Sharing some progress:

[COSXJFAN]

OK, so I have been butt deep into my XJ for quite some time now. I thought I would post some of the progress I have made in the last few weeks.


Starting with the gas tank skid * rear bumper:
http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics309.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics310.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics311.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics312.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics313.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics314.jpg



http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics335.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics338.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics339.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics340.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics351.jpg

Here are some shots of the rear bumper, and the gas tank skid mounted up and ready:

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics336.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics342.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics343.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics344.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics346.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics347.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics360.jpg


http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics366.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics364.jpg

[COSXJFAN]

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics369.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics370.jpg

T-case skid:

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics371.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics374.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics375.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics376.jpg

That is what I have been up to, and I'll be done very shortly!! I have to say that this has been a lot of work, but well worth it in the end!!

[Mudderoy]

Very nice. I especially like that gas tank skid. You could sell those! Everyone would be willing to pay you 1/2 what it cost to make. ;)

[COSXJFAN]

That might be an issue...LOL!!

[Voldemort]

I was wanting to ask you about the way you did your rear rocker panel. Did you weld a piece in after you cut it off or did you do that tuck and fold thing. I'm cutting mine off and planed on welding a piece back in and wanted to get some advise. Oh and everything looks good man nothing better than being able to do it yourself. I really like the rear bumper

[COSXJFAN]

The PO cut it all off, and I was left with patching it back in. If I was going to do it over from the beginning, I'd cut and fold it, that way you don't have to try to weld to the sheet metal, which sucks!! But to answer your question, I welded a piece in place of what was removed. I did not continuously weld, but spot welded it in place, and used flashing sealant to seal it up. The sealant is what they use on roof tops to patch in duct work and the like, and it seems to be silicone based, and still flexible with no leaks that I have found. I plan on using it to seal up around the rear wheel wells, where the fenders were trimmed. HTH!!

[Melissa]

Wow, lookin good!!

[COSXJFAN]

Thanks much!!

[Voldemort]

The PO cut it all off, and I was left with patching it back in. If I was going to do it over from the beginning, I'd cut and fold it, that way you don't have to try to weld to the sheet metal, which sucks!! But to answer your question, I welded a piece in place of what was removed. I did not continuously weld, but spot welded it in place, and used flashing sealant to seal it up. The sealant is what they use on roof tops to patch in duct work and the like, and it seems to be silicone based, and still flexible with no leaks that I have found. I plan on using it to seal up around the rear wheel wells, where the fenders were trimmed. HTH!!

Thanks for the advise. I hope mine turns out looking as good as yours.

[BlueXJ]

Good work COS. How did you make those bends in that diamond plate for the gastank skid. Do you have a hydralic brake?

[UKJeepThang]

Lookin good COS! A lotta fine work in there!!:D

Nice workshop too........I'd give anything for a car lift in my workshop!!

[COSXJFAN]

Thanks for the advise. I hope mine turns out looking as good as yours.

Thanks for the compliment!! Keep me posted on your build, and if you have any questions, I'd be glad to help anyway I can!!


Good work COS. How did you make those bends in that diamond plate for the gastank skid. Do you have a hydralic brake?

I didn't bend it, I cut it and welded it with the bends in it. That made the structure stronger, because of the seams. Thanks for the kudos Blue!!


Lookin good COS! A lotta fine work in there!!:D

Nice workshop too........I'd give anything for a car lift in my workshop!!

The lift has been a TON of help. After all of these years of working on my own stuff, I have always just laid on the ground to do the work....man, what a difference the lift makes!! It is nice not to have to roll around on the ground to do the work!!

[Voldemort]

You have also given me a lot of great ideas for my own stuff. Thanks

[Howler_GT]

I noticed the nice "military-wrap" spring packs you have there are stamped "CANADA"

Are those the 4WDHardware lifted springs?

[COSXJFAN]

Honestly, they were on this Jeep when I bought it. I believe the PO said they were all BDS, but I really have no clue who made them, and wish I did!! I put RE's 4.5" packs on my previous XJ. and they always felt stiff to me. These are a lot lighter in the rate, so they flex a lot better, but the down side is I lost some payload capacity. I'll take that trade off though!!LOL!!

[Dirt Dogg Rydas]

is that a piece of angle iron you put under the doors?

[Punisher]

Very nice work... I know I'm not going to do any rock crawling but I might consider on doing the same... just for the looks... Nice job ! ! !

[COSXJFAN]

is that a piece of angle iron you put under the doors?

Yes, 3"x3"x.250" angle iron.


Very nice work... I know I'm not going to do any rock crawling but I might consider on doing the same... just for the looks... Nice job ! ! !

Thanks!!

[N1TZU]

Awesome fabbing there COS,Nice build on your ride.........

[COSXJFAN]

Thank you!! More pics coming soon, I finished it today, aside from some odds and ends...bringing it home tomorrow!!:driving:

[COSXJFAN]

OK, I had to redesign the steering set up, but there are pics of both in here to explain. Here are all of the pics that I have to this point. I'm going out today to load the Jeep up, and bring it home. I got the steering issues resolved, I think, so it should be good to go!! Here are the pics:

Getting ready to pull the radiator, so I got the tools cleaned up and organized:
http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics379.jpg

Rad is out:
http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics381.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics382.jpg

Back in and up to temp, all is well:
http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics383.jpg

I made this sleeve out of a piece of hydraulic ram that was around, nice and strong. I placed the grade 8 bolt in it, and welded the poo out of it, then I turned it in the lathe:
http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics386.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics390.jpg

This is the piece that it goes into, I needed another adjustment point, so I used another grade 8 bolt, but this one is 1" in diameter.
http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics391.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics392.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics393.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics394.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics395.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics397.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics399.jpg
All of these pics were of the design that DID NOT work. It would shift from side to side, due to the heims moving, then I went with a double shear design, that I think is going to work. For me to have room for the newer set up, I had to lose the sway bar, but I'm not too worried about it. It is a trail rig that sees very little on road action, so all should be fine:
http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics403.jpg

http://i293.photobucket.com/albums/mm74/cosxjfan/miscpics404.jpg

Well, she is all done, and ready to go. I can't wait to get her out, and see how it all works!!

[BlueXJ]

Good work and it seems your welding has improved quite a bit. Practice is the key.

My only question is why did the radiator have to be removed for your steering upgrade?

[COSXJFAN]

I had to remove the rad and have it repaired, it had developed some leaks from the zip cords that were holding my fan on to it.

[COSXJFAN]

Practice is the key.

Yeah, and I have gotten enough practice that I wanna puke!!LOL!!:yack:

[96xj]

I had to remove the rad and have it repaired, it had developed some leaks from the zip cords that were holding my fan on to it.

was that a after market high performance fan ???
i just got ont one and was going to install it with fan zip ties any other ideas for installing them?
:smiley-scared002::smiley-scared002::smiley-scared002::smiley-scared002::smiley-scared002::smiley-scared002::smiley-scared002::smiley-scared002:

[COSXJFAN]

I found some tiny all thread that I used. I put pads between everything, and tightened the pee out of it. The problem that I had was the fan had worked it's way loose, and the bouncing caused the holes in my rad. There is no movement what so ever with the all thread, and I think that it will work well.

[BlueXJ]

Yeah, and I have gotten enough practice that I wanna puke!!LOL!!:yack:

I burned the crap out of my eyes when I first started to learn how to weld(Stick welding) and am scared a little bit and very respectful until this day. So I appreciate those that can weld and make a pretty job of it. Puke away but that is nice welding.

[COSXJFAN]

I have been lucky enough to not get flash burn in all of the years that I have been welding. (knocking on wood as we speak!!) I have heard how enjoyable it can be, and think that I really don't have to experience it to be quite honest!!LOL!! I appreciate the compliments Blue!! I really take a lot of pride in my welding, and my work in general, and I like it when people can see that!!:D

[Mudderoy]

I've wanted a welder for years. I need to get me one and start playing with it. Based on what I have read I think I want a TIG welder. Maybe I should just get a simple ARC welder. I dunno.

[COSXJFAN]

Your best bet for price, and ease of operation is a MIG. TIG is nice, but very hard to do, and the MIG will work for all things Jeep. HTH!!

[Howler_GT]

Weld-flash is NOT fun.

I work in an industrial fabrication shop.
HI-power 440 migs running all the time. Very easy to get "flashed"

A quick zap...thats nothing. Ya see some spots and you're fine.

Its the biger (longer) ones that give you a glow-spot in the middle of your vision that will get you.
You may be fine for the rest of the day, thats what fools you.

You will wake up in the middle of the night (usually screaming), feeling like someone threw a handful of coarse sand or salt in your eyes.

I usually give the Mrs a heads up before I go to sleep.
"Hun, I got flashed today."
"Okay, I'll wear my earplugs to bed."

[COSXJFAN]

Weld-flash is NOT fun. You will wake up in the middle of the night (usually screaming), feeling like someone threw a handful of coarse sand or salt in your eyes.


That is exactly how I have heard it described!! OUCH!!:thumbdown:

[COSXJFAN]

I went out and picked her up last night. It was a pretty late night with all of the running around I had to do in order to get this done. It drove great, and the front end feels A LOT tighter than it did!! I actually drove it to work today, to show it off a little!!LOL!! Everything seems to be fine, and I'm really happy with it so far. I even took it out to a dirt road to check out the locker in the front. I was thinking that it would push more than it did, so that is a plus!! It actually turned a nice tight radius, and pushed very little!!

[Voldemort]

Hey did you make the rear bumper or did you buy it? I want to make one very similar and wanted to know what the total steel price was?

[COSXJFAN]

I built it, and when I bought the steel it was when they thought the stuff was gold!! I paid around $200.00, maybe a little more, for all of the steel for both of the bumpers.

[COSXJFAN]

OK, so I have not been coming around here as often as I should, so I wanted to give an update on the XJ. I had installed the Quick Lock locker in the front axle, which proved to be a complete POS!! I wheeled it twice, and it broke, AWESOME!! I went back to an open front diff for awhile, and then the EZ Locker that was in the rear axle started to make a lot more noise than usual. I had this locker in for about 2 years, and it started making way more noise when turning to the right than it did when turning left, and I mean a lot!! I decided that I was done with this crap, so I ordered a Detroit Locker for the front, and a full spool from Yukon Gear for the rear. I know the spool is a little hard core, but these auto lockers are making me crazy!! They are in my rig now, and I have to say that I'm happy so far. I have not had a chance to test the front locker, but I can really tell the spool is working!! LOL!! It is as I expected it to be, but I didn't realize how much tire scrub and lurching there would be! I'm used to it now, and compared to the noise that the EZ made, it is WAY better!! Now, when the dang snow melts, I can get back to wheeling!!

[rguignard]

i took my lockrite out for the same reason to much noise i just went and welded mine up :eek: what rear do you have?

[COSXJFAN]

D44, geared 4.88...

[rguignard]

D44, geared 4.88...

btw nice work i like looking at other peoples work allways nicer to make it if you have the means and skill :thumbsup: and if you dont have the skill a grinder is your best friend :smiley-laughing021:

[4.3LXJ]

Hey COS, this is the first time I have sen all your build. Looks like you are ready to rock.

[COSXJFAN]

Thanks 4.3, I certainly hope so!! Of course there are more things I want to do, but the wallet is begging for mercy right now!! LOL!!

[Mudderoy]

OK, so I have not been coming around here as often as I should, so I wanted to give an update on the XJ. I had installed the Quick Lock locker in the front axle, which proved to be a complete POS!! I wheeled it twice, and it broke, AWESOME!! I went back to an open front diff for awhile, and then the EZ Locker that was in the rear axle started to make a lot more noise than usual. I had this locker in for about 2 years, and it started making way more noise when turning to the right than it did when turning left, and I mean a lot!! I decided that I was done with this crap, so I ordered a Detroit Locker for the front, and a full spool from Yukon Gear for the rear. I know the spool is a little hard core, but these auto lockers are making me crazy!! They are in my rig now, and I have to say that I'm happy so far. I have not had a chance to test the front locker, but I can really tell the spool is working!! LOL!! It is as I expected it to be, but I didn't realize how much tire scrub and lurching there would be! I'm used to it now, and compared to the noise that the EZ made, it is WAY better!! Now, when the dang snow melts, I can get back to wheeling!!

I like the idea of the spool, however might be a little ruff on a daily driver. I'm assuming with 4.88 gears, yours isn't a daily driver?

[COSXJFAN]

No, I put less than 5K miles a year on it, so a spool made sense. I want to do selectables down the road, but it was too much for the pocket book ATM! I went as steep as I could on the gears, because I wheel in rocks, and the deeper gearing helps a lot!!

[SargDeath]

Yes, 3"x3"x.250" angle iron.



Thanks!!

Do find angle iron is strong enough for rock gaurds. I want to do that on my XJ but I was thinking of going with square tubing, not sure if that is overkill or not.

[COSXJFAN]

It hasn't even acted like the abused that I have dished out so far has bothered it in the least. It is very solid...