forums. I found a donor '99 XJ close to where I live and bought it. It was rolled so no body parts I can use, but the mechanical things I need are all good.

Here is a pic of her Jeep when we first saw it:

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep5.jpg

I found a donor for the mechanical parts I need, a '99 XJ that had been rolled.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep23.jpg

I removed all of the damaged parts:

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep17.jpg
http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep14.jpg

Here is what I found that I need to replace in the engine bay:

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep12.jpg

Since I am new to uni-bodies, this is going to be my learning curve:

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep10.jpg

I will post updates as I progress. :thumbsup:

[bigjim350]

Wow glad she was okay. Ill keep an eye out for some body parts for you. Gonna be hitting up a few junk yards around Houston this weekend.

Sent from my VM670

[cantab27]

glad to hear daughter was ok ...that looks like a hard hit...watching with interest ..keep the pics coming..

[matchframe]

Wow glad she was okay. Ill keep an eye out for some body parts for you. Gonna be hitting up a few junk yards around Houston this weekend.

Sent from my VM670

That would be great!!

BTW, when I get all the parts off the '99 that I need, I will be parting out the rest if anyone is interested. Not exactly sure what is good on it just yet. I started pulling it apart yesterday.

[matchframe]

glad to hear daughter was ok ...that looks like a hard hit...watching with interest ..keep the pics coming..

Thanks! We are very grateful that she is ok. The State Trooper told me later that she stopped just 15 feet from going into head-on traffic. Makes my heart almost stop to think about that!

[bigjim350]

That would be great!!

BTW, when I get all the parts off the '99 that I need, I will be parting out the rest if anyone is interested. Not exactly sure what is good on it just yet. I started pulling it apart yesterday.

Id be intrested in front and rear axle.

[prcjeep]

Really glad to hear your daughter is okay. Sad to see two wrecked xj's in one post, but hopefully the outcome will be another lively one. Looks like it could be saveable with a good amount of work. Will be watching this thread. Thanks for joining up with xjtalk!

[dancome433]

looks like she took a hard hit, but glad she wasnt hurt. If you need any body parts, theres a pick and pull junkyard off of 45 near West Road, its alled LKQ Northville, I was there last week and there were 3 97+ XJs in the newer section, I know one had a decent header panel, 2 others had decent fenders and flares, I know none of them had decent bumper caps, one of them still had a decent bumper

[JENSSEN]

It looks like the main damage is above the frame rail, you can remove the p/s tin above the rail with a drill and spot weld remover. I would check all the diff control arms on the front to be safe. How is the wire harness?

I have done some collision work so if I can assist let me know!

Many tools can be repurposed to become frame pullers and body tools ;) a key thing is look at how the damaged occoured and the steps that happened to create the damage and systematically try to reverse the damage in the same steps

[matchframe]

looks like she took a hard hit, but glad she wasnt hurt. If you need any body parts, theres a pick and pull junkyard off of 45 near West Road, its alled LKQ Northville, I was there last week and there were 3 97+ XJs in the newer section, I know one had a decent header panel, 2 others had decent fenders and flares, I know none of them had decent bumper caps, one of them still had a decent bumper

That's cool to know about the Pick and Pull. Right now I am focusing on taking apart the '99 parts Jeep I have and have the hulk hauled away. I got a red sticker ticket on the Jeep yesterday saying I need to put the vehicle in the garage. Really made me mad since our neighborhood does not have a restrictions like most neighborhoods and we don't pay yearly dues for such patrols. This came from the city of Dickinson, but we live outside of the city limits. Anyway, I have to finish up as quick as I can since I don't have the room inside the garage for the Jeep. I will hit the Pick a Parts and Pull A Parts probably after the Easter weekend. Good to know that there are those parts out there. :thumbsup:

[matchframe]

It looks like the main damage is above the frame rail, you can remove the p/s tin above the rail with a drill and spot weld remover. I would check all the diff control arms on the front to be safe. How is the wire harness?

I have done some collision work so if I can assist let me know!

Many tools can be repurposed to become frame pullers and body tools ;) a key thing is look at how the damaged occoured and the steps that happened to create the damage and systematically try to reverse the damage in the same steps

The damage is above the frame rails and missed the suspension. What she hit was a 2 inch diameter post that holds up the cables between the freeways. The post went neatly between the front tire and the frame rail and stopped before the suspension. The only wiring damage I have found is the front plug to the fuel rail computer that mounts on the inside of the fender. I guess that is what that is. The harness goes from the straight to the fuel injectors. I have the harness off the '99 that I will use in its place.

I have the tin off that holds the headlight. That took the most damage and was crumpled up like a wad of paper. I drilled out the spot welds and was able to work it off of there without any damage to the body structure it was welded to. I think I can use the same piece from the '99. It has some damage, but looks to me like it can be straightened out with a little work. Since I have to get the '99 gone, I plan to sawsall the piece out of the '99 behind the piece I need and work it off the spot welds later. I have a stick welder but not a mig welder. I have a lot of experience welding with a stick, but this metal is so thin, I am not so sure if stick welding it in place will work. Do you know if MIG would be better? If so, this may be my chance of justifying buying a mig.

I would be happy for any advise about how to do all of this. :thumbsup:

[4.3LXJ]

MIGs are always better for sheet metal

[JENSSEN]

Sell welding and metal fab stuff for a living,.. Now you can do it with stick, but the ease and accuracy of a MIG in this situation will defiantly be worth the added cost, of your looking at smaller MIG machines always go on level higher than you want as once you get rolling with it you have more power to grow. Look at a miller 180 with autoset, the 140 would also cut it bit the 180 is far more versatile.

Also I am in the process of real inning the side of a Comanche and doing similar work, if you want I can take some video or do more detailed write ups on sheet metal swaparoo's

[4.3LXJ]

I agree. It takes some skill to weld sheet metal with a stick.

[matchframe]

Sell welding and metal fab stuff for a living,.. Now you can do it with stick, but the ease and accuracy of a MIG in this situation will defiantly be worth the added cost, of your looking at smaller MIG machines always go on level higher than you want as once you get rolling with it you have more power to grow. Look at a miller 180 with autoset, the 140 would also cut it bit the 180 is far more versatile.

Also I am in the process of real inning the side of a Comanche and doing similar work, if you want I can take some video or do more detailed write ups on sheet metal swaparoo's


That would be great!! I not only have this project to complete, but also need to replace a quarter panel on my '73 VW. The more I learn about how to MIG the better. What would be the cost range of a Miller 180?

[matchframe]

I agree. It takes some skill to weld sheet metal with a stick.

Years ago (1975) I replace a quarter panel on my '68 Camaro. I started out using a stick and quickly found out this was not going to work. I ended up braising it on use a acetylene torch. I was able to get is finished up that way, but the heat from the torch warped the metal. Lots more bodywork to fix that but it ended up ok. I bet if I had been able to used a MIG, it would have turned out much better.

[4.3LXJ]

Yes, it would have. Stitching is much easier with a good MIG. You have to do that with auto body. In fact they make machines just for that. An auto darkening hood is a valuable thing for that too.

[matchframe]

I have the drivetrane out of the '99 XJ. Only thing left for me to pull is the front and rear axles, then it is time to have the rest hauled off.

I got the thumbs up from my wife to buy a MIG welder. So I will be looking this week for where I can buy one. I will definitely be getting the auto darkening helmet. I have been wanting one of those for a long time to use with the welder I have now. I kept the hood off the '99 even though it is not good so I can use it to get use to the MIG and to do paint trials with it.

[Mudderoy]

I have the drivetrane out of the '99 XJ. Only thing left for me to pull is the front and rear axles, then it is time to have the rest hauled off.

I got the thumbs up from my wife to buy a MIG welder. So I will be looking this week for where I can buy one. I will definitely be getting the auto darkening helmet. I have been wanting one of those for a long time to use with the welder I have now. I kept the hood off the '99 even though it is not good so I can use it to get use to the MIG and to do paint trials with it.

The HTP MIG-160 was recommended to me. :link: (http://www.htpweld.com/products/mig_welders/mig_160.html)

http://www.htpweld.com/products/mig_welders/images/mig160.jpeg

[matchframe]

The HTP MIG-160 was recommended to me. :link: (http://www.htpweld.com/products/mig_welders/mig_160.html)

http://www.htpweld.com/products/mig_welders/images/mig160.jpeg

That looks like a great welder!! I watched the video on the link and now have a much better idea of how MIG welding works.

[Mudderoy]

That looks like a great welder!! I watched the video on the link and now have a much better idea of how MIG welding works.

I may get it after I see how bad I get hit on April 15th....

[XJ Wheeler]

Wait... Nope... Halt... Go back...

What model '73 VW?

[4.3LXJ]

Once you get one, you will be spoiled. I rarely if ever use my stick machine now unless is is some specialty I don't have wire for.

[JENSSEN]

That would be great!! I not only have this project to complete, but also need to replace a quarter panel on my '73 VW. The more I learn about how to MIG the better. What would be the cost range of a Miller 180?

http://www.millerwelds.com/products/mig/product.php?model=M00209

[msmoorenburg]

http://www.tractorsupply.com/hobart-handler-reg-140-mig-welder-3812040


This is what I have and used to install my frame stiffeners

[matchframe]

Wait... Nope... Halt... Go back...

What model '73 VW?

I have a '73 VW Super Beetle. It was my son's first car before he moved on to a Mini Cooper. It needed some body workfrom an accident in the high school parking lot. I plan to get it back on the road sometime to save some gas driving to work.

Here is what it looked like when my son was still driving it:

http://i10.photobucket.com/albums/a122/matchframe/BDG/Img0852.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Bug5-1.jpg

Here is what it look like today. The quarter panel behind the door is what I need to replace.

http://i10.photobucket.com/albums/a122/matchframe/BDG/BugWrx1.jpg

[matchframe]

I finished pulling the donor XJ apart today. Sort of sad in a way to see the end of a Jeep like this, but the parts pulled from the '99 will bring new life back to Kermit. I will now shift my focus to working on Kermit.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Chili11.jpg

Last thing I pulled from the donor Jeep is the axles. I have already made a deal to trade the front axle for a set of wheels like Kermit had since one was broken in the wreck. The rear axle I plan to use in my '53 Chevy Wagon. it is the right size and being from a 4X4 Jeep, it is a pretty strong unit and should handle a small block with no problems.


http://i10.photobucket.com/albums/a122/matchframe/BDG/Chili8.jpg

Kermit in the background ready to recieve some of Chili Pepper's parts. I have affectionately been calling the '99 donor XJ Chili Pepper. Not sure why, but it seem to fit.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Chili7.jpg

Not much left on Chili Pepper.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Chili10.jpg

I have a lot of stuff I will be selling later that I pulled from the donor if anyone is interested. I will list them on this site later.

[XJ Wheeler]

I have a '73 VW Super Beetle. It was my son's first car before he moved on to a Mini Cooper. It needed some body workfrom an accident in the high school parking lot. I plan to get it back on the road sometime to save some gas driving to work.

Here is what it looked like when my son was still driving it:

http://i10.photobucket.com/albums/a122/matchframe/BDG/Img0852.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Bug5-1.jpg

Here is what it look like today. The quarter panel behind the door is what I need to replace.

http://i10.photobucket.com/albums/a122/matchframe/BDG/BugWrx1.jpg
Not bad, looks like its in a lot better shape than mine. My '74 was the same color when i got it (at least it looks like it). I like the tail lights.

[msmoorenburg]

Save the tail lights someone will need a spare :sign0181:

[matchframe]

Save the tail lights someone will need a spare :sign0181:

I can't get the rear hatch open to pull the tail lights. I have tried everything except a cutting torch to open the gate.

Any suggestions on pulling the tail lights without opening the hatch?

[msmoorenburg]

I can't get the rear hatch open to pull the tail lights. I have tried everything except a cutting torch to open the gate.

Any suggestions on pulling the tail lights without opening the hatch?

its not gonna happen unless the hatch is open :cry:

[matchframe]

its not gonna happen unless the hatch is open :cry:


That's what I thought. :(

[matchframe]

I have not been this worn out in a long time.

I took the complete Jeep to this in 8 days. That was when I was not at work or other obligations. When I was young I could do this kind of work all the time, but now it takes it out of me. Several people stopped by to see what I was working on and one guy told me that "..... you can't buy fun like this!" I guess he was right. Anyway, the driveway is now empty and cleaned off. Now to concentrate on Allison's Jeep. I think I will wait until this weekend is over however.

Here was the last I saw of the donor Jeep:

http://i10.photobucket.com/albums/a122/matchframe/BDG/Chili12.jpg

I will be posting parts for sale later in the Houston section if anyone is interested. I still have to go through what I pulled off the Jeep to see what I will not be using on Kermit and also to see what parts are good.

[matchframe]

I have a question.... The Jeep I am working on is a '97 with a 4.0, the donor Jeep was a '99 with a 4.0. I need to use the intake from the '99 4.0 to the '97. There is a noticeable difference in the intake runners, the '99's intake has much larger runners compared to the '97. It looks like to me that they will interchange. My question is, what about the intake gasket, do I get a gasket for a '99 since that is the intake I will using or for the '97, since that is what the head is.

Thanks!!

[Mudderoy]

I have a question.... The Jeep I am working on is a '97 with a 4.0, the donor Jeep was a '99 with a 4.0. I need to use the intake from the '99 4.0 to the '97. There is a noticeable difference in the intake runners, the '99's intake has much larger runners compared to the '97. It looks like to me that they will interchange. My question is, what about the intake gasket, do I get a gasket for a '99 since that is the intake I will using or for the '97, since that is what the head is.

Thanks!!

Using the 99+ intake is a common upgrade. 5 to 25 hp gains are reported. Which gasket I don't know yet, but I'm putting a 99+ intake on my motor that is in the process of being built, so I'll know soon. ;)

[4.3LXJ]

IIRC if you use the 99+ manifold you need the 99+ gasket. The runner i a little larger and you need to port the head a little to match it.

[matchframe]

IIRC if you use the 99+ manifold you need the 99+ gasket. The runner i a little larger and you need to port the head a little to match it.

Thanks!! Good to know! :thumbsup:

[matchframe]

IIRC if you use the 99+ manifold you need the 99+ gasket. The runner i a little larger and you need to port the head a little to match it.

Another thought, since I have the complete '99 4.0 should I use the head from that engine instead of porting the head of the '97?

[4.3LXJ]

Use the 97 head. It breathes better. The original intent was to up the horsepower of the 99 engine, but they couldn't use that head design to pass emissions in 99 with that much horsepower, so they restricted the ports a little to make up for it. So the HO head breathes better, and the 99 intake breathes better. The hot combo is with those two pieces.

[matchframe]

Use the 97 head. It breathes better. The original intent was to up the horsepower of the 99 engine, but they couldn't use that head design to pass emissions in 99 with that much horsepower, so they restricted the ports a little to make up for it. So the HO head breathes better, and the 99 intake breathes better. The hot combo is with those two pieces.

Cool ! Good to know!! Thanks!! :thumbsup:

[matchframe]

Look what FedEx brought yesterday!

http://i10.photobucket.com/albums/a122/matchframe/BDG/Untitled-2.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Untitled-1.jpg

[matchframe]

I finally bought a MIG Welder! I have been welding with a stick welder for more years than I care to remember. Lately, the type of welding I have been needing to do is mostly bodywork such as on Kermit and on my '73 VW Bug.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Untitled.jpg

Trying out the new MIG on some scrap metal. Right now I am just using flux core wire. Later I will get a tank and try out solid core wire welding.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Welder2.jpg

[4.3LXJ]

Now it is play time :woot:

[JENSSEN]

Great choice on the Welder!

Model 500-500 by chance?

[matchframe]

Great choice on the Welder!

Model 500-500 by chance?

It's the Handler 140.

[bluedragon436]

Need to pick up a new grill like that to replace my cracked one, and would love to pick up a welder like that to learn with... Can't wait to see progress on Kermit

[matchframe]

Need to pick up a new grill like that to replace my cracked one, and would love to pick up a welder like that to learn with... Can't wait to see progress on Kermit

I highly recommend a welder like this! I have been welding for more years that I care to remember using a stick welder. Seems like most times I have to do a practice bead before I get to the real work with the stick welder. I practiced once the day I bought this one and yesterday when I used it I did not do a practice bead, I went straight to work with it, it was a whole lot easier using this wire welder.

[matchframe]

Yesterday I got a lot done on Kermit's engine. I pull the exhaust off, welded up a small crack at the collector. I re-installed the exhaust, then installed the '99 intake. Going to a '99 intake on a '97 engine is pretty straight forward. I had to extend one wire connector to reach it's sensor, had to drill a hole so I could mount the fuel line bracket and re-route a couple of vacuum lines to reach. I still have one vacuum line I need to extend and one vacuum port to block off.

Did not take any pics since I was so focused on the engine work. I will try to take some pics this afternoon to show the progress. :thumbsup:

[4.3LXJ]

I highly recommend a welder like this! I have been welding for more years that I care to remember using a stick welder. Seems like most times I have to do a practice bead before I get to the real work with the stick welder. I practiced once the day I bought this one and yesterday when I used it I did not do a practice bead, I went straight to work with it, it was a whole lot easier using this wire welder.

Yes, you are now spoiled. I only use my stick welder for special jobs.

[matchframe]

I almost have the engine ready to start. The main thing I have left is one of the connectors to the computer was damaged in the wreck so I will need to swap out the connector case. I have the connector from the donor Jeep so I plan to try to move these wires and pins to that connector housing. One wire does need to be spliced however but I have a good idea of how to do that. Still have not figured out exactly how to go about moving all the wires with pins over to the replacement housing. Any suggestions would be greatly appreciated! :thumbsup:

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep21.jpg


Here are some shots of the engine showing how much I have done so far.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep20.jpg

Here is the '99 intake in place. I have all the wiring and vacuum connected.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep23-1.jpg

[4.3LXJ]

Generally the pins are fed through from the back and have little clips that secure them in. There is a tool for this that I have seen at electrical shops that you slip in from the pin side and it pushes the clips in so you can pull the pin out the back.

[Carves]

Generally the pins are fed through from the back and have little clips that secure them in. There is a tool for this that I have seen at electrical shops that you slip in from the pin side and it pushes the clips in so you can pull the pin out the back.


X 2

Be careful tho ... the clips get fragile with heat & age.

As a clip "tool" ..... sometimes, a thin, plastic ziptie, cabletie or ziplock or whatever you fellas call em ... will get the job done too.

[msmoorenburg]

I have a complete harness out of the 98 the grounds were cut if you want to save some time. You may have to used the sensors off the 99. The Iac was different

[matchframe]

I have a complete harness out of the 98 the grounds were cut if you want to save some time. You may have to used the sensors off the 99. The Iac was different

I was able to solder all 20 wires to the '99 connector! Got the cables dressed back to the harness, plugged the computer back in, bled fuel on the fuel rail and cranked it up! Engine fired right up and I got good readings on the oil pressure. I could not let it run long since trans fluid was being projectiled across the driveway. My wife called our daughter so she could hear Kermit run. I started it again for her to hear. Again, only let it run for about 10 seconds before I had to shut it back down.

I plan to go to Pick A Part on Wednesday afternoon to shop for a hood, fender and other misc. stuff. Once I find a fender, that will help guide the welding of the inner fender/unibody.

To me, this is the exciting part of a re-build - once you hear the engine fire up. :thumbsup:

[bluedragon436]

I'm sure your daughter was happy to hear it start up, and will be even happier when she is able to enjoy driving her Kermit again!

[matchframe]

I went to Pick-A-Part this afternoon and look what I found!!! The exact color of everything I need to put Kermit back on the road.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep30.jpg

I got these today and plan to go back tomorrow to get the passenger fender and aluminum raditator.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep32.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep31.jpg

[4.3LXJ]

Nice find. Kermit will look as good as new, well almost

[matchframe]

Nice find. Kermit will look as good as new, well almost

These pieces are pretty good shape. A few small dents here and there but those can be hammered and dollied out while I have the pieces off the Jeep.

[Brasscatz]

These pieces are pretty good shape. A few small dents here and there but those can be hammered and dollied out while I have the pieces off the Jeep.

Great find! You could also leave the few dings in there as "battle scars".... wear them like a medal!

Can't wait to see that thing all together!:D:D

[Mudderoy]

I went to Pick-A-Part this afternoon and look what I found!!! The exact color of everything I need to put Kermit back on the road.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep30.jpg

I got these today and plan to go back tomorrow to get the passenger fender and aluminum raditator.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep32.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep31.jpg

:wow: Kermit has a guardian angle! Which pick-a-part is that? I'd like to get that side molding, oh assuming you're not getting it. PM me if you don't want to divulge the location until you are done scavenging! :D

[matchframe]

:wow: Kermit has a guardian angle! Which pick-a-part is that? I'd like to get that side molding, oh assuming you're not getting it. PM me if you don't want to divulge the location until you are done scavenging! :D

It is the Pick-A-Part on Wallisville Rd. This XJ in in the new car section. I am heading back there today to get a few more things. I almost had the passenger-side fender off when they stopped me because they were closing. I need to go back for that fender and the radiator. I was not in the market for a radiator, but this one has an aluminum one and I want to grab it. I also need the clock spring out of it as well.

I did not know about the new car section when I first got there. There was not much of an XJ selection in the main part. I called Matt to ask if some of the older XJ parts would fit a '97. In the conversation he said did you look in the new car section. That is when I found this XJ. I texted my daughter a picture of it and she was very excited about this find!!

BTW, it also has an overhead console. I don't need it, but FYI.

[Mudderoy]

It is the Pick-A-Part on Wallisville Rd. This XJ in in the new car section. I am heading back there today to get a few more things. I almost had the passenger-side fender off when they stopped me because they were closing. I need to go back for that fender and the radiator. I was not in the market for a radiator, but this one has an aluminum one and I want to grab it. I also need the clock spring out of it as well.

I did not know about the new car section when I first got there. There was not much of an XJ selection in the main part. I called Matt to ask if some of the older XJ parts would fit a '97. In the conversation he said did you look in the new car section. That is when I found this XJ. I texted my daughter a picture of it and she was very excited about this find!!

BTW, it also has an overhead console. I don't need it, but FYI.

I went through a multi-year fight with running hot on the highway. 3 core all metal fail! Went to a single row aluminum plastic and problem was cured! Don't use anything but aluminum. I'm going to get a 2 row all aluminum when I can find the right one.

[matchframe]

I finally got all the pieces I needed off the Jeep at Pick-A-Part.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep41.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep40.jpg

I also got a lot more that are not in these pics, such as the radiator, condenser, air box, clock spring, cruise control buttons....etc.

Just as I was finishing up today, a gentleman showed up and was asking me some questions about the vacuum lines which operates the air vents. He has a '97 XJ Country. I am not that familiar with the way Jeeps are set up so I recommended he sign up here at xjtalk.com and that someone here would be able to help him. I hope he signs up. :thumbsup:

[matchframe]

I installed the 2 airbags over the weekend and got most of the dash re-installed. Only thing left on the dash is to re-install the radio and center trim. We took the radio out the night Allison had the wreck since we were not sure of Kermit's future at that time. Also did some other minor stuff but did not take any pics. I will take some pics this afternoon and post them.

The outside of Kermit still looks the same, but that will change this week. :thumbsup:

[matchframe]

Here are some pics of Kermit's new airbags installed. The radio will probably be the last thing I install after the bodywork is complete.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep47.jpg

We cleaned out the interior this afternoon and let it air out some. When Allison went through the ditch in the wreck, thankfully the ditch was full of water which help slow her down a lot before impact. She went from 65 MPH to 0 MPH in less than 50 feet. I had washed the mud off the outside, but noticed this afternoon some of the mud which got between the doors and door frames.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep46.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep45.jpg

If you ever wonder how big airbags are once deployed, here are what Kermit's looks like. This one is the passenger side. I put it in this chair to give a size comparison.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep50.jpg

This is the drivers side airbag. I hug it on the engine lift hook when I first started working on Kermit to show what helped keep Allison from getting hurt. I may keep it up there for a while.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep52.jpg

[Brasscatz]

That's a nice stingray too.... '78?

[matchframe]

That's a nice stingray too.... '78?

It is a '78. One of my many projects. It is off the frame right now which is why it is so high up in the air. I am about to drop it back on the frame since I finished welding gussets to strengthen the frame from flexing. I am building a Gen V 454 Big Block for it. It is going to be my street bruiser..... that is if I can afford to keep gas in it. I was close to dropping it back on the frame when Allison had her wreck and I had to shift my focus from the Vette to the Jeep.

[Brasscatz]

It is a '78. One of my many projects. It is off the frame right now which is why it is so high up in the air. I am about to drop it back on the frame since I finished welding gussets to strengthen the frame from flexing. I am building a Gen V 454 Big Block for it. It is going to be my street bruiser..... that is if I can afford to keep gas in it. I was close to dropping it back on the frame when Allison had her wreck and I had to shift my focus from the Vette to the Jeep.

Very nice!!! I love those old Vettes! I estimate you'll get about 8-13 mpg in it... maybe :D

I had an '80 T/A with the 400 BB 6.6... I got about 8 mpg with the wind behind me going downhill!!! Of course at .98 a gallon, wasn't a big deal back then!

[matchframe]

Today I started installing the inner fender support.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep56.jpg

In order to make sure that it is in the right spot and level, I leveled out the Jeep first.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep57.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep58.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep59.jpg



Then I used the support brackets to bolt it into place as well as the upper radiator support. I mocked up the front header panel/grill to see if it was level and square.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep63.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep61.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep62.jpg

I spot welded the fender support in place then installed the driver's side fender to make sure it lines up correctly. Everything lined up right except the two front bolts on the fender to fender support. I will need to grind off the spot welds and move the fender support forward about 1/16 of an inch. that is where I will pick up tomorrow.

[msmoorenburg]

looks good

[Mudderoy]

Very gratifying to see XJs being brought back, you know instead of going to the crusher.

[matchframe]

I got the inner fender welded in today. The tricky part is getting the piece in the right spot before welding it in. I got the distance from the firewall correct by loosely bolting the fender on to make sure all the bolt holes line up. I spot welded the fender in place then took the fender back off.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep70.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep71.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep69.jpg


In order to make sure the front of the inner fender was at the same level as the opposite fender I put a piece of wire between the inner fenders and clamped them in place I had a turn buckle to tighten the wire so it would be straight across. I checked the level then adjusted the height of the new inner fender. Once it was level I spot welded in place

I completed the welds and started installing the plastic inner fender, the washer tank and the driver's side fender.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep67.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep68.jpg

The fender is in the right spot but I will need to adjust the door height.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep66.jpg

[4.3LXJ]

That is coming along very nicely. Jensen, one of our members, also known as our unofficial "Cherokee Rescue" would definitely approve

[JENSSEN]

)))high-five(((

[xjrev10]

Very cool. Nice job! I've crushed XJs that where damaged less!

[Brasscatz]

Very cool. Nice job! I've crushed XJs that where damaged less!

Noooooooooooo! :sign0024:

[matchframe]

I have not been able to do any work on Kermit lately because my son's Mini Cooper has had problems. My son is a student at the Art Institute in Dallas. My wife and I drove to Dallas on Wednesday afternoon to leave him my wife's van to drive while we trailered hi Mini back home. Mini Coopers tend to be real expensive to have fixed so therefore I really did not trust anyone in Dallas to work on it. Long story short, The Mini threw it's belt and the first thing shops want to do is replace the Super Charger which cost $2,700 just for the parts. I was not convinced that the SC had gone bad so that is why I brought it home to find out for myself. If anyone here has a Mini and you want to find out good info on them, I recommend www.motoringalliance.com (http://www.motoringalliance.com/#axzz1uTbC7iaE). The folks there have been a tremendous help so far.

Here are a couple of shots of the Mini on the trailer:

http://i10.photobucket.com/albums/a122/matchframe/BDG/MINI-3.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/MINI3-1.jpg

Mini Cooper have a neat way of safety chaining which is there because of the English Channel Ferries require this.

http://i10.photobucket.com/albums/a122/matchframe/BDG/MINI2-2.jpg

[bluedragon436]

My commander at work at his S do the same thing... All we did was replaced the belt, because the SC spun just fine by hand, and didn't feel like it had any binding or anything like the dealership said it did... He has been running it with the new belt on it for over a year now with no issues... I think the stealerships just love trying to get one over on folks!!

[matchframe]

My commander at work at his S do the same thing... All we did was replaced the belt, because the SC spun just fine by hand, and didn't feel like it had any binding or anything like the dealership said it did... He has been running it with the new belt on it for over a year now with no issues... I think the stealerships just love trying to get one over on folks!!

That is good to hear!! I plan to look everything over but anticipate doing what your Commander did.

Thanks!!

[dancome433]

I have not been able to do any work on Kermit lately because my son's Mini Cooper has had problems. My son is a student at the Art Institute in Dallas. My wife and I drove to Dallas on Wednesday afternoon to leave him my wife's van to drive while we trailered hi Mini back home. Mini Coopers tend to be real expensive to have fixed so therefore I really did not trust anyone in Dallas to work on it. Long story short, The Mini threw it's belt and the first thing shops want to do is replace the Super Charger which cost $2,700 just for the parts. I was not convinced that the SC had gone bad so that is why I brought it home to find out for myself. If anyone here has a Mini and you want to find out good info on them, I recommend www.motoringalliance.com (http://www.motoringalliance.com/#axzz1uTbC7iaE). The folks there have been a tremendous help so far.


My commander at work at his S do the same thing... All we did was replaced the belt, because the SC spun just fine by hand, and didn't feel like it had any binding or anything like the dealership said it did... He has been running it with the new belt on it for over a year now with no issues... I think the stealerships just love trying to get one over on folks!!

Wow, thats good to know, my mom has...well my sis kinda stole it from my mom, a 05 Mini S. Its been a pretty good little car so far, havent had any real issues with it(knock on wood). Just out of curiosity how many miles does your son's Mini have? Just to be on the look out for any hints of that problem once my mom/sis' Mini hits that general mileage, currently it has 73xxx miles.

[Brasscatz]

One of my stores is the Mini store in The Woodlands... I can make sure they treat you right if you ever need to go up there.

[bigjim350]

Most the imports now have those hookups in the bumper like that. Thats the only way you can load them on a flatbed wrecker cause there is nothing else to hook to.

Sent from my nerdy smartphone

[matchframe]

Wow, thats good to know, my mom has...well my sis kinda stole it from my mom, a 05 Mini S. Its been a pretty good little car so far, havent had any real issues with it(knock on wood). Just out of curiosity how many miles does your son's Mini have? Just to be on the look out for any hints of that problem once my mom/sis' Mini hits that general mileage, currently it has 73xxx miles.


His Mini has 49,000 mile on it.

I took a quick look without digging in to it and I think it may be the idler pulley. It looks like it has gotten really hot. First chance I will have to take it apart to get a closer look at it is next Tuesday. Tomorrow and Monday are really booked for me with other stuff.

[matchframe]

Kermit is ALIVE!!!

I got it ready to take the first test drive today. I still have lots of little things to do to finish, but was able to do a test drive.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep74.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep73.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep76.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep75.jpg

Allison got to be the one to take Kermit for the first test drive:

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep72.jpg

[matchframe]

Here is a video I took with my phone of the first test drive. Not very good quality, but captures the event.

BDG :: Jeep1stDrive.mp4 video by matchframe - Photobucket@@AMEPARAM@@file=http%3A%2F%2Fvid10.pho tobucket.com%2Falbums%2Fa122%2Fmatchframe%2FBDG%2F Jeep1stDrive.mp4@@AMEPARAM@@file=http%3A%2F%2Fvid1 0.photobucket.com%2Falbums%2Fa122%2Fmatchframe%2FB DG%2FJeep1stDrive.mp4

[matchframe]

One of my stores is the Mini store in The Woodlands... I can make sure they treat you right if you ever need to go up there.

I really appreciate that!! :thumbsup:

Is the Mini store a repair place or where you can buy parts?

[oderdene]

congrats bro, you did great job for your daughter and of course for the XJ. See the light on her eyes

[4.3LXJ]

:congrats::woot::woot:

[Brasscatz]

Here is a video I took with my phone of the first test drive. Not very good quality, but captures the event.

BDG :: Jeep1stDrive.mp4 video by matchframe - Photobucket (http://s10.photobucket.com/albums/a122/matchframe/BDG/?action=view&current=Jeep1stDrive.mp4)

Lookin good buddy!!!


I really appreciate that!! :thumbsup:

Is the Mini store a repair place or where you can buy parts?

It's the Mini Cooper Dealership that's part of the BMW dealership up there. They do it all. If they don't have parts, they can order them. I've known the General Manager, General Sales Manager, etc. for about 5 years now. The Service Manager is pretty cool too.

Just let me know if you need to go up there for anything, and I'll make sure they know you're a friend of mine. They'll treat you right.

[Mudderoy]

Lookin good buddy!!!



It's the Mini Cooper Dealership that's part of the BMW dealership up there. They do it all. If they don't have parts, they can order them. I've known the General Manager, General Sales Manager, etc. for about 5 years now. The Service Manager is pretty cool too.

Just let me know if you need to go up there for anything, and I'll make sure they know you're a friend of mine. They'll treat you right.

I read "mini store" and thought of Quicky Mat from the Simpson.... :rotfl2:

[matchframe]

Lookin good buddy!!!



It's the Mini Cooper Dealership that's part of the BMW dealership up there. They do it all. If they don't have parts, they can order them. I've known the General Manager, General Sales Manager, etc. for about 5 years now. The Service Manager is pretty cool too.

Just let me know if you need to go up there for anything, and I'll make sure they know you're a friend of mine. They'll treat you right.

Thanks!! I appreciate it!! :thumbsup:

[Brasscatz]

Thanks!! I appreciate it!! :thumbsup:

Anytime! My pleasure sir! :thumbsup:

[matchframe]

I went to Pick-A-PArt to get a set of hood hinges and a fan shroud. I had 2 sets of hinges, but both sets, the driver's side were bent. They did not look like it until I installed them. This afternoon, Allison is going to help me install the hood. Once that is done, there are just a few details to take care of and Kermit will be done.

I will post some final pics later. :thumbsup:

[Mudderoy]

I went to Pick-A-PArt to get a set of hood hinges and a fan shroud. I had 2 sets of hinges, but both sets, the driver's side were bent. They did not look like it until I installed them. This afternoon, Allison is going to help me install the hood. Once that is done, there are just a few details to take care of and Kermit will be done.

I will post some final pics later. :thumbsup:

So glad there are people that will take the time to keep the beloved XJs on the road. :thumbsup:

[matchframe]

Allison helped me install the hood this afternoon. Took us awhile to get it all adjusted right, but we finally got it.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep78.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep77.jpg

I am pretty much finished re-building Kermit and I made it before my goal of May 19th, which is Allison's 19th birthday. When I first started this project, I wanted to finish before next Fall so she could have Kermit to take back to school, but it all went together a whole lot quicker than I thought.

There are just a few things I have left to do such as install the airbox, electric fan, and finish & vacuum/charge the A/C. Oh, and Allison reminded me that the radio needs to be re-installed. The engine runs great. Funny thing happened this afternoon however, I could not get the engine to idle down, it would run about 3,000 RPM. I was almost convinced there was a vacuum leak so I started tracing out hoses to make sure everything was plugged. I noticed the air intake hose that goes to the top of the airbox and throttle body was loose so I pulled it off to re-set the locking ring. When I did that, I found a red rag down inside the throttle body holding the butterfly open. Once I pulled the rag out, the engine ran much better. :)

I want to thank everyone here for advice, help and encouragement this past couple of months. You all have been a great help!!

Allison also thanks you! She got her Kermit back.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep83.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep79.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep81.jpg

[Brasscatz]

That's great buddy!!! Looks amazing! Again, glad she's ok, and glad that Kermit could be put back together again!

[4.3LXJ]

Good job man. Can't tell it was wrecked

[XJ Wheeler]

Good as new! Nice job, you're a good dad.:thumbsup:

[oderdene]

congrats bro. Good Dad and lucky girls, rejoined with each other (Allison and XJ) :)

[Carves]

...... Once I pulled the rag out, the engine ran much better. :)

:D :D


Nice job .... looks good as new .. :thumbsup:

[cantab27]

top job and top write up .....shes looking good ...cant kill the green ones

[matchframe]

I have to hand it to Jeeps...... they are a whole easier and cheaper to work on than Mini Coopers!!! I had to replace the harmonic balancer/crank pulley along with the tensioner assembly and idler pulley. All of that in a space where it is almost impossible to get your hands into. And, it takes special tools which I had to build myself (Because I don't like to spend money on something I might use once)

Here is a link to that discussion on a MINI forum if interested: http://www.motoringalliance.com/forums/cooper-s/13290-belt-bypass-supercharger.html#axzz1vFGRBoDq

[Mudderoy]

I have to hand it to Jeeps...... they are a whole easier and cheaper to work on than Mini Coopers!!! I had to replace the harmonic balancer/crank pulley along with the tensioner assembly and idler pulley. All of that in a space where it is almost impossible to get your hands into. And, it takes special tools which I had to build myself (Because I don't like to spend money on something I might use once)

Here is a link to that discussion on a MINI forum if interested: http://www.motoringalliance.com/forums/cooper-s/13290-belt-bypass-supercharger.html#axzz1vFGRBoDq

Oh I'm amazed at how easy Jeeps are (at least the XJ and the TJ). Reminds me of how my 250, 327, 350 engines were in my Ventura and Nova, just lasts longer with my foot.

[4.3LXJ]

I have to hand it to Jeeps...... they are a whole easier and cheaper to work on than Mini Coopers!!! I had to replace the harmonic balancer/crank pulley along with the tensioner assembly and idler pulley. All of that in a space where it is almost impossible to get your hands into. And, it takes special tools which I had to build myself (Because I don't like to spend money on something I might use once)

Here is a link to that discussion on a MINI forum if interested: http://www.motoringalliance.com/forums/cooper-s/13290-belt-bypass-supercharger.html#axzz1vFGRBoDq

As far as I can tell from my limited experience, that is typical Brit engineering.

[cantab27]

As far as I can tell from my limited experience, that is typical Brit engineering.

outta bmw the copper...????but ya right about the brits...50 thousand bolts to hold things togeather.....my old brick...

http://i469.photobucket.com/albums/rr52/cantab27/20-10-08_1559.jpg

[Brasscatz]

outta bmw the copper...????but ya right about the brits...50 thousand bolts to hold things togeather.....my old brick...

http://i469.photobucket.com/albums/rr52/cantab27/20-10-08_1559.jpg

I make the comment all the time when I'm at the Mini Dealership how funny it is that they have British flags on EVERYTHING, but the cars are made by Germans in Germany....

[Carves]

I make the comment all the time when I'm at the Mini Dealership how funny it is that they have British flags on EVERYTHING, but the cars are made by Germans in Germany....


Not those "Minis", Brasscatz .... proper Minis - like in Cantabs piccy ....

:p

:D:D


ooooooops .... no .... he has a 2006 model after all .... :o .. :smiley-laughing021:

[matchframe]

I make the comment all the time when I'm at the Mini Dealership how funny it is that they have British flags on EVERYTHING, but the cars are made by Germans in Germany....

When I was working on my son's MINI I looked up the VIN to see where it was made and it showed it was built in Oxford UK. There was BMW on all of the parts since they bought out MINI several years ago.

[matchframe]

I have finished up all of the details of Kermit and Allison has been out driving it today. Only thing that still needs to be done is the A/C which I plan to take care of this week. I will post updates as I work on that. :thumbsup:

[Mudderoy]

I have finished up all of the details of Kermit and Allison has been out driving it today. Only thing that still needs to be done is the A/C which I plan to take care of this week. I will post updates as I work on that. :thumbsup:

Good job and good Dad! :thumbsup:

[Brasscatz]

When I was working on my son's MINI I looked up the VIN to see where it was made and it showed it was built in Oxford UK. There was BMW on all of the parts since they bought out MINI several years ago.

Good call, I forgot to add in there that the Countryman is the first Mini built fully outside of the UK, it is in fact built in Austria. :thumbsup:

[matchframe]

Good call, I forgot to add in there that the Countryman is the first Mini built fully outside of the UK, it is in fact built in Austria. :thumbsup:

That's interesting! I did not know that.

[matchframe]

How many pounds of R134 does an xj A/C system hold?

Thanks!

[msmoorenburg]

How many pounds of R134 does an xj A/C system hold?

Thanks!

Don't quote me like 1.5 cans. I charge via superheat and its 2 1/2 times ambient temp for the high side pressure, and low should be 32~40 or same as discharge temp (well real close). the fan should be on high with recirc on and windows and doors shut.

hope it helps

[Brasscatz]

According to mine...

http://i356.photobucket.com/albums/oo7/thestalliontruck/Red%20Bandit%20XJ/IMAG0812.jpg

[Brasscatz]

Don't quote me like 1.5 cans. I charge via superheat and its 2 1/2 times ambient temp for the high side pressure, and low should be 32~40 or same as discharge temp (well real close). the fan should be on high with recirc on and windows and doors shut.

hope it helps

you beat me to it! LOL! :love0055:

[JENSSEN]

Allison helped me install the hood this afternoon. Took us awhile to get it all adjusted right, but we finally got it.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep78.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep77.jpg

I am pretty much finished re-building Kermit and I made it before my goal of May 19th, which is Allison's 19th birthday. When I first started this project, I wanted to finish before next Fall so she could have Kermit to take back to school, but it all went together a whole lot quicker than I thought.

There are just a few things I have left to do such as install the airbox, electric fan, and finish & vacuum/charge the A/C. Oh, and Allison reminded me that the radio needs to be re-installed. The engine runs great. Funny thing happened this afternoon however, I could not get the engine to idle down, it would run about 3,000 RPM. I was almost convinced there was a vacuum leak so I started tracing out hoses to make sure everything was plugged. I noticed the air intake hose that goes to the top of the airbox and throttle body was loose so I pulled it off to re-set the locking ring. When I did that, I found a red rag down inside the throttle body holding the butterfly open. Once I pulled the rag out, the engine ran much better. :)

I want to thank everyone here for advice, help and encouragement this past couple of months. You all have been a great help!!

Allison also thanks you! She got her Kermit back.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep83.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep79.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep81.jpg

Top notch repair Sir, my hats off to you!

I am glad I am not he rebuilder/savior or these old jeeps

[Mudderoy]

Now it's time to lift it! :D :popcorn:

[matchframe]

Don't quote me like 1.5 cans. I charge via superheat and its 2 1/2 times ambient temp for the high side pressure, and low should be 32~40 or same as discharge temp (well real close). the fan should be on high with recirc on and windows and doors shut.

hope it helps

Thanks!!! This does help!! :thumbsup:

[matchframe]

According to mine...

http://i356.photobucket.com/albums/oo7/thestalliontruck/Red%20Bandit%20XJ/IMAG0812.jpg

I guess that sticker is gone off of Kermit. I looked for one like this. Thanks for posting this pic! :thumbsup:

[matchframe]

Top notch repair Sir, my hats off to you!

I am glad I am not he rebuilder/savior or these old jeeps

Thank you Sir!!! :thumbsup:

[matchframe]

Now it's time to lift it! :D :popcorn:

If it were mine I would lift it. :D

[4.3LXJ]

You can lift it and get her some platforms to wear so she can get in and out :D

[Brasscatz]

I guess that sticker is gone off of Kermit. I looked for one like this. Thanks for posting this pic! :thumbsup:

Anytime buddy. I was looking at the one on the hood (or bonnet for cantab and carves :D) then I finally spotted it in front of the radiator. I knew I had it somewhere!

[matchframe]

I replaced the drier and vacuumed/charged the system yesterday. I don't have a vacuum pump so I did that the old military way.... I used the engine vacuum to pull the system down. Only problem with doing it this way is the deepest pull you can do is about 25-27 pounds. Ideally you need to pull the system down to 30 plus pounds.

I found my old A/C manifold which is old school R-12. I cleaned it up and converted it to R-134 with new hoses and adapters.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep85.jpg

Here is a vacuum port I connected the A/C manifold to:

http://i10.photobucket.com/albums/a122/matchframe/BDG/Untitled-3.jpg

I changed the manifold connectors to accommodate the vacuum hose which connects to the engine intake manifold:

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep84-1.jpg

Here is the complete set up:

http://i10.photobucket.com/albums/a122/matchframe/BDG/Untitled-4.jpg

I ran the engine for about 30 minute at about 2,800 RPM

http://i10.photobucket.com/albums/a122/matchframe/BDG/Untitled-6.jpg

Showing the vacuum:

http://i10.photobucket.com/albums/a122/matchframe/BDG/Untitled-5.jpg

I closed off the manifold and the vacuum held for about 30 minutes. I then charged the system and it blows cold air. I still sort of feel like I may be chasing a small leak later, but I guess time will tell.

[Mudderoy]

Very cool, pun intended! :drinking:

[matchframe]

Very cool, pun intended! :drinking:

:)

[Brasscatz]

Nicely done!

[XJ Wheeler]

Didn't know you could do it that way, rather cool use of available means.

Would you possibly suck anything in the engine like that?

[matchframe]

Didn't know you could do it that way, rather cool use of available means.

Would you possibly suck anything in the engine like that?

This method is a military way of doing it. A vacuum pump is one less thing to take when deploying. Since the A/C system was opened to replace the drier, there should only be air and residue of R-134 and oil, which is combustible. Since the engine is running above idle, around 2,800 RPM, what little goes into the engine does not stay very long so there is no harm to the engine.

[Mudderoy]

This method is a military way of doing it. A vacuum pump is one less thing to take when deploying. Since the A/C system was opened to replace the drier, there should only be air and residue of R-134 and oil, which is combustible. Since the engine is running above idle, around 2,800 RPM, what little goes into the engine does not stay very long so there is no harm to the engine.

Would a lower RPM give you a better vacuum though?

[matchframe]

Would a lower RPM give you a better vacuum though?

I sort of played around with different RPMs and 2,800 seemed to be optimal. Anything higher was actually less vacuum. Be interesting to do a test to see what the highest vacuum @ rpm would be.

[matchframe]

There is an A/C leak and I have traced it to the Evaporator. :(

I have the dash almost pulled back out and plan to get to the Evaporator this afternoon. While I am in there, I plan to also replace the heater core since it has 220,000 miles on it.

I will post pics later. :thumbsup:

[msmoorenburg]

There is an A/C leak and I have traced it to the Evaporator. :(

I have the dash almost pulled back out and plan to get to the Evaporator this afternoon. While I am in there, I plan to also replace the heater core since it has 220,000 miles on it.

I will post pics later. :thumbsup:

Its fun to do and not that hard enjoy :)

[Mudderoy]

There is an A/C leak and I have traced it to the Evaporator. :(

I have the dash almost pulled back out and plan to get to the Evaporator this afternoon. While I am in there, I plan to also replace the heater core since it has 220,000 miles on it.

I will post pics later. :thumbsup:

How did you find it. I was looking for dye last night and saw no leaks.

[matchframe]

How did you find it. I was looking for dye last night and saw no leaks.

I got an electronic leak detector from harbor freight: http://www.harborfreight.com/electronic-freon-and-halogen-leak-detector-92514.html

I could not get any readings with the leak detector until I put the sensor past the grommet where the evaporator tubes go through the firewall. I got a pretty good hit there.

I am not a big fan of HF tools, but for the price, they work pretty good. If these tools were to be used a lot, I would get Craftsman, Huskey or if I used them all the time I would get Snap-On.

Another cool tool I picked up at HF was this: http://www.harborfreight.com/air-vacuum-pump-with-r134a-and-r12-connectors-96677.html

I have not used it yet, but for the price I had to get it. I understand that you have to have a large volume air compressor for this to work right and mine is an 80 gallon.

[Mudderoy]

I got an electronic leak detector from harbor freight: http://www.harborfreight.com/electronic-freon-and-halogen-leak-detector-92514.html

I could not get any readings with the leak detector until I put the sensor past the grommet where the evaporator tubes go through the firewall. I got a pretty good hit there.

I am not a big fan of HF tools, but for the price, they work pretty good. If these tools were to be used a lot, I would get Craftsman, Huskey or if I used them all the time I would get Snap-On.

Another cool tool I picked up at HF was this: http://www.harborfreight.com/air-vacuum-pump-with-r134a-and-r12-connectors-96677.html

I have not used it yet, but for the price I had to get it. I understand that you have to have a large volume air compressor for this to work right and mine is an 80 gallon.

I forgot all about those electronic sniffers!

[matchframe]

The whole dash along with the steering column has to come out in order to get to the box that has the evaporator and heater core. One thing I did trying to save time, but would not recommend is I left the console in. You have to take out the lower bracket and to get to it you have to move the console back about 6 inches. I could have done that, but I had the rear seat folded forward to make room to store the dash parts and that kept the console from going back far enough. Lots of squeezing and trying to take out bolts under the front of the console was a pain, but I finally got them out. Allison helped me lift the base of the dash out. Really odd seeing the inside without the dash.

I have not taken the case apart that has the evaporator and heater core yet, I will do that tomorrow.

Here is what the inside looks like without the dash but with the core case still in:

http://i10.photobucket.com/albums/a122/matchframe/BDG/Dash1.jpg

http://i10.photobucket.com/albums/a122/matchframe/BDG/Dash2.jpg

[bluedragon436]

Definitely not looking forward to when that needs to be done on my XJ

[msmoorenburg]

Definitely not looking forward to when that needs to be done on my XJ

Its easier than you think. I did Tony's in 3~4 hours while pulling another one apart for the parts

[Mudderoy]

Its easier than you think. I did Tony's in 3~4 hours while pulling another one apart for the parts

Yeah he was moving fast too. That was on the 1999.

[msmoorenburg]

Yeah he was moving fast too. That was on the 1999.

i think you were still in shock when i said let yank it now :D

[Mudderoy]

i think you were still in shock when i said let yank it now :D

Yeah I felt bad, it was a lot of work.

[matchframe]

I got everything put back together and it works great! Even though pulling the dash and evaporator box was involved, it was not really hard to do. I am amazed at how these Cherokees are designed! The whole dash assembly was designed very well to pull apart and put back together without much effort.

Once I got everything back together, I pulled vacuum on the A/C system for about an hour, closed the valves and let it sit for about 40 minutes. There was no vacuum loss so I charged the system. Allison drove Kermit to Galveston yesterday and said the A/C worked great. :thumbsup:

[matchframe]

Allison leaves tomorrow, 15 August to return to Baylor. I guess this officially ends the re-birth of Kermit since I have been able to fix all the little intermittent issues since the re-build. Recently I had to track down why I was getting an airbag light. I ended up replacing the module under the console with the one I pulled from the '99. That solved that issue. The airbag light comes on at start up and now goes out after about 5 seconds. The A/C is blowing cold air and has not lost any R-134 in over a week now. I put the gauges on last night and it has full pressure. I had an alignment done yesterday and only adjustment they had to do was a little toe out. I was impressed that was all they had to do since the Jeep was hit pretty hard in the front.

I appreciate everyone's help and advice here at XJTalk. I could not have done this without you all. I plan to hang around from time to time since this is a great bunch of folks here.

http://i10.photobucket.com/albums/a122/matchframe/BDG/Jeep83.jpg

[OrangeXJ]

I'm glad every thing worked out for the good

[bluedragon436]

Glad to see Kermit lives again.... And I'm sure the happiness in your daughter's face made all the hard work worth it!!

[Brasscatz]

Yep, you have to come back regularly. It's the rules since you have an article published :D

[matchframe]

Yep, you have to come back regularly. It's the rules since you have an article published :D

That is so cool!!! :cool0010:

I did not know about the article. Thanks!!!! :thumbsup:

[matchframe]

Kermit (and Allison) are back at school. This is the first time since last March Kermit has been back at Baylor. One cool thing they do when the student arrive, is they have lots of help on hand to unload your vehicle and take your things to your room. Average time to unload a vehicle is about a minute. Yesterday they had Kermit unloaded in 50 seconds. Here is a video from my phone: 82153150-7123-4152-9079-53CCC8B5B14E-4128-00000508796E1933.mp4 video by matchframe - Photobucket@@AMEPARAM@@file=http%3A%2F%2Fvid10.pho tobucket.com%2Falbums%2Fa122%2Fmatchframe%2F821531 50-7123-4152-9079-53CCC8B5B14E-4128-00000508796E1933.mp4@@AMEPARAM@@file=http%3A%2F%2F vid10.photobucket.com%2Falbums%2Fa122%2Fmatchframe %2F82153150-7123-4152-9079-53CCC8B5B14E-4128-00000508796E1933.mp4

[Mudderoy]

Kermit (and Allison) are back at school. This is the first time since last March Kermit has been back at Baylor. One cool thing they do when the student arrive, is they have lots of help on hand to unload your vehicle and take your things to your room. Average time to unload a vehicle is about a minute. Yesterday they had Kermit unloaded in 50 seconds. Here is a video from my phone: 82153150-7123-4152-9079-53CCC8B5B14E-4128-00000508796E1933.mp4 video by matchframe - Photobucket (http://s10.photobucket.com/albums/a122/matchframe/?action=view&current=82153150-7123-4152-9079-53CCC8B5B14E-4128-00000508796E1933.mp4)

What a great way to meet girls! Oh sorry Dad. :rotfl2:

[matchframe]

Well, it has now been a full year since I finished rebuilding Kermit. I gave Kermit back to my daughter May 15, 2012. I am still amazed at how well these XJs are designed and built. Allison had no problems whatsoever this last year going to Waco and back home. She did however have a little anxiety when she was driving home for Spring-break this year since she was driving home on the year anniversary of her wreck. I drove to Bucees in Maddisonville, TX to drive with her past the spot where she had her wreck. I think just seeing my Tahoe driving with her helped keep her mind off the year before.

Also another milestone for me...... I am now one year Cancer Free as of May 8th :thumbsup:

BTW, I still have some XJ parts I need to sell. I have the 4.0 out of the '99 XJ which is complete minus the intake manifold.

[msmoorenburg]

Well, it has now been a full year since I finished rebuilding Kermit. I gave Kermit back to my daughter May 15, 2012. I am still amazed at how well these XJs are designed and built. Allison had no problems whatsoever this last year going to Waco and back home. She did however have a little anxiety when she was driving home for Spring-break this year since she was driving home on the year anniversary of her wreck. I drove to Bucees in Maddisonville, TX to drive with her past the spot where she had her wreck. I think just seeing my Tahoe driving with her helped keep her mind off the year before.

Also another milestone for me...... I am now one year Cancer Free as of May 8th :thumbsup:

BTW, I still have some XJ parts I need to sell. I have the 4.0 out of the '99 XJ which is complete minus the intake manifold.

Congrats :thumbsup: and good news on the Jeep no issues. No issues with mine either but only 3500miles so far

[XJ Wheeler]

Hey Bill! Long time. Great to hear about your one year milestone, that's awesome. Glad its going well. Coming up on the one year mark of remission for my mom too.

Still think about the rebuild of Kermit every once in a while. That's great its performing admirably, shows the quality of these things. How nice of you to go all the way to Madisonville just to do that for her.

[NW99XJ]

Also another milestone for me...... I am now one year Cancer Free as of May 8th :thumbsup:


This...right here....are the kinds of statements that really make me grateful for every day. I have lost a lot of my family to cancer, and thankfully my mother is a survivor, and into her 6th year of remission after a bout with breast cancer and colon cancer too. Congratulations from the bottom of my heart on your one year.....may there be many many more.

[Brasscatz]

Well, it has now been a full year since I finished rebuilding Kermit. I gave Kermit back to my daughter May 15, 2012. I am still amazed at how well these XJs are designed and built. Allison had no problems whatsoever this last year going to Waco and back home. She did however have a little anxiety when she was driving home for Spring-break this year since she was driving home on the year anniversary of her wreck. I drove to Bucees in Maddisonville, TX to drive with her past the spot where she had her wreck. I think just seeing my Tahoe driving with her helped keep her mind off the year before.

Also another milestone for me...... I am now one year Cancer Free as of May 8th :thumbsup:

BTW, I still have some XJ parts I need to sell. I have the 4.0 out of the '99 XJ which is complete minus the intake manifold.

Congrats! Very glad to hear the Jeep is still doing well! I know I had trouble driving past the spot where my dad was almost killed in an accident. Not sure if it ever fully goes away...
Tremendous of you to meet her part way and be the comforting factor. You are an amazing dad.
Congrats on being cancer free! That's so wonderful to hear! You and your family definitely have somebody watching over y'all!
You should hold onto that motor... never know when you might need that thing! Well... knowing these Jeeps, it'll probably be another 20 years, but still! They are getting harder and harder to find

[matchframe]

It is hard to believe that it was 3 years ago today that my daughter had her wreck in Kermit. Kermit is still driving strong and dependable. Allison is home right now on her Spring Break. She will graduate Baylor this May. For her graduation all she wants is the title of Kermit signed over to her and a black kitten. I think I can handle that :)

On a side note, my son will start at Baylor next Fall as a transfer student.

[Mudderoy]

It is hard to believe that it was 3 years ago today that my daughter had her wreck in Kermit. Kermit is still driving strong and dependable. Allison is home right now on her Spring Break. She will graduate Baylor this May. For her graduation all she wants is the title of Kermit signed over to her and a black kitten. I think I can handle that :)

On a side note, my son will start at Baylor next Fall as a transfer student.

Glad you're keeping us up to date on this. Before reading your post I was afraid you were going to say something bad about Kermit, that maybe it was being traded in or something major mechanically had failed.

Great heart warming story to hear your daughter loves it so much she wants it in her name. You may need to keep that spare motor so you can swap it when she hits 300k miles on Kermit! :patriot:

[Brasscatz]

Awesome, bud! They grow up so fast! Thanks for stopping by and giving us an update :thumbsup:

[matchframe]

Glad you're keeping us up to date on this. Before reading your post I was afraid you were going to say something bad about Kermit, that maybe it was being traded in or something major mechanically had failed.

Great heart warming story to hear your daughter loves it so much she wants it in her name. You may need to keep that spare motor so you can swap it when she hits 300k miles on Kermit! :patriot:

When she got home last Friday, we were talking about her graduation. I told her I could just sign the title over to her or whatever she wanted. She was thrilled about the title. She told us that she will never get rid of Kermit. She will keep it even if she gets something else to drive. She said she will put it out to pasture before ever getting rid of it :) Good idea of hanging on to that other 4.0. Probably would be a good idea to go ahead and freshen it up so when it's needed, we can just swap it out. :thumbsup:

[matchframe]

Awesome, bud! They grow up so fast! Thanks for stopping by and giving us an update :thumbsup:

All of you guys were such a big help back when I needed it. Just the encouragement was huge for me back then. They do grow up fast ! Where did the time go?

[4.3LXJ]

Yup, they grow up fast. My son and I are talking about an XJ for my granddaughter. So you going to put your son in an XJ? Cuts down on parts that way :D

[matchframe]

Yup, they grow up fast. My son and I are talking about an XJ for my granddaughter. So you going to put your son in an XJ? Cuts down on parts that way :D

He has a Mini Cooper S. I don't think I could get him out of that car :)

[Brasscatz]

Yeah, my wife is pregnant with our first... just the pregnancy has flown by. I can only imagine how fast they grow up from there.

[matchframe]

Yeah, my wife is pregnant with our first... just the pregnancy has flown by. I can only imagine how fast they grow up from there.

The best time of your life is just around the corner for you. Cherish every minute.

[matchframe]

Yeah, my wife is pregnant with our first... just the pregnancy has flown by. I can only imagine how fast they grow up from there.

A few months ago my daughter asked me "What is the secret of being a good parent?" I responded, " I am not sure I would the best one to ask about being the best parent, but for me, whatever was important to your child, should become just as important to you." What I thought of when I told her that was one time my son wanted a specific DVD and we were having a difficult time finding it. We went to several different stores. We ended up at a Barnes & Noble and I can recall that finding that DVD was Priority One. Here I was 40 plus years old and the most important thing to me at that moment in time was finding this DVD that I will never watch because it was a kids cartoon movie. We found it and he paid for it with money he earned. A satisfying end for me as well as for my son.

[autotech98]

Yep you just want them to be happy.

Sent from my SAMSUNG-SGH-I547

[XJ Wheeler]

Awesome to hear she wants to keep it always. That's how i feel about mine. Thanks for coming by Bill, always a pleasure.



Sent via messenger pigeon - i talk, he types.

[Poorboy]

All of you guys were such a big help back when I needed it. Just the encouragement was huge for me back then. They do grow up fast ! Where did the time go?

I just binge read the entire thread. Congrats on restoring Kermit. My own daughter will be 12 this year. They grow up fast!


Yeah, my wife is pregnant with our first... just the pregnancy has flown by. I can only imagine how fast they grow up from there.

Congrats! Babies are awesome, even when they aren't tiny babies anymore.


The best time of your life is just around the corner for you. Cherish every minute.

(Morgan freeman voice) "He's right you know".

[Pookapotamus]

Just read through this rebuild, good job!!!