Project ASAT

[OneArmArrowSlinger]

Well, I figured I would post my continous build that I'm calling ASAT, or All Seasons, All Terrain after my favorite camo pattern and the goal behind my machine. I have no specific "wheeling style" except find the skinny pedal, hang on! I also didn't want to build it specifically for mud, or sand, or rocks etc., so I figured ASAT was appropriate. I traded my tricked out Honda FL400 for the XJ pretty much the way it is.

6.5" lift
LCA
Ford 8.8
SYE
4.0, 5spd, 143xxx on odo
Sway Bar disco's

Loading up
http://i62.photobucket.com/albums/h106/jruzich43/IMG_1631.jpg

New home
http://i62.photobucket.com/albums/h106/jruzich43/IMG_1634.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_1637.jpg

[OneArmArrowSlinger]

First thing I did was take off the 35x12.50x15 MT's and put on a set of 33x12.50x15 Boggers. But before they went on I cut the tread some.
http://i62.photobucket.com/albums/h106/jruzich43/IMG_1890.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_1894.jpgdid all 4 like the one on the right

first trip out after
http://i62.photobucket.com/albums/h106/jruzich43/IMG_1900.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_1907.jpg

I don't care to get stuck by myself so next I put on a winch, a Smittybilt X2O, 8000# w/ synthetic line. Adapted my front bumper in the shop at work. Didn't get fancy since I'm going to build something a little nicer this winter, just wanted to keep the winch on the bumper. Used 1/4" plate & MIG welded into place. Also added front tow points. Welded around the front then drilled 2 holes through back of bumper & plug welded.http://i62.photobucket.com/albums/h106/jruzich43/IMG_2010.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2011.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2012.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2013.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2014.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2015.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2016.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2018.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2019.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2020.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2021.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2022.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2023.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2024.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2025.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2026.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2027.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2028.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2030.jpg

I have also put in a hand throttle and I did the removable front door mod that was on here (super easy BTW) but no pics. I drove her back to my shop & cleared the back corner. Now that its winter, time to start in on some changes I want to make. First thing I'm doing is prepping the unibody for frame stiffeners from HD Offroad. Have some frame rot to take care of.http://i62.photobucket.com/albums/h106/jruzich43/IMG_2888.jpg
I took hammer drill and knocked out rust.
http://i62.photobucket.com/albums/h106/jruzich43/IMG_2889.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2890.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2891.jpg
Then used angle grinder w/ cutoff disc to remove junk and I cleaned up w/ cutoff disc and wire wheel on grinder. Then I shot it w/ rust inhibiting primer.http://i62.photobucket.com/albums/h106/jruzich43/IMG_2904.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2893.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2905.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2907.jpg
I've cut a 2x2 piece of tube to use as the backbone of the section removed although I will also need to add some flat stock.http://i62.photobucket.com/albums/h106/jruzich43/IMG_2906.jpg
I've also started to take apart front clip to do a little body repair. Long story short, parking brake doesn't work better than gravity, hahahttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2909.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2910.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2911.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2913.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2916.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2917.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2918.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2919.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2896.jpg


For the new backbone of the repair, I used a piece of 2"x2" tube and had to weld a piece of 1/4"x2" flat stock onto each side of the tube to make it wide and strong enough to replace the section I took out. I'll clean up the welds here soon and plate the bottom and inside after I put the frame stiffeners on.
{bottom}http://i62.photobucket.com/albums/h106/jruzich43/IMG_2921.jpg
{top}http://i62.photobucket.com/albums/h106/jruzich43/IMG_2922.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2923.jpg
Had to do a little trimming here & there to get it to fit perfect but I got it where I wanted then tacked in and stitch welded.http://i62.photobucket.com/albums/h106/jruzich43/IMG_2924.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2925.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2927.jpg

I also primed some quarter panel armor from JCR Offroad.http://i62.photobucket.com/albums/h106/jruzich43/IMG_2915.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2928.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2934.jpg

I thought I'd snap a couple pics of the shop since I was here alone. The second one is almost a full 180 panoramic shot.http://i62.photobucket.com/albums/h106/jruzich43/IMG_2933.jpghttp://i62.photobucket.com/albums/h106/jruzich43/IMG_2932.jpg

Cleaned up welds & prepped some for putting first section of stiffeners on frame rail.
http://i62.photobucket.com/albums/h106/jruzich43/0896ED81-9834-47C6-8558-FD3EEFF06829.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Mobile%20Uploads/2AFBAC9E-3BFE-40FB-AE04-9CCC891EE6D7.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Mobile%20Uploads/46F67F26-EF7F-4D02-814C-566AF9FFC1F4.jpghttp://i62.photobucket.com/albums/h106/jruzich43/9F2A672A-4D63-4044-AD33-CBCDB27B1B42.jpghttp://i62.photobucket.com/albums/h106/jruzich43/335E5659-DFBF-4D36-8268-C79462634969.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Mobile%20Uploads/A3A562E3-5BBE-4DE9-ACF4-6E335A6F0471.jpg
You can really see I did a pretty good number on the front rails by the angle of the bumper.
http://i62.photobucket.com/albums/h106/jruzich43/234887EB-6A5A-4737-8D21-AB0327FAA4E1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/6DFF5E4F-9401-492A-8AB3-5A5632A292BB.jpg

Started cleaning the middle section of the frame rail, put on rear passenger frame stiffener and cut out passenger rocker all the way to the pinch seam to make room for my 2x6 rock slider rocker.
http://i62.photobucket.com/albums/h106/jruzich43/911CCF9D-947E-4A49-9AC6-4D7C725FE72E.jpghttp://i62.photobucket.com/albums/h106/jruzich43/BF979D51-7A06-423B-BA02-D738AB49C1C7.jpghttp://i62.photobucket.com/albums/h106/jruzich43/B105C13B-302B-4878-B017-33FDE349E0AC.jpghttp://i62.photobucket.com/albums/h106/jruzich43/CCB5B9A9-0682-43FA-BBDF-EFD6586B1DDF.jpghttp://i62.photobucket.com/albums/h106/jruzich43/A1BB7877-DAA2-43B3-B288-A4C634413C6E.jpghttp://i62.photobucket.com/albums/h106/jruzich43/91536DDB-B7E9-450B-8CC5-AAD91CCAADBE.jpghttp://i62.photobucket.com/albums/h106/jruzich43/4C36A8FC-BEA5-42CA-86AF-81CFA4C5002C.jpghttp://i62.photobucket.com/albums/h106/jruzich43/88794E4F-BEB7-4807-8E36-A518B7906111.jpghttp://i62.photobucket.com/albums/h106/jruzich43/DD9EA308-D5D2-4595-8F3E-4135E34D47C2.jpghttp://i62.photobucket.com/albums/h106/jruzich43/D5590BD8-BA89-4F8B-B448-7BD6E9CEB626.jpg

Finished burning in the rear passenger stiffener. Let me tell you, this has been some of the most difficult welding i've ever done. Between the differences in metal thickness, some uncomfortable positions, and the multiple other things that make welding onto a 1997 unibody tough, I laid some of the ugliest welds in many years! lol Oh well, just makes me better I guess. I went ahead and did a little smoothing on the welds so they don't look as bad. I also finished cutting out my rocker at the pinch seam. That was made a little tougher due to the goofy looking boatside at the long control arm mount that the PO welded on. I then did some more prep work to the middle section of the frame rail.
http://i62.photobucket.com/albums/h106/jruzich43/AA9B8049-1E5C-4969-A5C5-6F3D14CEA8C3.jpghttp://i62.photobucket.com/albums/h106/jruzich43/3892014E-F1D3-4A28-AD86-9CBDCD004007.jpghttp://i62.photobucket.com/albums/h106/jruzich43/C2CA89E8-CDB2-4F45-BCF4-736EFDF144C6.jpghttp://i62.photobucket.com/albums/h106/jruzich43/EB274F9E-E004-438D-8371-333150AC2518.jpghttp://i62.photobucket.com/albums/h106/jruzich43/77153F20-DBA0-44E7-BD4F-B137D2FD096A.jpghttp://i62.photobucket.com/albums/h106/jruzich43/69C5627F-8CF0-4AD5-8A16-4A22D6E4A951.jpghttp://i62.photobucket.com/albums/h106/jruzich43/64E09494-2C72-437A-8575-1FF6390523FE.jpghttp://i62.photobucket.com/albums/h106/jruzich43/66985C3B-5EC8-43B9-AAD6-C110D415C3E7.jpg

[OneArmArrowSlinger]

I did some more prep work on the mid section of frame rail and rocker on the RH side tonight then took off the rear bumper. The PO had bolted it in at the stock location and the bumper mount had slots in it but they didn't use washers on the bolts. Needless to say, the bolt heads were pulled partially through some of the slots so I couldn't get a socket or anything on. The aggravation did not last long though, I broke out the cutting torch and whacked that dude off of there. I've been planning on making a new bumper anyhow since I have 20' of 2"x6"x1/4" tube to do the rocker project with. Besides, who doesn't enjoy slicing metal with fire!! I also cut out the hitch receiver with a cut off disc, will clean it up & re-install in the new bumper.
http://i62.photobucket.com/albums/h106/jruzich43/93274062-0E4E-4879-A1FD-97C88AC327A3.jpghttp://i62.photobucket.com/albums/h106/jruzich43/72B153E9-7576-4E90-A1E7-BCA65174FE13.jpghttp://i62.photobucket.com/albums/h106/jruzich43/FDA0C1B4-5C04-43E0-8954-873618ACA7CD.jpghttp://i62.photobucket.com/albums/h106/jruzich43/19383BF4-B7C3-44A9-BD27-D5BFF1D35AD5.jpghttp://i62.photobucket.com/albums/h106/jruzich43/827EBC46-B882-47CA-9B80-EB52C7364A28.jpg

It had been super cold the last few days so I've been able to get a lot done (for me anyhow, 90%+ of the work I do singlehandedly, pun intended:rofl:) w/ no work going on here at the shop. I was able to get the bumper mounts off successfully, my mid & rear section of frame stiffeners welded, ground & primed. Also been working on getting the rust out of the rockers so I can get my 2x6 tube installed.

Bumper off
http://i62.photobucket.com/albums/h106/jruzich43/B750D7CA-05EB-4526-92D1-C03CF58AAE93.jpghttp://i62.photobucket.com/albums/h106/jruzich43/7CBE8200-EE60-4543-A428-9AB1A2DA464E.jpg
Pattern to cover back side of frame rail where I patched and patch welded in.
http://i62.photobucket.com/albums/h106/jruzich43/84E56271-44C8-4267-8944-CBE56E8763F8.jpghttp://i62.photobucket.com/albums/h106/jruzich43/6E466759-47BB-49FB-AF8F-0A0910A2BCD4.jpg
Taillights out, making housing to fit my new LED's
http://i62.photobucket.com/albums/h106/jruzich43/69555C9A-4E7B-49AA-B0E2-F844DF537B03.jpghttp://i62.photobucket.com/albums/h106/jruzich43/4CD8C547-7986-4819-BF85-ABB6A5600931.jpg
All cleaned up underneath. Clean metal makes happy welds!
http://i62.photobucket.com/albums/h106/jruzich43/FEED1C90-D857-4229-ACC7-72BD69384AD2.jpg
As you can see in the previous pic, the aftermarket LCA mounting bracket is back at the tranny skid so I had to notch out my stiffeners and the cut and bend so it would fit properly. I actually had to cut it into 2 pieces. Took a little time but worked out great!
http://i62.photobucket.com/albums/h106/jruzich43/F3DA0FC1-0269-437C-BA02-1A4E84DC8683.jpghttp://i62.photobucket.com/albums/h106/jruzich43/CA4E4D1B-9C22-40E1-B47A-4DA34947AB02.jpghttp://i62.photobucket.com/albums/h106/jruzich43/97DE61DF-9048-497B-AE2B-5CB2A85EB1DA.jpghttp://i62.photobucket.com/albums/h106/jruzich43/90D9FFEA-5371-4194-A34F-9AE5B03564C6.jpghttp://i62.photobucket.com/albums/h106/jruzich43/32154CDD-9DAE-435E-97AD-069B22288995.jpghttp://i62.photobucket.com/albums/h106/jruzich43/55CC5EF8-36B9-44B5-BBB8-B2579E991EAD.jpg
Then with 2 jacks, some blocks of wood, a bunch of C clamps and loads of patience I got everything in position to burn in.
http://i62.photobucket.com/albums/h106/jruzich43/4E7E2350-AB89-4A88-BCBF-15A667D8D57E.jpghttp://i62.photobucket.com/albums/h106/jruzich43/F7F7E803-2FAC-42BB-BADD-57F13764E574.jpghttp://i62.photobucket.com/albums/h106/jruzich43/C4656D9A-5753-4255-811D-72DCDDCA8128.jpghttp://i62.photobucket.com/albums/h106/jruzich43/D127A11A-9AD1-4699-A705-76ECA5B317C5.jpghttp://i62.photobucket.com/albums/h106/jruzich43/FC38D5D8-8168-464E-9815-09563E381523.jpghttp://i62.photobucket.com/albums/h106/jruzich43/DCA5FB7E-7D01-421F-A999-07EDAFC41352.jpghttp://i62.photobucket.com/albums/h106/jruzich43/FCBE8653-F139-4948-9801-DB3DF77DFA77.jpghttp://i62.photobucket.com/albums/h106/jruzich43/54981537-848D-4A3B-A753-D4023EF5AF2A.jpghttp://i62.photobucket.com/albums/h106/jruzich43/9195124B-0236-487B-877E-006BC9DE556E.jpghttp://i62.photobucket.com/albums/h106/jruzich43/AC945285-D454-4463-8769-8A701BCB4A4D.jpghttp://i62.photobucket.com/albums/h106/jruzich43/6CCA9EC8-47F1-4DA1-B76A-27497DAC7F75.jpghttp://i62.photobucket.com/albums/h106/jruzich43/FAC9578E-8E01-4DEF-810D-27ACE1E6F94C.jpghttp://i62.photobucket.com/albums/h106/jruzich43/55FC1284-01C8-4DFA-A2A4-53B664C528B0.jpghttp://i62.photobucket.com/albums/h106/jruzich43/2F04C879-C7E8-4B63-AFD1-F132589CE4F5.jpghttp://i62.photobucket.com/albums/h106/jruzich43/28BEE74B-B298-4A87-B4F0-AA89615895C3.jpghttp://i62.photobucket.com/albums/h106/jruzich43/2114636D-2310-416B-9202-6957F1EF0C2B.jpghttp://i62.photobucket.com/albums/h106/jruzich43/16FA6199-9AC5-48B1-B8D4-CB0C815BAAC9.jpghttp://i62.photobucket.com/albums/h106/jruzich43/26CDBD15-CA41-4798-8D71-F84BA74D7B4F.jpghttp://i62.photobucket.com/albums/h106/jruzich43/6613DC51-50B3-4559-B3D5-228FE2FB9E45.jpghttp://i62.photobucket.com/albums/h106/jruzich43/9FB0F9A0-34E8-4A3F-AD2D-8835C60DDB08.jpg
I then cleaned and primed the bare metal w/ some Rustoleum Self Etching rattle can primer. After I'm done w/ the rocker sliders, I plan on coating w/ spray on bedliner.
http://i62.photobucket.com/albums/h106/jruzich43/D9142C74-E826-4281-BD37-AE23494C4362.jpghttp://i62.photobucket.com/albums/h106/jruzich43/0196B140-6D5D-4CD9-8B03-B014E4C7DA8B.jpghttp://i62.photobucket.com/albums/h106/jruzich43/D840F5AE-8723-496F-A290-58EBFDFE58F7.jpghttp://i62.photobucket.com/albums/h106/jruzich43/CBCD7157-ABBF-4239-A8AE-2E079BF1C113.jpg

[4.3LXJ]

I know what you mean about ugly welds on frame stiffening. Mine were nothing to write home about either. Great job so far. You get as much done with one arm as I do with two

[cantab27]

nice work mate .........keep the updates coming ........I now understand ya user name .......sense of humour a must round here...:D

[OneArmArrowSlinger]

Didn't get a lot done at the beginning of the week, last week. Was having a lot of phantom limb pain and just didn't feel like or have the energy to get much done. By Wednesday tho, the pain was letting up so I could get back at it. I got the left rocker cut out & prepped to put the new 2"x6"x1/4" tube in for the rocker/slider replacement; I should start tonight on that. I also got the mid & rear sections of sliders put in but I still need to clean up and prime. I also started on the rear quarter cut and fold and kept doing small things to get ready to fab up the rear bumper.

Quarter cut & fold

http://i62.photobucket.com/albums/h106/jruzich43/80F5CC23-24E6-4F4F-B1C8-72269D0A9925.jpghttp://i62.photobucket.com/albums/h106/jruzich43/9B4ECBE7-D306-4C05-BE20-8CF6EB97B75E.jpghttp://i62.photobucket.com/albums/h106/jruzich43/9703D865-F5DD-434B-B832-F8DE95E0F29C.jpghttp://i62.photobucket.com/albums/h106/jruzich43/F702095C-ED18-4FAC-AB6F-0A057DBCF111.jpghttp://i62.photobucket.com/albums/h106/jruzich43/7AFB125A-A53A-486A-9EC8-6E971A0754E0.jpghttp://i62.photobucket.com/albums/h106/jruzich43/6C01D7F7-36A6-4A24-A69C-254FD14A3199.jpghttp://i62.photobucket.com/albums/h106/jruzich43/BC77D303-39F8-4CEF-A1F9-F2B5C38C759A.jpgw/ Primerhttp://i62.photobucket.com/albums/h106/jruzich43/D6AABFD4-920E-4FB6-B404-29116C7DEAA9.jpghttp://i62.photobucket.com/albums/h106/jruzich43/DCF8A109-8502-46EC-9FC5-F05BF73A388D.jpg

Stiffeners

http://i62.photobucket.com/albums/h106/jruzich43/96ED8967-ECD9-4E65-8941-177FA70DC63E.jpghttp://i62.photobucket.com/albums/h106/jruzich43/AC99B188-4B7D-42D1-B669-5A93291C329C.jpghttp://i62.photobucket.com/albums/h106/jruzich43/7827EF68-DE94-4853-BB56-4647B0E43965.jpghttp://i62.photobucket.com/albums/h106/jruzich43/1636BFB0-64B0-4623-99BB-4017CD017797.jpg

Left side rockers

http://i62.photobucket.com/albums/h106/jruzich43/3BF2263B-F297-4814-BA76-653615EB0248.jpghttp://i62.photobucket.com/albums/h106/jruzich43/2CD9646D-F886-40B3-BFC4-D64C1680CF9A.jpghttp://i62.photobucket.com/albums/h106/jruzich43/246EE145-B7D9-485C-8FBC-D205875294EC.jpghttp://i62.photobucket.com/albums/h106/jruzich43/4EE51EA4-8A2F-4AF6-B9E3-92A887875987.jpg

Tube for rockers/sliders and bumpers

http://i62.photobucket.com/albums/h106/jruzich43/1AF27D6E-64F9-495B-9180-52D7DDE3AD1F.jpghttp://i62.photobucket.com/albums/h106/jruzich43/35847284-707E-490B-8B9C-EAB9A2A85836.jpg

My shop help!!

http://i62.photobucket.com/albums/h106/jruzich43/B5943F19-659E-42CD-ACC2-3C900B0BAD68.jpghttp://i62.photobucket.com/albums/h106/jruzich43/80D51199-2DD4-4870-8BF5-90AAD18C55E8.jpghttp://i62.photobucket.com/albums/h106/jruzich43/0683AF3A-02F0-4F3B-9F9D-8C4FD23FE2DF.jpghttp://i62.photobucket.com/albums/h106/jruzich43/ACAA2D21-1505-4BA2-9342-C27910EDCE78.jpg

[OneArmArrowSlinger]

I know what you mean about ugly welds on frame stiffening. Mine were nothing to write home about either. Great job so far. You get as much done with one arm as I do with two

Thanks!! I do most everything I used to do, just takes more time.


nice work mate .........keep the updates coming ........I now understand ya user name .......sense of humour a must round here...:D

Thanks, appreciate it! I'm all up to date on the build now so I'll keep things coming as I roll along with it. Yea, gotta have a sense of humor. Life too fun to be havin' your britches in a knot!!

[Pookapotamus]

Sweet build thread, and nice fab work! And yes my stiffeners have booger welds on them too!

I will be keeping an eye on this thread!

Pook

[NW99XJ]

Great work so far.
You got one helluva platform to start off of.
Cant wait to see how the rockers turn out.

[NW99XJ]

Great work so far.
You got one helluva platform to start off of.
Cant wait to see how the rockers turn out.

[XJ Wheeler]

My stiffeners don't have bad welds... because they're sitting on the floor. :rolleyes:

Nice work man. Taking care of the frame is a great move... makes for long lasting fun. Are you gonna make braces to connect the rockers to the stiffeners? I've got rot in my rockers too and plan on one day doing the tubing replacement as well. Can't wait to see the finished product... as i'm sure you are too!

I like the project name, although i have to admit when i saw "ASAT" my mind went straight assuming it was a play on "ASAP" by being As Soon As Tomorrow. :D

Sent via messenger pigeon - i talk, he types.

[Brasscatz]

Wow, that's one sweet build man! Lovin it! Looks like you got a great family there too

[OneArmArrowSlinger]

My stiffeners don't have bad welds... because they're sitting on the floor. :rolleyes:

Nice work man. Taking care of the frame is a great move... makes for long lasting fun. Are you gonna make braces to connect the rockers to the stiffeners? I've got rot in my rockers too and plan on one day doing the tubing replacement as well. Can't wait to see the finished product... as i'm sure you are too!

I like the project name, although i have to admit when i saw "ASAT" my mind went straight assuming it was a play on "ASAP" by being As Soon As Tomorrow. :D

Sent via messenger pigeon - i talk, he types.

Thanks! I agree, I figure if I want this rig to last a while I need to be reasonable and start where the problems are going to pop up first. Plus, I figured that like anything else, the foundation is the most important part to get right. Motor & axles come later. I do plan on bracing from the rockers to the frame using 2"x2" tube.


Wow, that's one sweet build man! Lovin it! Looks like you got a great family there too

Thank you!! The way I see it, the family that prays & plays together, stays together!!!

[Firemanray]

Great build, very inspirational, suscribed!!

[XJ Wheeler]

Thanks! I agree, I figure if I want this rig to last a while I need to be reasonable and start where the problems are going to pop up first. Plus, I figured that like anything else, the foundation is the most important part to get right. Motor & axles come later. I do plan on bracing from the rockers to the frame using 2"x2" tube.



Thank you!! The way I see it, the family that prays & plays together, stays together!!!

:applause: My way of thinking to a tee!

Sent via messenger pigeon - i talk, he types.

[jimmixj]

Sweeeeet build! But, to be honest, it was the panoramic of your shop that got my heart aracin'! You got somethin good goin there Jonathon! Really like your fabwork but more than that your ability to see past that rust. Admittedly, I have a serious tendency to not want to mess with it, which is why I live in Tucson. :D

[OneArmArrowSlinger]

Well, I know its been several days so I'll get right to it! BTW, thanks for all the encouragement, I get frustrated sometimes & this helps keep me on it.

Well, got a new toy at the shop. I like it, does pretty well.http://i62.photobucket.com/albums/h106/jruzich43/673354A4-DFF2-4F19-AC74-3DD2B2BF0BA7.jpg

Since I'm redoing my bumpers I want to beef up how they mount. First I took plasma and cut open the back of the frame rails. I then decided that instead of notching square tube, I'd use something different to slide under the fuel tube opening on the left side, I used 2"x1/4" C channel. I then used some 1 1/2" angle iron, 2" tube and a piece of 2" flat stock to make my left side. I welded nuts in the C channel and I will bolt through the bottom of the tube frame as well as through the side up by the rear leaf spring shackle. For the RH side I used 2 pieces of 2" square tube. I'll also drill through the frame rail & bolt in at least 2 places.http://i62.photobucket.com/albums/h106/jruzich43/4A45954B-6C25-487B-B14B-CF64E55F2097.jpghttp://i62.photobucket.com/albums/h106/jruzich43/BEED42F0-B72C-40C5-A36A-FB0A61648015_1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/E34010C0-5F87-4A67-9062-B6B56E0B462C_1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/8E8C3687-E71C-4E5C-9F75-D90916832211.jpghttp://i62.photobucket.com/albums/h106/jruzich43/C2D7F76A-B226-4A0C-AE81-8ECC9928A8B6_1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/F9DFDF17-B640-47C5-A21C-7C630506F80D_1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/4A379742-AA11-4147-AE4E-86A1983A4B51.jpghttp://i62.photobucket.com/albums/h106/jruzich43/A209D0DF-E53B-4443-BA09-198F0654D8A9.jpghttp://i62.photobucket.com/albums/h106/jruzich43/A03C8FDD-6A5F-42C8-8ED2-65968798402A.jpghttp://i62.photobucket.com/albums/h106/jruzich43/C42411C1-D54E-4F0F-93E4-D5F9503C9FC8.jpghttp://i62.photobucket.com/albums/h106/jruzich43/3C461B04-0949-48F6-BB36-2C13DE56F635_1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/7D5C1DA3-DDB7-411C-BB07-F3D13B6D59B2_1.jpg

I started on my rear bumper as well.http://i62.photobucket.com/albums/h106/jruzich43/0DD03BA9-845F-4E7C-9FC7-0EA4FCF00601_1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/D884CEB5-A75B-4616-B0D1-3AADBAB08DE5.jpghttp://i62.photobucket.com/albums/h106/jruzich43/695BDE16-3567-42FA-868F-7456961AC921.jpghttp://i62.photobucket.com/albums/h106/jruzich43/7D21D71B-E639-4DED-B1C3-CEA7BF92B81C.jpghttp://i62.photobucket.com/albums/h106/jruzich43/72FB91AD-DF29-44E4-A06B-177B3B191271.jpghttp://i62.photobucket.com/albums/h106/jruzich43/9FFA0042-0176-47DA-A9DF-F7E3B9C659A3.jpghttp://i62.photobucket.com/albums/h106/jruzich43/6CAB0D99-2572-437F-8239-FF4F5A008D85.jpghttp://i62.photobucket.com/albums/h106/jruzich43/573298E6-8CAD-4776-8576-26564906E815.jpghttp://i62.photobucket.com/albums/h106/jruzich43/FFBFFD72-2B5A-4EC3-9C50-C0B965E283B8.jpghttp://i62.photobucket.com/albums/h106/jruzich43/47118E8B-AD74-47D4-BF5D-4D649CCC2B86.jpghttp://i62.photobucket.com/albums/h106/jruzich43/C47921AA-5416-4D79-A079-097BDC30E788.jpghttp://i62.photobucket.com/albums/h106/jruzich43/FBDEBE3F-86A3-4909-9EAA-AE6DA5396C56.jpghttp://i62.photobucket.com/albums/h106/jruzich43/B99C2A1F-3B27-441E-8105-5B165A77CDA1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/40BAABA5-C305-4909-9F11-43AC1AD1B627.jpghttp://i62.photobucket.com/albums/h106/jruzich43/801E8147-C245-4D0D-8B5E-D7BB3CE104BF.jpg

Then the 2X6 sliders went into the rockers. I started out using 1 3/4" angle and punching holes every few inches then welding it into the body on the front & back side of rockers. I then capped off the ends to the sliders and ground down neat. I did some priming under the rockers then welded the tube in. After I welded in I primed the frame stiffeners and sliders.http://i62.photobucket.com/albums/h106/jruzich43/DF99EC7D-92CB-46F2-BAA9-E247CED7F23C.jpghttp://i62.photobucket.com/albums/h106/jruzich43/4575EE81-4D6E-48FC-A515-8E3476A11325.jpghttp://i62.photobucket.com/albums/h106/jruzich43/6E24B2F2-F101-427B-9304-6D4CAD723D95_1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/96960D68-1739-422A-A377-53DD2561D27B.jpghttp://i62.photobucket.com/albums/h106/jruzich43/98EAACEB-84EE-4121-889D-9EAFEC3882DD.jpghttp://i62.photobucket.com/albums/h106/jruzich43/735FE9A8-6FBE-485E-81BB-752EFA091F07.jpghttp://i62.photobucket.com/albums/h106/jruzich43/57BC2DB6-6B58-4033-BDCB-A39C95EE9A41.jpghttp://i62.photobucket.com/albums/h106/jruzich43/BC7D043B-7E0B-4118-9CD3-7A8429F78400.jpghttp://i62.photobucket.com/albums/h106/jruzich43/9D0C630B-EC10-4A31-A323-8FA32448395B_1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/66502F87-485A-4894-A51B-FB835ADB6B5A_1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/33E04E7C-FFA4-454B-B8AC-BA093EF69F79_1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/07345647-D9EC-4A25-948A-11D2DB591A9B.jpghttp://i62.photobucket.com/albums/h106/jruzich43/3B638388-8685-43ED-9C6A-2EB9432AD656.jpghttp://i62.photobucket.com/albums/h106/jruzich43/CADA6047-6C2F-4813-A876-AAB69BEB0FA4.jpghttp://i62.photobucket.com/albums/h106/jruzich43/973BC4BB-8621-4EBB-A911-0D0F679833B4.jpghttp://i62.photobucket.com/albums/h106/jruzich43/B8FA47CE-030B-4353-A86A-9FCE9F5D132A.jpghttp://i62.photobucket.com/albums/h106/jruzich43/6FB3BA71-0D39-4323-93AF-6A0ACAE45BF9.jpghttp://i62.photobucket.com/albums/h106/jruzich43/2E1B1A86-D48A-4D48-B2CF-5B445C8919B1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/14CA0C64-451A-4375-9FDD-35ADA7A248CA.jpghttp://i62.photobucket.com/albums/h106/jruzich43/294495D3-43C8-4D27-AE58-8FDD16351E1C.jpghttp://i62.photobucket.com/albums/h106/jruzich43/B5C78C40-AEA3-471E-BB7E-A04498D970EE.jpghttp://i62.photobucket.com/albums/h106/jruzich43/68E46D04-6506-4EE1-8489-62E3AF2D70AA.jpghttp://i62.photobucket.com/albums/h106/jruzich43/7C6A3B50-E3EA-4F4A-89B3-465171D588F7.jpghttp://i62.photobucket.com/albums/h106/jruzich43/3DB3C155-6832-4009-B850-1BC1DBFE2CCD.jpghttp://i62.photobucket.com/albums/h106/jruzich43/18EF97E8-983F-44F8-AC22-3F1B1041928C.jpghttp://i62.photobucket.com/albums/h106/jruzich43/667459BE-280C-4C0B-A070-1C0DF4CB7095.jpghttp://i62.photobucket.com/albums/h106/jruzich43/E70158E6-E5A0-465C-AA8B-0C4A148EE2B6.jpghttp://i62.photobucket.com/albums/h106/jruzich43/6245E1DE-3BE2-4106-978C-510342D45E2D.jpghttp://i62.photobucket.com/albums/h106/jruzich43/EAC3B50D-6D61-4B61-8D22-53334DFC76D5.jpghttp://i62.photobucket.com/albums/h106/jruzich43/B7ECD2CA-8FFD-4DAF-929A-B5C664DB4449.jpghttp://i62.photobucket.com/albums/h106/jruzich43/73E16E68-A492-4D21-8830-A4AD50A893DC.jpg

[Brasscatz]

Wow... I need to borrow you for some fab work on mine!!

Sent from my Samsung Galaxy S4 because my microwave couldn't do it

[XJ Wheeler]

Great work! I like how you did the angle. Mine needs the rockers done BADLY.

Sent via messenger pigeon - i talk, he types.

[4.3LXJ]

Nice rockers

[OneArmArrowSlinger]

Thanks again guys! My plan is to have the other rocker in this week & to brace the sliders to the subframe. I also hope to get my rear bumper mounted so I can start on the tire carrier and I need to get my dad out of his body shop and see if he can fold my rear quarters for me since I need an extra hand or two to do correctly. If I get all that done I will either have my dad go ahead & straighten the front frame rails so I can finish my stiffeners and front bumper OR start on my exo; all depends on what dad has on his schedule.

Thought I'd post another pic of my helpers; I guess some might call me a proud daddy, I'd say they're right!http://i62.photobucket.com/albums/h106/jruzich43/5B2CA0B7-21CC-4A7E-BF5A-48A7E9EBEC77.jpghttp://i62.photobucket.com/albums/h106/jruzich43/4BA833B7-1D79-443F-840E-33C3EA35BEB5.jpghttp://i62.photobucket.com/albums/h106/jruzich43/EB10721F-EB9C-4783-B331-E5DA737AD46D.jpg

[4.3LXJ]

Feed them well. The bigger they get, the more help they are :D

[OneArmArrowSlinger]

Feed them well. The bigger they get, the more help they are :D

NOOOO! They're growing way too fast on me as it is man. But they are great to have around, such a blessing to my wife & I.

[4.3LXJ]

Don't worry, the bigger they get, the more fun they get. Mine are all grown up and I still have plenty of fun with them

[NW99XJ]

Yea..... I've decided I'm just going to drop my jeep off for a while and let you go to town on it.... Simply amazing work Jonathon. I can tell you're not just hacking away and welding crap in. There's a very apparent forethought that has gone into every aspect of this so far.
Keep up the excellent work, and if you see a black XJ with Oregon plates on it, parked out in front of that awesome shop you have there, dont worry, it's just your (i mean ) my new project:D

[OneArmArrowSlinger]

Hey, you buy the supplies & I'll get on it!

[OneArmArrowSlinger]

Update time! Well, its been another busy week at work so I didn't get everything I wanted done but I knocked out a decent chunk. Here is part of a slat that fell in a pit while being replaced. Talk about heavy! http://i62.photobucket.com/albums/h106/jruzich43/4BD5DA34-9096-4DEA-835A-4000AB4A0AFD.jpghttp://i62.photobucket.com/albums/h106/jruzich43/B15516B0-62E9-4989-A070-63C3241A5DE1_1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/D5E08100-A9F1-4858-A389-A8C39E0774F5.jpg

I did get my rear bumper finished and primed, so I'm pretty stoked about that. It's one heavy duty sonuva buck but its gonna last! As I posted previously, I didn't like the way the stock bumper mounts directly to the rear of the wagon and there is no other support. So I opened up the rear of the frame rails and built the inserts.

This brings us up to date; next I got to thinking about how to extend out from the mounts to the bumper and also how I was going to make good, strong tow points. Extending the mounts was easy, I'd take a 5 1/2" piece of the 2x6 tube I had leftover and weld them to the mounts and to the bumper. Easy peasy, but how about those tow points & how would I construct them? My first thought was that I don't have any pieces of 1" thick steel but the more I thought about it, why not make them a laminate piece? I know from experience in construction and even archery, that laminated materials are by nature stronger than solid, one piece construction in a lot of applications. I have never seen any laminate tow points so I thought I'd experiment some! I took some 2"x3/8" strap and cut to 10 1/2"s so I could weld to the bumper mount plate and extend them through the bumper, welding along the way. I punched a 1 1/16" hole for my clevis to attach too and also punched some 1/2" rosettes in the pieces intended to be on the outside. I made sure my edges were beveled well, stacked 3 on top each other and clamped down then welded.http://i62.photobucket.com/albums/h106/jruzich43/D29A03C8-376D-4DBB-B42B-323CE4C266D7.jpghttp://i62.photobucket.com/albums/h106/jruzich43/EC2FA224-CE23-4063-8535-9A0B66401AB6.jpghttp://i62.photobucket.com/albums/h106/jruzich43/8095A4B4-1CC3-4497-980C-C8D0CEE71BB8.jpghttp://i62.photobucket.com/albums/h106/jruzich43/C565B3DE-FE3D-425F-B6C7-E145090FB54A.jpghttp://i62.photobucket.com/albums/h106/jruzich43/291A66C3-7938-4A50-ACD4-0076E574B30B.jpghttp://i62.photobucket.com/albums/h106/jruzich43/1E386BB2-5278-45B5-A44E-F0FE26E29320.jpg
http://i62.photobucket.com/albums/h106/jruzich43/953A153C-35BC-4708-BDFB-CB187D39D229.jpghttp://i62.photobucket.com/albums/h106/jruzich43/790DD586-56B9-47F8-A42E-016A4309C8DB.jpghttp://i62.photobucket.com/albums/h106/jruzich43/C795E687-87F0-450E-A266-4550AF114300.jpghttp://i62.photobucket.com/albums/h106/jruzich43/0901E81E-1E18-4678-A436-65B0FFDFBD8A.jpghttp://i62.photobucket.com/albums/h106/jruzich43/A1B1B952-3E00-444B-8C55-EB8FA93689D5.jpghttp://i62.photobucket.com/albums/h106/jruzich43/DAAC1636-B783-428A-B4A1-D70A80DD8CBA.jpg
After I welded and wire brushed, I then centered & welded to the bumper mounts.http://i62.photobucket.com/albums/h106/jruzich43/F7E5D14A-DBCC-4A36-8BAE-EEC50C7405F6.jpghttp://i62.photobucket.com/albums/h106/jruzich43/B6EA3657-7D80-45A1-900A-B0D7E8AF2EB0.jpghttp://i62.photobucket.com/albums/h106/jruzich43/000DACCB-8DC1-48DD-9BC1-81F8FAC5CC77.jpg
Next comes the extensions to mounts the bumper too.http://i62.photobucket.com/albums/h106/jruzich43/D903F2DB-113E-409F-AE25-D0162BA60A78.jpghttp://i62.photobucket.com/albums/h106/jruzich43/96C59074-30DF-49E9-A8FD-2E52912BC6BD.jpg
Put a notch in the extensions to make fit, also able to weld the tow point to the 2x6 tube on the bottom & inside.http://i62.photobucket.com/albums/h106/jruzich43/DB8782D9-B6EA-454F-B438-EA367654E58A.jpghttp://i62.photobucket.com/albums/h106/jruzich43/24A476EB-EEE4-4798-904A-DB3EB63EBFFA.jpghttp://i62.photobucket.com/albums/h106/jruzich43/30F66372-489F-4248-A61E-8B2204EA6573.jpghttp://i62.photobucket.com/albums/h106/jruzich43/336AD471-F55D-4251-AA3D-5405C6596D89.jpghttp://i62.photobucket.com/albums/h106/jruzich43/E73C8763-E129-454C-B65F-C232F38DB9E6.jpg
Next, I began to work on the bumper itself w/ a little help from my good friend Jonathan. We cut holes in bumper, front and back for the tow points to slide through. I then welded around the points in the front and welded the bumper to the extensions on the mounts. I did all this while the bumper was bolted to the Jeep so it will hopefully not have twisted while cooling down.http://i62.photobucket.com/albums/h106/jruzich43/7CEE797C-EDB4-4D0B-9C38-3B008478F271.jpghttp://i62.photobucket.com/albums/h106/jruzich43/689FB1FF-B87B-4CE4-A58C-E3C3EE7AF821.jpghttp://i62.photobucket.com/albums/h106/jruzich43/FDD02D51-DCD6-440B-9D0B-0DBA307CEAA9.jpghttp://i62.photobucket.com/albums/h106/jruzich43/4BD81611-CDD3-43F2-98FE-758A424B33D1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/F5B59061-1B52-4D46-90CD-A17BB4478E3E.jpghttp://i62.photobucket.com/albums/h106/jruzich43/8F6C6323-F116-4B3E-8E87-7BD78F14D72F.jpghttp://i62.photobucket.com/albums/h106/jruzich43/E25DCBAD-AFF4-49CB-B690-E36F7B834229.jpg
After the bumper cooled completely, I pulled, wire wheeled, primed the whole thing and painted the frame extensions with our company color, we call it Longhorn Blue. Its super tough industrial paint so I figured it'd be ok on the inside.http://i62.photobucket.com/albums/h106/jruzich43/A7368108-31EF-447B-93A5-6DA449216118.jpghttp://i62.photobucket.com/albums/h106/jruzich43/3774B73D-1B71-4C98-95A9-E0411B4EEF0B.jpghttp://i62.photobucket.com/albums/h106/jruzich43/4BE9079B-AC6E-43F4-A6AF-451ED71E10A0.jpghttp://i62.photobucket.com/albums/h106/jruzich43/BB801BBE-976F-4E73-A75C-E78A6731B130.jpghttp://i62.photobucket.com/albums/h106/jruzich43/2A989B16-925E-49CF-988C-5F8E61F3FE01.jpghttp://i62.photobucket.com/albums/h106/jruzich43/3699D829-C5CC-48E8-B820-82FFF8DA3AC2.jpghttp://i62.photobucket.com/albums/h106/jruzich43/C12AC5CA-0623-422F-A374-39903F24E5E5.jpghttp://i62.photobucket.com/albums/h106/jruzich43/F4106DFD-03CC-4E48-B107-97D94DD07AF9.jpghttp://i62.photobucket.com/albums/h106/jruzich43/A0174934-B508-4C6B-8F5D-5A6719628D41.jpghttp://i62.photobucket.com/albums/h106/jruzich43/BB0EC436-179A-43EB-A88E-7109749961C9.jpghttp://i62.photobucket.com/albums/h106/jruzich43/0710FA5B-8D53-4C8E-8804-3B3AA8588048.jpghttp://i62.photobucket.com/albums/h106/jruzich43/33CA90D2-EFCB-4C5C-92CB-077FFDDA478D.jpghttp://i62.photobucket.com/albums/h106/jruzich43/9BC8099F-0CBA-4D4C-85E7-BD74A6087E49.jpg

[OneArmArrowSlinger]

Last night I also started on the RH rocker/slider. Got my outside piece of angle all welded in.http://i62.photobucket.com/albums/h106/jruzich43/8322CC90-79BA-4000-A611-3A00FD086B95.jpg
Today's project brought to you by the letter C! lolhttp://i62.photobucket.com/albums/h106/jruzich43/0F8F956F-C18D-4691-9836-1DE439732821.jpghttp://i62.photobucket.com/albums/h106/jruzich43/33D6D64A-F27B-4228-ADA7-C8F4D982E335.jpghttp://i62.photobucket.com/albums/h106/jruzich43/751E8A4F-8846-43E1-94AD-0F831BF36B28.jpghttp://i62.photobucket.com/albums/h106/jruzich43/620F18FC-B03B-4519-942D-58555C7F1ED5.jpg

I'll get some pics of it in after lunch or during break today. It holds my weight by itself and I'm 235#'s.

[abebehrmann]

Great work, as usual!

[XJ Wheeler]

Man, that's some nice building going on! I like the bumper mounts, and being all tied together is a great idea... One i wish the aftermarket took note of more.

Sent via messenger pigeon - i talk, he types.

[OneArmArrowSlinger]

Great work, as usual!


Man, that's some nice building going on! I like the bumper mounts, and being all tied together is a great idea... One i wish the aftermarket took note of more.

Sent via messenger pigeon - i talk, he types.

I really can't express my gratitude for the compliments, means the world to me guys. You all have no idea how nice it is to be able to do things like this when just a few years ago I thought it was all gone from me for good. Takes some extra time to get done what needs done but the sense of accomplishment is worth it. So thanks again.

I hear ya Jake, in all my searching I don't think I have come across any bumpers quite like it. Is it over engineered?? Heck no, just a little heavier!! haha:smiley-laughing021:

[Brasscatz]

Very impressive bro, very impressive

Sent from my Samsung Galaxy S4 because my microwave couldn't do it

[XJ Wheeler]

I really can't express my gratitude for the compliments, means the world to me guys. You all have no idea how nice it is to be able to do things like this when just a few years ago I thought it was all gone from me for good. Takes some extra time to get done what needs done but the sense of accomplishment is worth it. So thanks again.

I hear ya Jake, in all my searching I don't think I have come across any bumpers quite like it. Is it over engineered?? Heck no, just a little heavier!! haha:smiley-laughing021:

Jon, i'm not feeding you any kind of line when i say this. A LOT of people (myself included) really do wish they had your talent and expertise. It may have slowed you down but you've proven with God and willpower it will never stop you.
Nah, you can never over engineer bumper mounts in my opinion. :D

Sent via messenger pigeon - i talk, he types.

[Firemanray]

Awesome work! I'm with others here, your ability to overcome your hardships to accomplish your goals is impressive.

I'll definitely be following this build!
http://i223.photobucket.com/albums/dd11/firemanray21/Deer-popcorn_zpsebafab2e.gif

[OneArmArrowSlinger]

Well, been a long week at the Ruzich household. Daughter w/ pneumonia & several other sick. Tonight first chance I've had to work on the XJ since Sunday. I built my RH side rocker slider tonight, welded outside angle iron on top at door sill, and slid bumper in to see how I liked it.
http://i62.photobucket.com/albums/h106/jruzich43/E7A526BB-F5F9-438F-9741-F39240B349BA.jpghttp://i62.photobucket.com/albums/h106/jruzich43/54117CE2-9CA4-4576-81CF-22A095C4194C.jpghttp://i62.photobucket.com/albums/h106/jruzich43/4131F844-517E-4E2B-83F8-08A270D37D8B.jpg

forgot to take pics of slider after I dressed up the welds. In case anyone wants the specs on sliders, before I forget, they are: 2"x6"x1/4" tube @ 65" long, the front angle is cut to where the bottom is 1.25" back from the front and the back angle is 1" forward from the back of the slider. Clear as mud? :smiley-laughing021:

Cleaned paint and rust off door sill.http://i62.photobucket.com/albums/h106/jruzich43/9AAA1033-5B9F-45A2-A3B5-5B259F77B9A8.jpghttp://i62.photobucket.com/albums/h106/jruzich43/C7237BAF-5EE1-463A-BEE5-74DA087E0B50.jpg

Spot welded sheet metal first with my welder down real low, that gave me something to weld into when I ran bead all the way down the sill.http://i62.photobucket.com/albums/h106/jruzich43/6AA33EED-AF78-4410-8236-062A79204926.jpghttp://i62.photobucket.com/albums/h106/jruzich43/09A8B04A-EBF2-4A30-9A2F-34869EDB3723.jpghttp://i62.photobucket.com/albums/h106/jruzich43/E2ED733E-C889-4E5E-A18E-FF88AE630B8A.jpghttp://i62.photobucket.com/albums/h106/jruzich43/4803AEB0-FBDE-4837-9193-2D9C39972BA3.jpg

Bumper slid into frame. Not bolted in yet.http://i62.photobucket.com/albums/h106/jruzich43/11FA1112-1597-4B31-8D07-2315A777A2E0.jpg

Inside of rocker, top of outside angle ironhttp://i62.photobucket.com/albums/h106/jruzich43/0BF336C7-EA23-499E-94C2-3A1EED25277F.jpg

Gas cans a buddy gave me, gonna bead blast and make a carrier.http://i62.photobucket.com/albums/h106/jruzich43/F1124D84-8FDF-4BF2-9EA6-D609E04C552F.jpg

[OneArmArrowSlinger]

Update!:

I really, really like the primer. I got it at our local Farm & Home Supply, its for tractors & other farm equipment. Its just brushed on but 2 coats with a brush really puts on a thick, smooth covering. Here is a pic of the primer & paint I got if anyone is interested.http://i62.photobucket.com/albums/h106/jruzich43/097708C1-EB1B-4266-861A-516192414631.jpghttp://i62.photobucket.com/albums/h106/jruzich43/C8745594-E6F5-415D-98A8-50A8835EA598.jpg


Here is my buddy Jonathan making my tail light boxes.
http://i62.photobucket.com/albums/h106/jruzich43/66381B11-74CC-4680-B359-BD5B584D5136.jpghttp://i62.photobucket.com/albums/h106/jruzich43/E66A81E3-208E-43F6-8C48-FD7733D79A8D.jpghttp://i62.photobucket.com/albums/h106/jruzich43/E12A9758-69EE-4355-9079-FB7A5F437D53.jpghttp://i62.photobucket.com/albums/h106/jruzich43/ECDF4279-C820-41EC-A573-701FBC00E0E5.jpg

Put some diamond plate on my bumper to fill the gap between the bumper & the body of the XJ.http://i62.photobucket.com/albums/h106/jruzich43/5260280C-A02F-41E4-A596-3A9D6D9FDF05.jpghttp://i62.photobucket.com/albums/h106/jruzich43/4F1B61A4-337F-46E5-87D8-53310DDC22CA.jpghttp://i62.photobucket.com/albums/h106/jruzich43/F67DC250-E14D-456D-A28F-728EBF79A77E.jpg

Got my 1/4 armor from JCR installed.http://i62.photobucket.com/albums/h106/jruzich43/4815C8FB-94C6-4F78-B12D-7A904B3890A1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/FF691ED5-995A-4CE1-A81A-8372E3859797.jpghttp://i62.photobucket.com/albums/h106/jruzich43/AEA79F88-49F7-4A0B-BAF5-A869CD80BC38.jpghttp://i62.photobucket.com/albums/h106/jruzich43/37CB7577-4D40-48DC-BC98-8C3D2C9EFD8D.jpghttp://i62.photobucket.com/albums/h106/jruzich43/6639392F-71BA-40BE-9AF2-EFB6F42D2E47.jpg

I finished welding in my passenger side slider then put braces from the slider to the frame on the drivers side, going to passenger side tonight. Used 1.75" tube @ 13.5" long, cut the ends to 45* and welded .25"x2.25" strap to it to close the ends.http://i62.photobucket.com/albums/h106/jruzich43/7703514F-F098-474B-B76C-E3815AA0AE83.jpghttp://i62.photobucket.com/albums/h106/jruzich43/97413B80-AE4A-4B94-B63C-121FC8CEE30F.jpghttp://i62.photobucket.com/albums/h106/jruzich43/4D9E346C-C74C-42E0-A553-9C0781A25AC5.jpghttp://i62.photobucket.com/albums/h106/jruzich43/FFA1AF81-7C15-42B2-942B-38EE8243F67A.jpghttp://i62.photobucket.com/albums/h106/jruzich43/06145097-6854-407C-9CA8-25C45E22CA77.jpghttp://i62.photobucket.com/albums/h106/jruzich43/9FC37E18-E47E-407C-900F-CAFB2DFA522B.jpghttp://i62.photobucket.com/albums/h106/jruzich43/73C24083-C474-402A-9EB9-B752BB75A7D3.jpghttp://i62.photobucket.com/albums/h106/jruzich43/763F35C9-8A7A-4F85-94D4-09C757B3B9D1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/C48F9E83-303A-430A-8123-E41CBA06EE38.jpg

[NW99XJ]

Update!:
Here is my buddy Jonathan making my tail light boxes.
http://i62.photobucket.com/albums/h106/jruzich43/E12A9758-69EE-4355-9079-FB7A5F437D53.jpg

Got my 1/4 armor from JCR installed.http://i62.photobucket.com/albums/h106/jruzich43/37CB7577-4D40-48DC-BC98-8C3D2C9EFD8D.jpg
I really like the idea of using the old lights as a die to bend the sheet meteal for the tail light boxes... thats a great idea! ... are they done yet? ...I wanna see moar pics of those! :camera:

And the slider bars on the quarter panels.... AWESOME IDEA!!!... I love that, it looks amazing, and will be very functional.

[OneArmArrowSlinger]

I really like the idea of using the old lights as a die to bend the sheet metal for the tail light boxes... thats a great idea! ... are they done yet? ...I wanna see moar pics of those! :camera:

And the slider bars on the quarter panels.... AWESOME IDEA!!!... I love that, it looks amazing, and will be very functional.

Thanks Josh. I wanted the metal to be close to the same shape so we made patterns w/ paper then started bending. I've not gotten anymore done on these since last week. Really want them done right so I've been waiting on the help, its very much a 2 handed job. I'll probably have my dad & grandpa do the finish work, they have been doing body work for years and years. Grandpa started in the early 40's & my dad grew up in his shop & I grew up in my dads. I'm hoping it will be a simple enough project that grandpa and dad can teach me the proper way to lead up the seams. By the time they were my age they had become sheet metal artists, time for me to step up to the plate & learn.

I am, also a big fan of the 1/4 sliders, looks different and will hopefully be equally functional. Was a simple fab and I figure will make a great anchor for my exo.

[bluedragon436]

This is an awesome build you've done here.. Glad to see that you are not letting anything get in your way of building up a rig like you want it to be.. I am with many of these guys... I wish I had half the talent/skills you have to build my next rig..... Look forward to seeing it as it progresses!!

[OneArmArrowSlinger]

Hey there fellas, how's it been?! Busy here. Been out of town couple times over the last few weeks for the IL Pork Expo, MO Pork Expo, & the IL Cattle Expo so updating my thread hasn't been a priority. I have however been working on my XJ as much as possible. I'll do my best to hit up the highlights.

So after I cut my quarters I decided to build rock sliders for the rear so it wouldn't smash the quarter all to heck if I do slam on something hard. I used the same 1.75" square tube I put on my quarter armor and welded to the frame, came straight out to the quarter then made a 90* turn straight back to the bumper. Instead of welding to the bumper, I welded a 2"x1.5" piece of square to the corners so that when the bumper is slid into the frame it would slide into the sliders and then I bolted w/ grade 8, 3/8"x2.5" bolts.
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/D66B667F-5048-4C39-913A-D2B2DCF77D15.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/D3464B50-B68D-4842-B9FD-B85A79FF788C.jpg
Where I cleaned primer off bumper.
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/AC2B9A21-2588-4B87-A375-4A0E7A09ED35.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/BBF8C4C2-0684-4AB9-8792-649F96267037_1.jpg
Quarter Slider
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/232B1178-12EF-438C-AFB5-DD09852449B6.jpg
Clean frame
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/96A9C73D-6DA1-430F-859A-75269D7C526D.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/BED53FA4-2FD5-45C7-8D35-BF51310B9569.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/314C3FAD-FA33-49DF-A840-A5A15DDB386D.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/36DC6644-C930-41AC-9196-9AC39C7532E4.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/ED8387B8-2CAE-4D99-AEE9-B26342669B90.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/65C0EAE7-74ED-4A03-9F57-ADD36B01D822_1.jpg
Welded in

Next step was to start on my exo since I am still waiting on my dad to get some time to straighten my front frame rails.

Disclaimer: This exo is only for body protection, not intended to be a roll cage! I know this, I designed it that way and understand its limitations.

That being said, I hate the look of round tube on an XJ. I know there is a lot of it out there, just not my preference. Luckily, we build our cattle gates out of square tube so we have a butt ton of scrap and cut off laying around. I used 1.75"x14 ga square tube to build this, gussets are 3/8" thick. Secondly, I designed the cage to be removable so that when things are bent, beat up or I need to work on the body of the jeep; I can pop off the cage & get to work. I used 1.5" square tube welded to the rocker sliders and quarter armor for studs and used grade 8 bolts to bolt it down.http://i62.photobucket.com/albums/h106/jruzich43/Jeep/855DEE56-2D35-4F09-9846-00A6E2C2553D.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/B382CBF7-598C-47B2-B0AC-1A64DB985A4C.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/11D0007C-2D61-48AE-99BC-4DAAA2342D46.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/894FA859-0E9E-41BB-85F0-8BFA51BAC2EA.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/B91E0BF9-E7DA-4A1E-98BE-56FFD8F97A45.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/DE4A310F-E1B1-44A0-AADB-6BFBFF696ABB.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/6D6FEFEE-3AE5-4F16-876D-22080AEA3E2C.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/E88A8A17-3533-4EFC-BAAC-2E9A2C33505E.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/E15BDD0B-6AEA-469F-ACFC-21A095B4F46C.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/2AD65505-62BE-4BAA-8194-2D3BDC719409.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/528C03ED-7DA4-43D6-81BF-D7F600041509.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/84C8EDE3-9058-48F7-BE1D-25DB69550E2B.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140215_155358.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140215_191249.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140215_191344-1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140215_191352.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140215_195656.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140215_224915-1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140215_224924.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140215_224936-1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140216_171007.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140216_171000-1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140216_222736-1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140216_222804-1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140216_222952-1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/F819797A-E2A5-42A1-ADE8-461238EF18FC.jpg
I reinforced the joints on the top w/ 5"x7"x.25" pieces of diamond plate and put on tabs for mounting lights.

Bad news time; I don't have a build on the tail light boxes. My buddy, Jonathan, is laid off right now and one day last week he surprised me by showing up at our shop while I was out at a job site, and he built my boxes for me!! What a friend!!! Here are the pics I do have. He said he just slowly hammered around the stock lights, welded the seams w/ real low heat on the MIG, then ground the welds down and smoothed up for me. I wish I had more pics of the build but I will share what I have.http://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140215_155408.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140215_155416.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140215_224946-1.jpg
Primed
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140215_233832-1.jpg
Painted
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140216_222849.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140216_222911.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140216_222931.jpg
Installed (not wired up yet)

[4.3LXJ]

Wow, that is a lot of steel. You won't have to worry about the body flexing for sure. Looks like y'all will be plenty safe

[NW99XJ]

The light boxes look great!
That cage is something else man.... Square tube huh?...thats going to create a ton of wind noise going down the road, but looks insanely beefy.....

[OneArmArrowSlinger]

Wow, that is a lot of steel. You won't have to worry about the body flexing for sure. Looks like y'all will be plenty safe

:lolsign: It is a lot of steel for sure. I told you guys I over engineer everything! :rotfl2:


The light boxes look great!
That cage is something else man.... Square tube huh?...thats going to create a ton of wind noise going down the road, but looks insanely beefy.....

Yeah, 2 reasons for the square tube; 1)I prefer the look 2) its free... Wind noise not a big deal to me, I bet I don't put more than 200-300 road miles a year on it. I believe it will serve its purpose, lol!

Thanks on the light boxes! I gotta give Jonathan the credit on them, he'll be pleased to hear that you guys like them!!


Man am I ansty to hit the trail.....:xj-black::xj-blue::xj-red:

[4.3LXJ]

I don't think wind noise will be an issue running boggers. Those would be enough to drive me out

[OneArmArrowSlinger]

Next, I started on my swing out tire carrier. Unfortunately I don't have all my pics. I broke my phone and lost a few. I used 2"x3"x1/4" tube to make the swing out arm on the carrier. My buddy Jonathan & I used a pretty sweet drill press at another friend's shop in order to drill the hole for the spindle.http://i62.photobucket.com/albums/h106/jruzich43/Jeep/20140215_114925.jpg
Holy drill press Batman!! haha

I purchased my spindle from A to Z Fabrication and I really like the look and quality of the construction. Very well built. Well, as I am sure you guys are aware, swing out carriers for XJ's are few and far between. I did lots of searching on the net, looking at pics, mulling ideas over in my head & talking w/ friends to engineer my ideal carrier. If you've followed much of my build you obviously will note my missing left arm, can't miss it, lol. Although I have more strength in my arm than most do in both, lifting a 33" bogger on and off will be a difficult task. My solution was to create swing out then down so that it would be easier for me to accomplish this task. Now that I had my plan in mind, what would I use for a hinge that would be strong enough to hold the weight and vibrations? What I landed on was a hinge for folding up a long tongue on trailers for boats so you are able to shut the garage door. It is cast steel and rated at 8000 lbs.http://i62.photobucket.com/albums/h106/jruzich43/Jeep/B4A33B2B-3FFC-4BF5-B003-099AAC3A6B8F.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/F2F75EB7-0719-4804-90B6-9A8C85E5C36B.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/2E0F2218-2BAD-46D2-92F6-18CF09F8FAD8.jpg

I wanted to find a place for the gas cans that were given to me so I placed them closest to the spindle.http://i62.photobucket.com/albums/h106/jruzich43/Jeep/A870B84B-0E9B-4D21-8D8B-90A95353BE1A.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/61AF3F68-E6A0-4572-8764-812A1A0E3770.jpg

Hinge openhttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/BFF53227-9302-4D74-B593-44EE26A30B3E.jpg

Hatch needed a little trim...http://i62.photobucket.com/albums/h106/jruzich43/Jeep/ABC8A5A4-AACD-4C18-A9DB-1A764836BCCA.jpg

Then I built the tire carrier portion. I made it like a reese hitch in that I will have the tire/wheel bolted to a plate that is welded to a piece of tube so it will slide in & out of the 1.75" tubing I used on the carrier receiver.http://i62.photobucket.com/albums/h106/jruzich43/Jeep/D2E274DF-1DE1-4C65-9270-3C2B882FB3E7.jpg

The rest of the carrierhttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/9E69F9D0-BCF6-42DB-B8B7-591AC93D62F2.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/E25AE5DA-4E63-498D-B720-550C2BAC496E.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/2316616E-5B39-46D0-A893-F80698FBDF76.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/88D42891-660E-46FD-9EBE-9AC1155447F6.jpg

Put a piece of pipe in the receiver and set tire up on it to see how it looked.http://i62.photobucket.com/albums/h106/jruzich43/Jeep/3C91AB65-4ADD-45B3-84CD-4931925E3049.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/5F107BC4-1ECB-4049-9A59-872D45B73E77.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/7CF79208-C27C-401E-98A1-84C1971C8F1F.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/91AA67FF-FAA8-439B-BE67-BBDD02BE3279.jpg

I do have a few tweeks I need to do on the carrier but for the vast part, its done. Tonight I will be straightening the front frame rails w/ my dad & grandpa. Dads frame puller is down so we're gonna do it the old fashioned/redneck way, a forklift & possibly a tractor. LOL

[abebehrmann]

Looking good! Man I wish I still lived in St. Louis so I could come check it out in person and help out/learn.

[OneArmArrowSlinger]

Thats would be pretty awesome if you still lived there Abe. I'm all for the extra help and an extra set of eyes to spot out any potential problems. Plus, you can never, ever, have too many Jeepin pals!!!

[XJ Wheeler]

That is certainly gonna be a cool, one of a kind jeep!!! Love the ingenuity of that swing out tire/can carrier. Where there's a will, there's a way, right?! I never thought square tubing could look as clean as you've got it going on with that cage/armor. Nice work, all around bud!

Sent via messenger pigeon - i talk, he types.

[OneArmArrowSlinger]

Thank you Jake, much appreciated. Yes, I've found that where I have enough will, YHWH makes up the difference in my shortcomings and provides a way. I really can do all things through Christ, as long as I give him the credit.

So last night, my dad and grandpa came up to the shop to get the front end straight enough that my new bumper build and front frame stiffeners can get started on. Since my dad's frame puller is down, grandpa said we could get it close enough the way he used to do it "before all those fancy machines." LOL I asked Grandpa how long he had been doing body repair and he said about 70 years, he knew it was before he was married and that happens to have been 65 yrs ago today; I asked dad the same question to which he replied, "I dunno, about like you, grew up in the shop and knew enough by college that I did odd jobs for money." So my best estimate to years of experience in that specific discipline between the two would be somewhere between 110-119. Talk about knowledge! So armed with some chains & binders, oak blocks, 3 hammers, 2 bottle jacks and a forklift we got to work.

Positioning the blocks and bottle jack.
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/667445FB-926B-436A-AE75-4459D9B7830A.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/2B41152F-D317-4768-8F7C-71CB15CB27C6.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/301FBE5A-6DA9-4D35-A259-63F7E148EA1F.jpg

Jacking up on Jeep to put frame under pressure.
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/7DD14364-BA6B-4E14-9228-681A87775086.jpg

With frame under tons and tons of pressure, dad & grandpa would tap and beat on the frame strategically in order to make it move back. You will literally see the metal "jump" back towards its original form.
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/1AFE286F-1C71-4BBF-B894-D0760BA6AEC4.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/550B0193-85AA-44B1-BBA3-116E416F6EFF.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/E194DB79-0064-4F2D-B25C-A25359438E91.jpg

We had to go through the process of taking slack out of chains, jacking up and hammering several times but it only took about an hour total. As you can see, its not perfect because we didn't have on a laser guided machine and the bumper is a little twisted from all the pulling and the damage from the initial accident so its pointed a little down but its night and day compared to before plus the front of the frame horns are now straight. This will definitely be ok for the purpose in which this rig will be used. http://i62.photobucket.com/albums/h106/jruzich43/Jeep/61B07018-541C-43F6-84EE-0E169BEC5DD9.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/0F3D60E8-7A5E-4ED4-A64E-47500E7738F6.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/47EC84B9-C89E-483D-9BDA-1A086C1BA297.jpg

[bluedragon436]

Looking good.. Love seeing old school work like that, wish I had known more folks like that growing up to learn awesome tricks of the trade old school like that..

[4.3LXJ]

Nothing like Yankee Ingenuity

[NW99XJ]

Man...three generations working on one Jeep..... you sir, are luckier than you will ever know.

[OneArmArrowSlinger]

So after another 2 weeks I figure I should probably update my build. As of last night I am done w/ the structural welding, so now I can wheel this weekend! After I was able to get help straightening the front as best we could I got right into installing the front frame stiffeners and building the front bumper. My dad came out and welded the stiffeners while I worked on bumper for the front.

Dad not happy with angle of left front frame horn so he got out the hot wrench and the slide hammer. It is as close to straight as it will ever get w/out a true frame puller.http://i62.photobucket.com/albums/h106/jruzich43/Jeep/F19AD1CA-7000-4A8B-9D89-349A16496532.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/C0110F44-A6F4-4E89-8D91-F243ADBFBE04.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/7D000FED-7C7D-4566-B363-003C3A21F78F.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/C950747A-183E-46B3-A0C5-9DC5840BFC93.jpg

Wife snapped this of my grandfather, dad, son & I all inspecting a part we had put on drill press. I'm a lucky guy.http://i62.photobucket.com/albums/h106/jruzich43/Jeep/27F5566B-08C4-4CD4-B4D4-B704F0A18E25.jpg

Front bumper mount extensions. Made from 3/8" plate.http://i62.photobucket.com/albums/h106/jruzich43/Jeep/E4710DAD-DFCD-4409-825E-FE8B9ACBABF5.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/F470CEBD-676A-49F5-9961-C40405B8C221.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/3EB6DD26-ABDF-4AFF-B9B1-7C69FEFBECC6_1.jpg

Stubby front bumper build w/ stinger & 2" receiver for winch cradle.http://i62.photobucket.com/albums/h106/jruzich43/Jeep/B62DBA1C-1E46-4665-B502-6C997E71E298.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/AD586ADA-BF4B-43EC-9EAF-FCE5E3F3763F.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/3394AE76-3CF9-4F9E-B7BD-C21DD76F633A_1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/E3F0CCF1-8B20-4537-908D-90745A785B6A_1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/BE603AD8-E308-41E8-8704-808C0E14E4BA.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/A641750E-1D2A-4FE6-82E4-E2EFE0DBCC23.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/43095D76-5D4A-4CCC-AAB1-40266A82F69B.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/233BF13C-7F76-4A63-BAD7-D0C7A2C2C4C1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/F51FCEB9-ED01-4E2C-8968-D6A2A1B68EEF.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/404349F2-5FB4-4D5E-AC92-C75EA6AF7F3F.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/C7677315-BA71-4925-97E5-1E6A385023F6.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/B501D12A-F140-4FF9-9F20-A46ADA61FC76.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/6591DF5F-2192-4DA8-B8E3-D08B75A34E67.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/E8A99C28-5668-4100-AE79-CB16E16425B0.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/1700022C-1349-411B-9B44-043F06D49BDA.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/63B3D309-4E8C-4071-BA8B-A85E07A3457F_1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/EAD965A8-3722-48BE-9620-AB4430D149CA.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/F059A0FF-5BDD-4146-899D-5F2E9BA677B8.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/A253A9CE-337D-4D78-8376-CB0C69BAF7B5.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/F9E2DCED-F8B0-4035-BE5A-9410D389571F.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/01A444BD-7CE5-4880-8336-2EF17820CBCD.jpg

[OneArmArrowSlinger]

Here are the pics of my front hoop & fenders w/ mud flares. Rear tire carrier done, will get pics in a little bit.
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/EAD965A8-3722-48BE-9620-AB4430D149CA.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/F0DF039B-6B40-4DF7-BBC9-4AB22BE329E3.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/EA117DE5-9FA7-4BCD-98D7-D26225CAB5B1_1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/5F434D61-3AD0-42D6-9377-A4E264CA5F27.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/AC3194C3-5268-4644-B5C8-81DD76B08743.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/7B850A32-D209-4BA0-B9BD-C88FBB040F3B.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/6FF3E60E-3647-4794-BC59-9DEECDDAFC73_1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/8840BD87-BA99-46D5-A72B-4C88EC0BD4B3.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/54F08A8B-1F12-43E1-937A-29936E4A6CA7_1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/E0761D27-4808-4CE2-A7CE-C65120D0BD8B.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/DCD85191-9A8F-4673-8431-CFCFC15A7AEA.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/7C443421-1B45-498C-89B8-FE4C4AD85ACC.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/A0466356-CE2B-49E8-B2D1-72CED34CD756.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/2123E812-A6AB-4C25-806E-2E1D0B72E68F.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/053CEA3E-4E22-436C-93E2-FAC0319C9353.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/F3472346-FD52-4FC6-AD0C-4383DC116EF1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/6F991E8E-74E8-4760-9CED-CF5EBA8C40A5.jpg

tube for flares is 3/4"x3/4" 16 ga, diamond plate is 1/4"

[4.3LXJ]

OK, I am staying away from that rig. If it toughed mine it would crush it :D

Nice work

[cantab27]

nice work...........how heavy do you think it will be now .....cool seeing pics off 4 generations jeepin......

[XJ Wheeler]

That is AWESOME having four generations wrenching together, love that pic! You are truly blessed with them!

Sent via messenger pigeon - i talk, he types.

[OneArmArrowSlinger]

nice work...........how heavy do you think it will be now .....cool seeing pics off 4 generations jeepin......

Honestly, I think I'm only adding 500 to 600#'s over where I started from, tops. The exo can be picked up by my wife & I so can't be more than 200#'s, the rockers were about 65#'s each (weighed them on UPS scale), I replaced the bumpers w/ something similar in weight, tire carrier weighs less than the spare itself; so all in all it shouldn't be much. Now as far as how heavy over stock? No idea, a 1000#'s maybe? I'm going to see if they'll weigh it at the scales outside town when I'm totally done. Thanks for the compliment!


That is AWESOME having four generations wrenching together, love that pic! You are truly blessed with them!

Sent via messenger pigeon - i talk, he types.

Thanks Jake, not a day goes by I don't thank The Lord for my family and our heritage.

[NW99XJ]

Is it just me, Or is any one else more than a little intrigued about what this thing would look like with dually's in the back? :)
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/DCD85191-9A8F-4673-8431-CFCFC15A7AEA.jpg

[OneArmArrowSlinger]

Thats awesome b/c you don't know how many times that thought went through my head! My son even said the same thing. Maybe I need to build myself a pulling rig!?

[OneArmArrowSlinger]

Primed the front here. Time to put it back together & get it on the trail for the Two Rivers Jeep Club run this weekend! I have a lot of little things left to do like wiring lights, cb, etc., but I can wheel Saturday w/o that stuff.http://i62.photobucket.com/albums/h106/jruzich43/Jeep/A0392B4A-E60C-4B41-9F77-C6C0764B90F0.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/1AAB2373-72E7-45A9-9F1B-E7359AF5F995.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/6415782E-82C2-45C9-9B63-AED2289485FF.jpg

My beautiful assistant http://i62.photobucket.com/albums/h106/jruzich43/Jeep/981C7570-02CE-4178-9B12-20AB69C4EDCC.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/EADE2763-749E-4CC6-8727-0C19740672FE.jpg

Completed tire carrier w/ jerry can holder. Still gotta find a place for my hilift, just unsure as to location.http://i62.photobucket.com/albums/h106/jruzich43/Jeep/60C2D2DA-4946-4D55-B7F9-78C239E65586.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/15734C25-BED0-42A1-88EA-6D9409F6C7F8.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/412659E1-7323-400C-B459-8CFAC41C2567.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/803908EF-1713-423F-90A2-369FC7E1E143.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/6663DEF2-B5F5-4E59-B167-4814DFCB7AB5.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/AE5167E0-9261-450D-BEF0-5BA739876742.jpg

And painted ....http://i62.photobucket.com/albums/h106/jruzich43/Jeep/B3803796-4E4F-4C52-9A98-915B2C4BD116.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/F0DE32DF-A9B9-41A2-9B7E-00939A8123C1.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/380E1C4F-8F53-4CFE-B542-75D027EAC028.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/7F6C37F0-46B2-476A-9324-C831A805EFF3.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/73223D81-70A6-497E-BD5D-B7AA7DFB4B1A.jpg

[OneArmArrowSlinger]

So I finished Stage 1 tonight and moved it outside the shop. Ready to wheel Saturday now! Still have to put skin on my fenders, wire & stuff before road legal but thats not what I really care about, haha Will get plenty of pics this weekend but until the kids pine wood derby cars are done I've gotta put the rest of the project on hold, although it won't be long until I get them finished. Here's the last few I snapped tonight.http://i62.photobucket.com/albums/h106/jruzich43/Jeep/4A9B9475-EEB4-4CE8-A05C-56F1655AAF09.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/9ABB4A5E-1180-4506-836F-9567B6BBBB15.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/DEADCB58-ED62-4918-9285-F0C916B2EF5D.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/3BAA51B7-2965-4656-80AA-C0F730AA0509.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/E566AFE6-7165-40F8-AD68-C75C3EBD4EDB.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/ECB1B1B9-C782-4C69-847C-DE50EFABEBFF.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/A433E0F0-516F-401B-AD3A-3904F95CD8E6.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/56D07237-38D4-4FA8-8436-9330A3CC843B.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/74D8538B-2E67-4E8F-88B5-3408E1E03C00.jpghttp://i62.photobucket.com/albums/h106/jruzich43/Jeep/9E8D398C-4B88-4F83-911C-49AF005F5248.jpg

[4.3LXJ]

Ok, waiting for the action pics :D

[OneArmArrowSlinger]

Well, Murphy was at it again. Was pulling out of shop Saturday morning when I heard a loud POP and had trouble steering. It seems the steering box spacer has broken and I couldn't go wheelin'...:bang: All that work to be stopped by a spacer! :nutts: I'm just thankful the good Lord let it break down there instead of on the trail, it was slicker than all get out. My hope is that I can fab up a new spacer and get back on the road.

[4.3LXJ]

Always something on a rig that gets wheeled

[OneArmArrowSlinger]

Yup, Murphy was an optimist.

[NW99XJ]

Meh... its an easy fix, and luck was on your side that it didnt happen further away.

[OneArmArrowSlinger]

Fixed! You were right Josh, easy fix. Made a spacer similar to JCR Offroad sans the bumper bolt hole. Used 1/2" SS nuts for collars welded to a piece of flat 3/16" steel cut from an outline of the old spacer. Phone was dead, didn't get any pics, sorry guys. Will crawl under today & see if I can get some.

[rabies]

where did you go? :(

[OneArmArrowSlinger]

where did you go? :(

Sorry, been so busy this summer I haven't hardly had time to wipe. :smiley-laughing021: Anyhow, working on the WJ knuckle upgrade right now & trussing the front. Will get pics on here of some progress after the weekend.

[XJ Wheeler]

Good to hear from you Jonathan! The jeep looks great and appears you've been having fun. Don't wait so long to get back here!

Sent via messenger pigeon - i talk, he types.

[Brasscatz]

Welcome back! XJ is still looking sweet :thumbsup:

[cantab27]

yep good to hear from ya .....keen to see the wj bits up grade ...have a friend down here doing simular.....

[prcjeep]

Missed this build before, Looks awesome! Great work! I've got some HD offroad engineering frame stiffeners sitting in my garage waiting the last 4-5 months to go on.

[OneArmArrowSlinger]

Thanks guys! Been working on the front when I can. Got my pitman arm and WJ knuckles bored out to 5/8" for the 1 ton steering I'm building. My dad & grandpa pulled the whole front end out for me while I was at work one Saturday so it'd be easier for me to weld on and just work on in general. So now I've got my Artec truss welded on, tubes welded to pumpkin and ball joints out. Gonna clean up tonight & rattle can it so I can start my assembly.


Drilling out some holes
http://i62.photobucket.com/albums/h106/jruzich43/IMG_3595.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_3596.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_3597.jpg

XJ right now
http://i62.photobucket.com/albums/h106/jruzich43/IMG_3562.jpg

Putting the truss on. Had to modify the truss as it ended up I got a JK model instead of the "XJ truss" that I had purchased on ebay. No biggie really but just aggravating. With a little snipping on our new ironworker it was short work. The new ironworker is a 90 ton Piranha capable of sheering a piece of 1"x8" steel like butter. Pretty cool machine.
http://i62.photobucket.com/albums/h106/jruzich43/IMG_3438.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_3598.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_3599.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_3600.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_3601.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_3602.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_3603.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_3604.jpg

Couldn't get the nuts off the ball joints so out came the hot wrench and no more problems w/ them! Workin w/ my 86 yr old grandpa & brother on this. Ball joints out successfully.
http://i62.photobucket.com/albums/h106/jruzich43/IMG_3560.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_3561.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_3626.jpg

Will be starting to put back together this week. Hoping to rattle can it tonight then hammer down. Should be done by next weekend :pray:

[Pookapotamus]

Definition of tank: see this build!

Nice work!

[NW99XJ]

Nice Pook! lol
But seriously Jon, great work so far... I love the looks of those Artec Trusses...
...and that Ironworker ...wholy cow,...what a piece of machinery to have access to!
I cant wait to see this thing all rattle canned and lookin purty!

[OneArmArrowSlinger]

Thanks guys, working on it tonight! Was going to last night but I put in 13 at work and was whipped.

Josh, I'm still waiting for your rig to be in my driveway one morning with a rough sketch & a note, lol

[autotech98]

That thing is a beast! Cant wait to see more

[OldFaurt]

Wow, that is no longer an XJ, that looks like a bullet proof Next gen Tank!
Beautiful job. What are you going to power that chassis with?
I think the 4.0L may be a bit anemic!

Wonderful build report!

[OneArmArrowSlinger]

Well, putting ball joints in tonight, been BUSY with work. Terrible excuse I know. But here is where it is now. @Oldfaurt; the 4.0 seems to do ok w/ the 4.10 gears but my goal is to upgrade to some 4.88's next summer. I think the 4.0 will do just fine.

[4.3LXJ]

No rust :D Bet some people are jealous now :D

[autotech98]

I know i am..looks awesome!!:cool:

[oderdene]

well done, looks awesome

[XJ Wheeler]

I've made my peace. I accept my jeep doesn't have rust, but my rust has a drivetrain and upholstery.

Sent via messenger pigeon - i talk, he types.

[NW99XJ]

NIIIIICE!!!!
Looks killer Jon!
Now hurry the "F" up and get all that under the Jeep already!
(work be damned!)
:D

[rabies]

luuuuuuuuuuucky. i would love to glue that under my jeep.

is it me or....in the 2nd primered pic..the right side long arm at frame end look bent? maybe that towl is too heavy and bent it

[OneArmArrowSlinger]

Yes, you're correct. I had a bit of a mishap while transporting w/ the forklift to be prepped for paint. All I feel like commenting on about it, rofl. It's not quite as bad as it looks in the pic actually so I'm gonna run it for the time being.

On a positive note, I got ball joints in, WJ knuckles on, axle shafts in, and hubs on last night. Gonna load back on forklift & drive down the road to my dad's shop where the XJ is at, after work. Will get pics this afternoon. So far, the WJ swap is going well. There are some detailed threads out there (one in particular Josh sent me, I'll have to find it) that I just followed out and I couldn't be happier. Can't wait to get the Sturdy-30 under my baby. Sorry this build is taking so long guys.

[OldFaurt]

No rust :D Bet some people are jealous now :D

NO!!! YOU THINK?
I Know I AM!
That is one awesome axle! Sweet Long arm, too!

[OneArmArrowSlinger]

So here's where I am after the weekend.

Put axle assembly back into Jeep! Also drilled out my front rotors so that my lug pattern would be correct after the WJ knuckle swap. I just clocked the new rotor on the old and tack welded, tossed on drill press, cleaned off tack weld and done. Went to start installing brake components and had some missing hardware from the parts store, called them & my brother will be picking up for me today when he gets off work. Threw a couple bolts through the RuffStuff heims and man they look awesome! Can't wait to get this ol girl back out there.

[OneArmArrowSlinger]

Moar!

[abebehrmann]

Yes, you're correct. I had a bit of a mishap while transporting w/ the forklift to be prepped for paint. All I feel like commenting on about it, rofl.

HAHAHAHAHAHA! I bet there were quite a few choice words said when that happened! Jeep's looking great!

[OneArmArrowSlinger]

HAHAHAHAHAHA! I bet there were quite a few choice words said when that happened! Jeep's looking great!

As many as my religion allows and a few I had to ask forgiveness for, lol!

[autotech98]

That looks awesome man! love the bumpstops.

[OneArmArrowSlinger]

Good news, weather has warmed and I've had a chance to get the WJ knuckle conversion done & 1 ton steering on!!! Bad news, my solid brake lines up front are rotten and I can't bleed brakes because 1 side has pinhole & the other broke off completely. Here are the latest pics tho.

Calipers and hub assembled.

http://i62.photobucket.com/albums/h106/jruzich43/IMG_5298.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5299.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5300.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5301.jpg

Wheels on & mocking up linkages for steering.

http://i62.photobucket.com/albums/h106/jruzich43/IMG_5323.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5324.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5325.jpg

1.5"x.25" wall DOM & RuffStuff heims

http://i62.photobucket.com/albums/h106/jruzich43/IMG_5343.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5344.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5345.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5346.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5347.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5348.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5349.jpg

Test fit on XJ

http://i62.photobucket.com/albums/h106/jruzich43/IMG_5350.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5351.jpg

Made first track bar too short like the rookie I am on this part.

http://i62.photobucket.com/albums/h106/jruzich43/IMG_5353.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5354.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5355.jpg

All bolted in!!!

http://i62.photobucket.com/albums/h106/jruzich43/IMG_5404.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5405.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5406.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5408.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5411.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5410.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5412.jpg

Stinkin rotten brake line, way to hold me up...

http://i62.photobucket.com/albums/h106/jruzich43/IMG_5409.jpg

But this came for the front to brighten my day!

http://i62.photobucket.com/albums/h106/jruzich43/IMG_5361.jpg
http://i62.photobucket.com/albums/h106/jruzich43/IMG_5363.jpg

[4.3LXJ]

Jon, I like that second set of tie rods and drag links you made. Very solid. I have a similar high steer from Tereflex that looks the same except for brake size. Good job on the conversion. One thing I ran into is death wobble from a short drag link. Just saying. I cured that by extending the frame mount for the track bar over to about even with the outside of the spring and made everything parallel. Now no more bump steer or death wobble under any conditions. I hope you don't have to do that with all the work you put into it, but I had to so I thought I would offer that up as a helpful hint. :thumbsup:

[xj-jake]

Let me know what you think of that Spartan John. I'm looking for lockers for mine just haven't decided which way I wanna go. Brand wise that is.

[OneArmArrowSlinger]

Jon, I like that second set of tie rods and drag links you made. Very solid. I have a similar high steer from Tereflex that looks the same except for brake size. Good job on the conversion. One thing I ran into is death wobble from a short drag link. Just saying. I cured that by extending the frame mount for the track bar over to about even with the outside of the spring and made everything parallel. Now no more bump steer or death wobble under any conditions. I hope you don't have to do that with all the work you put into it, but I had to so I thought I would offer that up as a helpful hint. :thumbsup:

Very helpful, hopefully I don't need to move it but if I do now I know how to fix it. Much appreciated!


Let me know what you think of that Spartan John. I'm looking for lockers for mine just haven't decided which way I wanna go. Brand wise that is.

Will do. My cousin has wheeled w/ one in his XJ for a few years now so I went with it. Plus its assembled in the US and the price reasonable.

[xj-jake]

I think they have a $30 rebate out on them now too if you didn't know Jonathon.

[OneArmArrowSlinger]

I didn't. Bought it from a store on ebay, wonder if I could still get it. It's new.

[xj-jake]

I didn't. Bought it from a store on ebay, wonder if I could still get it. It's new.

As long as they're an authorized dealer I believe you should qualify..

http://www.yukongear.com/springrebateprogram

[OneArmArrowSlinger]

Gonna give it a shot, might as well right?!

[xj-jake]

Gonna give it a shot, might as well right?!

Can't hurt anything. You see the 44 I got going into mine? My Holy Grail XJ 44 lol.

[OneArmArrowSlinger]

I did. It's a good thing you were able to get those spiders out. Gonna be a sweet rear end man. You gonna convert to discs?

[xj-jake]

I did. It's a good thing you were able to get those spiders out. Gonna be a sweet rear end man. You gonna convert to discs?

Right now no. I'm sticking a ton into this axle as it is the wife would hang me. I'm almost at $500 already and I haven't decided on a locker yet. I know that's still cheap but explain that to a woman...

[OneArmArrowSlinger]

LOL, I know the feeling exactly. I need rear leafs & shocks but my wife isn't so sure I need them this season. :bang:

[OneArmArrowSlinger]

So the WJ knuckle conversion & OTK steering is done and it wheels great! Going again tomorrow on the annual TRJC Safari. Should be over 100 rigs in town this weekend.
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/IMG_5442.jpg
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/IMG_5444.jpg
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/IMG_5445.jpg
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/IMG_5447.jpg
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/IMG_5448.jpg
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/IMG_5450.jpg
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/IMG_5457.jpg
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/IMG_5520.jpg
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/IMG_5531.jpg
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/IMG_5585.jpg
http://i62.photobucket.com/albums/h106/jruzich43/Jeep/IMG_5620.jpg

[NW99XJ]

Glad to see the WJ knuckle swap went well... I'd love to hear about how it went... and what you learned along the way... and of course...what you would do differently if you were to do it all over again.

[4.3LXJ]

That is something I have been studying too, so I am interested in hearing how that went to. And don't forget to take lots of pics of your trip. We expect a full report of course

[OneArmArrowSlinger]

Overall, the project was fairly straightforward and not too hard IMO. Although I took forever to get it done, it wasn't due to the project's complexity but rather winter, me getting parts together or lack of help (if you have two hands you probably won't require help as I did, won't be easy but I'm confident you can do it).

What I would do different:
1) Make sure I got the correct caliper bracket bolts. Since it is a different knuckle, it takes a different bolt than the stock XJ caliper bracket bolt. The bolt you'll need is a M12 x 1.25 x 40mm grade 10.9 bolt. I ordered the wrong ones accidentally from McMaster Carr and now have $20 worth of bolts I won't use. So I drilled out the caliper brackets and tapped it to accept a 1/2" coarse thread, grade 8.
2) Using the same hubs. Mine have some use on them, I'd probably put new ones in and put old ones in the my trail parts kit.

What I would do the same:
1) Buy junkyard or salvage knuckles. Most economical.
2) Buy all new hardware like brake calipers, pads, brackets, ball joints etc. JY stuff not cheap enough to not know how good of condition its in.
3) Take the knuckles and pitman arm to be drilled out. Those big bits are expensive and a local guy did it for cheap.
4) Drill new lug pattern in rotors. If you have a welder & drill press it's not difficult to do.
5) Heim joint everything on my steering. IMHO, only way to go.

I basically followed the thread I've pasted below. Had I had all my ducks in a row and materials in hand, I could have finished the project in 2 weekends, tops. If you are confident in your welds and can put all new brake components on, you can do this swap.

http://www.frontrange4x4.com/forums/showthread.php?7906-Ridgerunner-s-WJ-knuckle-swap-build

[bluedragon436]

Glad the WJ knuckle swapped out and all worked well.. Looks like a good time was had... and that's always good to see!!

[autotech98]

That thing is a beast! I was wondering if the wj knucks would work on an xj. Seems more sensible to swap knucks than just modify them to accept the wj brakes. Deff gonna check that thread out.

Sent from my SAMSUNG-SGH-I547