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View Full Version : 97 xj build start to......finish?



xjfreak97
04-27-2013, 10:02 PM
OK this is my first build thread and my first xj build so i will probably be needing lots of advice along the way.
Stats- 97 cherokee 133k, 4.0l, auto tranny.
came with some sort of budget lift and 31's
THE PLANS
-fix the cancer(cut out rocker panels and convert rockers to sliders)
-replace floor pans
-6.5 inch long arm lift from IronRock Offroad
-35's or 33's (not sure which yet)
-build rear bumper
-mount a winch(not sure what kind)
-lockers
-cb radio
- chop top and build full roll cage

xjfreak97
04-27-2013, 10:08 PM
I got busy today cutting some cancer and cleaning up the front bumper.

bluedragon436
04-27-2013, 10:17 PM
Looks like it'll def be some work ahead of you... But very nice build plans and components you have lined out!! The IRO kit is a really stout setup from the ones I've seen online as well as a few I've seen out on the trail here in the north east!! Are you planning on making the rocker replacement sliders, or pickup a set already ready to install after you cut out the old rockers??

xjfreak97
04-27-2013, 10:23 PM
I'm planning on make them out of 2x6 tubing and then gusseting them to the frame, haven't drawn anything up yet but thats the general idea.

4.3LXJ
04-27-2013, 10:28 PM
Good start. IRO stuff is good stuff

XJ Wheeler
04-28-2013, 03:58 PM
Nice build, Seth. Good work so far too. Your rockers are worse than mine. I plan on doing the tubing rockers as well, and in all my researching suggest a good base. Frame stiffeners are a good idea so you distribute the stress along a larger area. Can't wait to see more...

Brasscatz
04-28-2013, 04:26 PM
Always good to have another red Jeeper!

xjfreak97
04-28-2013, 10:52 PM
Not much work today but here. new cap and rotor and mounted refurbished bumper.oh ya bought a welder hahaha:beer::beer:

xjfreak97
04-28-2013, 11:08 PM
here is my first build an 87 toyota 4runner.
next will be my 85 4runner and 87 wrangler

xjfreak97
04-28-2013, 11:11 PM
please quote me here. I will build one of the most bad ass cherokee's ever built.period... hold me too it

4.3LXJ
04-28-2013, 11:47 PM
You got it :poke:

Brasscatz
04-29-2013, 07:48 AM
please quote me here. I will build one of the most bad ass cherokee's ever built.period... hold me too it

I will hold you to it! Better tell Pookapotomus to watch out with his Mortis build! :D

xjfreak97
04-30-2013, 11:10 AM
Ordered some new floor pans yesterday from Classic 2 Current http://c2cfabrication.com/ .They have super deals on body panels, so we will see how they fit. Should have them by Friday.
-Also ordered some 2x6 1/8" tubing for the rockers that will be here tomorrow.
Ill be posting pictures of the progress this weekend.:D

xjfreak97
05-04-2013, 10:16 PM
Lots of work this weekend with lots of problems. Ripped out interior, took doors off, cut out floor pans and got passenger side floor pan welded in. Alot more work than i was expecting but the first side turned out great. this project is getting bigger and bigger as i go so this is going to be a crazy long build thread. i know alot of people need details so im going to do my best throughout this. pictures say a thousand words.... lots more to come.

xjfreak97
05-04-2013, 10:20 PM
My girlfriend is a pretty good welder so she threw some beads down on the floor pans im a lucky guy. well im going on the road again for work so there will be more progress in a couple of weeks guys.

xjfreak97
05-04-2013, 10:28 PM
my girlfriend and I welding

Mudderoy
05-05-2013, 01:33 AM
Lots of work this weekend with lots of problems. Ripped out interior, took doors off, cut out floor pans and got passenger side floor pan welded in. Alot more work than i was expecting but the first side turned out great. this project is getting bigger and bigger as i go so this is going to be a crazy long build thread. i know alot of people need details so im going to do my best throughout this. pictures say a thousand words.... lots more to come.

Great pictures thanks! :popcorn:

XJ Wheeler
05-05-2013, 02:36 AM
Thanks for the pics. I know this is in my future, just in denial. Great work. Keep em coming!

xjfreak97
05-12-2013, 03:52 PM
Work, Work, Work wish i had some progress to show but i wont for a while pretty booked up for work for the next month. at least im going to have lots of $$$$ for awesome parts!:cool0010:

xjfreak97
06-10-2013, 05:02 PM
Got a lot done in the past few days. Finished the driver side floor pan which really sucked since i had to fabricate a piece for the tranny hump. but all in all turned out good.
Next i tackled the rocker rock sliders. I think they turned out really good. Not too sure how i feel about my supports to the frame but we will see how they perform later.
I'll be uploading pics here in a few minutes when my camera gets charged.

xjfreak97
06-10-2013, 05:23 PM
Here is the progress!

xjfreak97
06-10-2013, 05:34 PM
In a couple weeks ill be ordering some spray in bed liner to finish out the floors and rockers.
I'm hoping to order my lift in the few weeks too. :D

xjfreak97
06-20-2013, 10:10 AM
http://www.ironrockoffroad.com/Merchant2/merchant.mvc?Screen=PROD&Store_Code=IROR&Product_Code=IR-X6CPK&Category_Code=PFX

Just ordered my lift kit, sye,driveshaft. I cant wait till they get here so i can start installing!

4.3LXJ
06-20-2013, 10:45 AM
Let the fun begin

XJ Wheeler
06-20-2013, 02:12 PM
Start the PB... NOW!

xjfreak97
06-20-2013, 03:14 PM
I've got my secret weapon AERO KROIL!

xjfreak97
07-02-2013, 08:22 PM
Started digging in to the lift today. i decided to start with the rear and the leaf spring bolts have been a total pain in my...... butt:bang: . the sleeves from the old bushing were totally seized! So needless to say i didn't get nearly as far i wanted to today. I actually had to cut off part of the front spring perch on the drivers side. so i will have some pics of the repair tomorrow. but for now here is my nemesis.

xjfreak97
07-02-2013, 08:23 PM
On another note the lift from IRO looks great. everything looks super beefy. Cant wait to try it out!

xjfreak97
07-03-2013, 09:05 PM
Fixed the leaf spring mount i cut off and nearly finished the rear lift today.

xjfreak97
07-13-2013, 09:02 AM
I finished the lift!

xjfreak97
07-13-2013, 09:24 AM
All in all i'm extremely happy with this lift kit! I will say though this is not a job for the faint of heart especially when you are dealing with a rust old jeep like mine. if you don't have a lot of experience working on your vehicle yourself don't try this.
So far these are the things i like about the kit.
-Flex is awesome!
-parts are extremely beefy
-everything fit perfect
-rides really nice on the road
-great customer service ( i called at least 6 times)
Things i don't like
-Didn't come with new hardware to mount leafs, shackles, long arms and shocks. i was expected to use all the old rusty nuts and bolts for these items. if a person is spending this kind of money on a lift they want everything new.
-instructions called for a size T drill bit for drilling and taping the 3rd bolt on the sub frame. It turns out size T is very hard to find. I went to fastnel after checking all the local hardwares for a size T and even the guys there couldn't order it and had no idea what it was. So i ended up drilling it with a 23/64 ths and it worked fine. if its that hard to find it should be included in the kit.
- Steering looks pretty bound up i think a steering kit should have been recommended with the kit or at least a drop pitman arm.

xjfreak97
07-13-2013, 09:41 AM
Here are some more random pics of the lift install

XJ Wheeler
07-13-2013, 04:54 PM
Looks good, its got flex now. :D Thanks for the review too.

xjfreak97
07-13-2013, 06:48 PM
O yeah its got flex! Now i just really need to figure out the steering. First I'm going to try a drop pitman arm. Then eventually ill do the full over the knuckle setup.
AHHHHHH the list continues and grows....
- drop pitman arm
- spray in bed liner
- tire and wheels
- put the interior back together
- Go wheeling!:bacondance:

XJ Wheeler
07-13-2013, 09:09 PM
I like step 5 the best. :D

bluedragon436
07-13-2013, 09:12 PM
The IRO setup was the one I looked at the most prior to piecing together my lift kit... But I have still been thinking about picking up the IRO LA upgrade and probably their 6" coils to replace my 4.5" coils I have now... Looks good, and love that flex pic you got!!

xjfreak97
07-14-2013, 10:13 AM
Yeah i would totally recommend the Long arm upgrade kit from them. they have really good prices in comparison with some other companies, just be prepared to buy some hardware.

xjfreak97
07-17-2013, 01:44 PM
Yesterday i put in a throttle body spacer and cleaned the throttle body.

http://i1348.photobucket.com/albums/p726/xjfreak97/DSCF1141_zpsf1b6a954.jpg

The set up from IRO
http://i1348.photobucket.com/albums/p726/xjfreak97/DSCF1132_zps90630457.jpg

All clean!
http://i1348.photobucket.com/albums/p726/xjfreak97/DSCF1138_zpsd5307104.jpg

xjfreak97
07-17-2013, 01:46 PM
http://i1348.photobucket.com/albums/p726/xjfreak97/DSCF1138_zpsd5307104.jpg

xjfreak97
07-17-2013, 01:48 PM
I tried to upload these the other way using photobucket but doesn't seem to be working so here they are.

XJ Wheeler
07-17-2013, 04:17 PM
On Photobucket, did you copy the "IMG" aka "image" code?

Sent via messenger pigeon - i talk, he types.

xjfreak97
07-18-2013, 04:35 PM
Yeah thats what in tried. but only one of the photos worked.

XJ Wheeler
07-18-2013, 04:43 PM
Did you perhaps move the photo(s) to a different album after copying the code?

Sent via messenger pigeon - i talk, he types.

Mudderoy
07-18-2013, 05:53 PM
http://i1348.photobucket.com/albums/p726/xjfreak97/DSCF1138_zpsd5307104.jpg

It worked, it's just the way that photobucket tries to create the [IMG] links for forums sucks. They want to put a link to their site so when you click the image (IF YOU CLICK THE IMAGE) it takes you to their site so they can show their ads. $$$ stuff. I don't blame them for trying to make money but...

Anyway I removed all that extra crap they put in there from your post and it's displaying correctly now. ;)

Mudderoy
07-18-2013, 05:56 PM
I wish someone would do good MPG calculations for a couple of months, add a spacer then continue the mpg readings and see if the throttle body spacer makes a difference. I've heard several times they don't do anything on fuel injected engines.

xjfreak97
07-18-2013, 07:57 PM
Thanks for working that post out for me! ill try it again next time see if it turns out better for me.

-I pretty much just ordered the spacer with my lift since they offered a nice discount on it with my purchase. I'm guessing it really doesn't do much but hey it looks cool :D . so if i get a little more mgp and maybe a slight boost in power its all good.

xjfreak97
07-19-2013, 09:45 PM
OK I've got a question that I can't find a definitive awnser to.
I want to order 35*12.5*15 Goodyear wrangler mtrs . The recommended wheel width is 8.5-11" . I've read that I might have fittment issues with a 10" rim. Is anyone running 10" wide rims? Also could I fit a 12.5 tire on an 8" rim?
Also what about back spacing?

4.3LXJ
07-19-2013, 09:58 PM
No problem with 10" rims. My rule of thumb is the rim should be the same width as the tread. 8" will work, but a bit narrow and a little squirmy gong into hard corners sometimes

xjfreak97
07-20-2013, 02:44 PM
What's your back spacing?

4.3LXJ
07-20-2013, 02:56 PM
I am running stock wheels with 1.5" spacers

Mudderoy
07-20-2013, 03:20 PM
I ran 10x15" wheels because I wanted the tire to fully expand out. I had 32x11.5x15's then went to 33x12.5.15's personally I wouldn't have wanted either on 7 or 8x15's wheels. Backspace is 3.75 on my wheels.

93xj97347
07-20-2013, 08:44 PM
I've got 35*12.50*15 on 15*10 rim and 3.75 backspace and they fit fine

xjfreak97
07-20-2013, 09:34 PM
Thanks a lot everyone. Looks like I'll be going with 15x 10's with 3.75 back spacing.

xjfreak97
07-21-2013, 11:06 AM
Found a good link for determining your backspacing.

https://www.rsracing.com/tech-wheel.html

xjfreak97
08-23-2013, 08:53 PM
wow long time no post whoops been busy. Got my tires and wheels.http://http://s1348.photobucket.com/user/xjfreak97/media/96f5f317-6709-4432-8199-a81dd68b0324_zpsac2c4d1e.jpg.html?state=copy

xjfreak97
08-23-2013, 08:55 PM
wow long time no post whoops been busy. Got my tires and wheels!http://s1348.photobucket.com/user/xjfreak97/media/96f5f317-6709-4432-8199-a81dd68b0324_zpsac2c4d1e.jpg.html?state=copy

xjfreak97
08-23-2013, 08:58 PM
here they are!

xjfreak97
08-23-2013, 08:59 PM
They are cragar deluxe 69 wheels

xjfreak97
08-23-2013, 09:13 PM
Next I started hacking on the body, i really like the way the rear turned out. i cut along the flat side of the outward bend then i heated a razor blade and cut my old fender flares to fit as best as fit. if you want to do this heat the blade often to make a clean cut. if you need further explanation on any pics let me know this stupid image upload things sucks! yeah thats you xj forum....

xjfreak97
08-23-2013, 09:16 PM
Cut the fronts outhttp://s1348.photobucket.com/user/xjfreak97/media/DSCF1323_zps423db0a5.jpg.html?sort=3&o=25
http://s1348.photobucket.com/user/xjfreak97/media/DSCF1335_zps56aec35d.jpg.html?sort=3&o=18

xjfreak97
08-23-2013, 09:21 PM
No worries xj forum ill do this again...... you image link sucks

xjfreak97
08-23-2013, 09:26 PM
More updates coming soon.

4.3LXJ
08-23-2013, 09:46 PM
You will have to give us an evaluation of the Goodyear tires

XJ Wheeler
08-23-2013, 10:07 PM
Next I started hacking on the body, i really like the way the rear turned out. i cut along the flat side of the outward bend then i heated a razor blade and cut my old fender flares to fit as best as fit. if you want to do this heat the blade often to make a clean cut. if you need further explanation on any pics let me know this stupid image upload things sucks! yeah thats you xj forum....

Smoothies!!! I like it.

Its hard for me to tell, but did you cut off the spot welds on the rear wheel openings?

Sent via messenger pigeon - i talk, he types.

xjfreak97
08-23-2013, 10:13 PM
will this work[IMG]http://s1348.photobucket.com/user/xjfreak97/media/DSCF1333_zps3af6e577.jpg.html?sort=3&o=19

xjfreak97
08-23-2013, 10:16 PM
sure did then fixed it up real nice like

xjfreak97
08-24-2013, 10:26 AM
I finished the rear off with sheet metal, rivets, a couple spot welds and under body paint. The final touch was some trim around the wheel wells. I used the old fender flares for the trim, I heated a razor blade and cut through them like butter then attached the trim with self taping stainless steel screws.

xjfreak97
08-24-2013, 10:41 AM
Here it is all finished up. It was very squirrelly driving down the road pulling back and forth and left to right so i installed a drop pitman arm which didn't help pulling back and forth but did help with the bumpsteer i was getting. Next i put on a rancho steering stabilizer this helped slightly. So from there i attacked the caster angle now i have it maxed to the positive side of the caster angle and handles good up to 40 mph then gets squirrelly again. I'm taking it to midas on Monday to get an alignment done so hopefully that fixes the issue. If anybody knows what the problem is with the steering i am open for ideas.

xjfreak97
08-24-2013, 10:49 AM
Another beauty shot

4.3LXJ
08-24-2013, 11:23 AM
Nice looking XJ, looks like it means business. I noticed your top bushing on the pumpkin is shot. This will affect your steering as your axle rocks back and forth. Been there, done that. Also I notice you have no sway bar. I just finally got one back on and it helps that steering situation a lot.

xjfreak97
08-24-2013, 12:04 PM
Thanks A Lot! Never thought about the bushing and it does have some slop. I have the sway bar back in now along with a Rancho steering stabilizer.

xjfreak97
08-24-2013, 09:24 PM
Put in the new bushing in tonight seems to drive a bit better but not all the way gone. we will see what happens after the alignment.

On another note some guy started talking to me in the parking lot of the local convenience
store, turns out the jeep used to be his brother in laws. Now he wants me to go out wheeling with him and his friends in the near future! AND HE HAS AN RTI RAMP!!!

Brasscatz
08-24-2013, 09:33 PM
I love that tube bumper man! May I ask where you got it?

4.3LXJ
08-24-2013, 10:16 PM
I love RTI ramps

xjfreak97
08-25-2013, 09:16 AM
The guy that i bought it from built it with his brother in law.

Roblaza
08-26-2013, 11:20 AM
I need more pics/details on how you did the rears. mine are SHOT and i'm looking to do the same as what you did!

xjfreak97
08-26-2013, 09:47 PM
Are you talking about how i did the cut on the rear?

xjfreak97
08-27-2013, 03:50 PM
News Update! steering was still a little shaky after the alignment at speeds between 20-40mph. After you speed up all seems to be well. This is not acceptable to me to i decided first to make a steering box brace. While i was taking measurement to build the brace i noticed that my sway bar bushings at the frame were shot so these got replaced at the same.
Hear is what you need to make a steering box brace

3" angle iron 5.5" long .250" thick
1" square tube 1/8" wall 21" long
2" riser clamp
4-3/8" bolts nuts and washers
weld and or bolt together(I welded then bolted in place)

All these parts cost a total of $15.00

xjfreak97
08-27-2013, 03:57 PM
After the steering box brace was installed along with sway bar bushings and re-tightening my pitman arm my steering is much better.
Next up is building frame stiffeners/bumper mounts. Should have this done later this week. :pray:

4.3LXJ
08-27-2013, 08:44 PM
Nice job on that brace man :thumbsup:

xjfreak97
09-02-2013, 01:28 PM
Well ive been seriously lacking on the updates, but i have been busy working on the jeep and Taking it out wheeling.
I started to fab up some frame stiffeners that are going to double as winch and bumper mount.
http://i1348.photobucket.com/albums/p726/xjfreak97/DSCF1360_zps69fbc06a.jpg
http://i1348.photobucket.com/albums/p726/xjfreak97/DSCF1359_zps8a70d1c5.jpg
Then found an RTI Ramp my best score was 722 and most everything seems to clear definitely need extended bump stops and limiting straps though.
also my drag link hits the sway bar lower mount when pulling the passenger side tire up.
http://i1348.photobucket.com/albums/p726/xjfreak97/DSCF1361_zps9e4fcc4f.jpg
http://i1348.photobucket.com/albums/p726/xjfreak97/DSCF1362_zps6aa82bc0.jpg
http://i1348.photobucket.com/albums/p726/xjfreak97/DSCF1365_zps267f288f.jpg
After that we hit some trials to give the jeep a good test run. the only thing that went wrong was the rear driverside shock fell off turned out i had a stripped bolt.
this was really the only pic i got and its yet another poser shot lol
http://i1348.photobucket.com/albums/p726/xjfreak97/DSCF1367_zps6dff9717.jpg

xjfreak97
09-02-2013, 01:36 PM
Once i got home i decided i really needed to mount my tool box and spare in the truck so this is my progress after a couple days.
Tool box is now mounted for easy removal.
http://i1348.photobucket.com/albums/p726/xjfreak97/DSCF1373_zps3bb53344.jpg
then i went to Menards and got these nice little spring loaded tie down points.
http://i1348.photobucket.com/albums/p726/xjfreak97/DSCF1376_zpsd6fa1611.jpg
This set up works very good for now. I cant even budge the tire.
http://i1348.photobucket.com/albums/p726/xjfreak97/DSCF1377_zps7db2688e.jpg
Also picked up a fire extinguisher. and mounted it.
http://i1348.photobucket.com/albums/p726/xjfreak97/DSCF1378_zps07750959.jpg
http://i1348.photobucket.com/albums/p726/xjfreak97/DSCF1379_zps5bda7896.jpg

There is more to come shortly. I picked up a shovel and mag light holder. next up is to mount these.

bluedragon436
09-02-2013, 01:43 PM
Looks good... So are you going to redesign your front bumper then with the new frame stiffeners, or incorporate them together??

xjfreak97
09-02-2013, 01:55 PM
Im going to redesign my mounts on the bumper to mate to the stiffeners.

xjfreak97
09-02-2013, 02:01 PM
Then add a winch plate to either the stiffeners or bumper haven't decided that yet. The stiffener upgrade probably wont happen till this winter some time. I want to replace the steering box with a dakota steering box and do 1 ton steering all at the same time. But we will see i get bored sometimes and things just happen lol.

bluedragon436
09-02-2013, 02:06 PM
LOL.. Nothing wrong with that kind of boredom!!