Project DOFOR 94 Jeep XJ [Archive] - xjtalk

JRW7072009

04-10-2014, 01:47 AM

Well I am not a vendor on here anymore but I figured I would still share my build with you all and post up as a normal member.

This is my project DOFOR, I chose the name because until I have the time & money to build my YJ how I want it, I am building the XJ up so I can have a decent rig to wheel. So I named it project "DoFor" I need something that will do for now.

Here is what I am starting with, a 94 Jeep XJ with 122k, 32" BFG ATs, 2" BB lift.
http://i588.photobucket.com/albums/ss323/jrw7072009/Sleeping%20princess%202014%20Feb/DSC_0130_zps6f1dca9c.jpg (http://s588.photobucket.com/user/jrw7072009/media/Sleeping%20princess%202014%20Feb/DSC_0130_zps6f1dca9c.jpg.html)

Here are the plans and everything I have already ordered....
Ruff Stuff 8.8 simple swap kit
Ruff stuff 3/4 heim steering
Ruff Stuff Uniframe stiffeners
Ruff Stuff 1" thick bumper clevis

I have also ordered a pieced together 4.5" Rubicon Express Long Arm kit with full leaf packs, shackles, quick discos, shocks, track bar and 4.5" coils.
5 35/12.50/15 BFG KM2 & flat black 15x8" Pro Comp Steel wheels
Rugged Ridge SYE
Rigid Industries Dually Series Flood LED Lights

I will be headed out to get a 8.8 rear end and I will be installing a Adams Driveshaft CV DL to finish it all off.

Then I have this steering box brace and frame support kit waiting to go on from my friend at Filthy Addictions Off Road and after the LA kit goes on he will be building a set of sliders.
http://i588.photobucket.com/albums/ss323/jrw7072009/jrw7072009001/IMG_0278_zps0d2537ed.jpg (http://s588.photobucket.com/user/jrw7072009/media/jrw7072009001/IMG_0278_zps0d2537ed.jpg.html)

For the front and rear bumpers I will be using my new bender to build some custom tube bumpers.

JRW7072009

04-10-2014, 01:50 AM

I started this build a couple weeks ago, here is when the parts started rolling in!
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/10155006_10152399764890625_1092180565_n_zpsb1fe79b 8.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/10155006_10152399764890625_1092180565_n_zpsb1fe79b 8.jpg.html)

http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/1926696_10152400467200625_1600297442_n_zps7a337811 .jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/1926696_10152400467200625_1600297442_n_zps7a337811 .jpg.html)

Small upgrade! From a 2" spacer to a 4.5" RE long arm kit!
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed1_zpscbca4ab8.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed1_zpscbca4ab8.jpg.html)

It begins!
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed_zps8ca2056b.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed_zps8ca2056b.jpg.html)

http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed6_zps055a88c5.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed6_zps055a88c5.jpg.html)

JRW7072009

04-10-2014, 01:51 AM

Can't forget these!
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed2_zps5a9f48e9.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed2_zps5a9f48e9.jpg.html)

JRW7072009

04-10-2014, 01:53 AM

Getting more progress done.
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed5_zps09ecb031.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed5_zps09ecb031.jpg.html)

Front kit is on except the steering and the track bar. RE sent the wrong spacers for the Heim joint!

This is pretty much ride height... I was hoping for it to be a little lower.
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed4_zps67f0b6e1.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed4_zps67f0b6e1.jpg.html)

Then I got a visit from UPS and FedEx!!
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed3_zps51554a59.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed3_zps51554a59.jpg.html)

JRW7072009

04-10-2014, 01:54 AM

This is the 8.8 I picked up. Here in Bullhead and surrounding areas there really are not many junk yards. This was the only disc brake rear end I found from a Explorer. Its from a 96 it has limited slip and 3.73 gears....

Ideal would have been 4:10s and open but its okay it will work fine.
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed9_zps17514cf2.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed9_zps17514cf2.jpg.html)

JRW7072009

04-10-2014, 01:55 AM

Next I was able to get the steering kit installed. I have to hand it to FilthyAddicitionsOffRoad.com for the design work of this kit. It fit perfect and easy to install.

http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed11_zps50660024.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed11_zps50660024.jpg.html)

http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed8_zps36fddc49.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed8_zps36fddc49.jpg.html)

http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed10_zps70cef400.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed10_zps70cef400.jpg.html)

This kit comes with a brace for the frame and the steering box its self. It all goes together nicely.

JRW7072009

04-10-2014, 01:58 AM

Next I got the axle under the Jeep. I did not get to work on it a whole lot this day but I managed to finish up the front and install the springs on the rear. At this point I was still waiting for the Ruff Stuff 8.8 easy install kit to arrive so I used some parts I had laying around my garage to mock it up.
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed16_zpsb23d2cb8.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed16_zpsb23d2cb8.jpg.html)

Lots in under coating to grind away for the stiffeners.....
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed15_zps1a5b8c55.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed15_zps1a5b8c55.jpg.html)

JRW7072009

04-10-2014, 02:00 AM

Got the 8.8 all welded up and installed under the Jeep. I have to say I love the whole kit from Ruff Stuff, its super beefy and everything went on very easy.

http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/5dcb0db5-350c-411c-bd18-454b9e0d64e3_zps8f11ddc9.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/5dcb0db5-350c-411c-bd18-454b9e0d64e3_zps8f11ddc9.jpg.html)

http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed18_zps39b38237.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed18_zps39b38237.jpg.html)

I welded up the center section like everyone says to do.
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed20_zpsdd2d6caa.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed20_zpsdd2d6caa.jpg.html)

Its back on its own feet!
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed21_zps9219adcb.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed21_zps9219adcb.jpg.html)

At this point I still had the rear brake lines, stiffeners, SYE, drive line and to finish up the steering drag link. The shocks, and the whole kit are on and next I am thinking of doing 4:56 gears and Aussies front and rear....

This was a lot of work to do on my back in the garage. What I would do for a vehicle lift...

JRW7072009

04-10-2014, 02:01 AM

A pic of the SYE and the new radiator.
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed22_zps00cff1ae.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed22_zps00cff1ae.jpg.html)

http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed23_zps783c54ee.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed23_zps783c54ee.jpg.html)

JRW7072009

04-10-2014, 02:04 AM

Next I started working on the brake lines now and the drive line was ordered as well as the rest of the Ruff Stuff order #2.

Some new turn signals.
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed24_zps701929dc.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed24_zps701929dc.jpg.html)

4:56s
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed25_zps9b35f2bf.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed25_zps9b35f2bf.jpg.html)

The start to a front bumper, I have never bent tube before.
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed26_zps35acbb56.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed26_zps35acbb56.jpg.html)

And to help with the gear install...
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed27_zps2dc20dc5.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed27_zps2dc20dc5.jpg.html)

JRW7072009

04-10-2014, 02:05 AM

After a few days off I was able to get back at it, here I have the steering all done.
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed28_zpse429d072.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed28_zpse429d072.jpg.html)

http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed29_zps7b6b56d5.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed29_zps7b6b56d5.jpg.html)

Next was the new drive shaft from Adams Driveshaft in Las Vegas NV. This is a super nice drive line and it was built new and shipped for $280
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed32_zpsca5849a9.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed32_zpsca5849a9.jpg.html)

http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed33_zpsa525ad34.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed33_zpsa525ad34.jpg.html)

JRW7072009

04-10-2014, 02:07 AM

My buddy Andrew dropped off a very nice set of FilthyAddictionsOffroad.com sliders he just built! I have seen them in action on his XJ but to see these in person up close is impressive. They are super strong and built nice. Like their steering kit they have really thought these out.
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed31_zps7b6b56d5.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed31_zps7b6b56d5.jpg.html)

http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed35_zpsa7e59e6c.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed35_zpsa7e59e6c.jpg.html)

http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed34_zps71c78a12.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed34_zps71c78a12.jpg.html)

JRW7072009

04-10-2014, 02:08 AM

This was testerday.
ITS ALIVE!!!!

http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed37_zps29e2e7de.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed37_zps29e2e7de.jpg.html)

http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed38_zpsc6b9f535.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed38_zpsc6b9f535.jpg.html)

I still have the gears, stiffeners, and bumpers to do but its drive-able.

JRW7072009

04-10-2014, 02:09 AM

This is as far as I am right now, today I got an early start on the Jeep and pretty much worked on it none stop all day only to stop and eat....
I started messing around with the front bumper and decided why not, so I started cutting, grinding, bending and welding. Here is what I started with.
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed45_zps85e2e6b1.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed45_zps85e2e6b1.jpg.html)

Its kinda hard to see it and I will get some better shots up as soon as I can but here it is all done.
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/57ad854e-0bd0-4d4b-bb86-34c1ee6a31ad_zps178855da.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/57ad854e-0bd0-4d4b-bb86-34c1ee6a31ad_zps178855da.jpg.html)

JRW7072009

04-10-2014, 02:10 AM

Then while the paint was drying I started tearing into the front end to install the new aluminum radiator.
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed39_zpse2aa5db2.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed39_zpse2aa5db2.jpg.html)

http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed40_zps20427a3c.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed40_zps20427a3c.jpg.html)

Figured while I was at it I would install a bigger trans cooler. :cool:
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed41_zps492f186a.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed41_zps492f186a.jpg.html)

http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed43_zps0f821be1.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed43_zps0f821be1.jpg.html)

This is the same picture as above but its with everything installed and put back together!
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed44_zpsd3f36f82.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed44_zpsd3f36f82.jpg.html)

JRW7072009

04-10-2014, 02:12 AM

I still have the sliders, gears, stiffeners, rear e-brake cables, and the rear bumper to do at this point.

Brasscatz

04-10-2014, 07:52 AM

A lot of very nice work man!!

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

4.3LXJ

04-10-2014, 10:58 AM

Nice work as usual Joey

Carves

04-10-2014, 07:02 PM

Quite a transformation .. :thumbsup:

Rocco83

04-10-2014, 07:31 PM

Damn good work. Your XJ in white looks badass enough to make me want to keep mine white.

Pookapotamus

04-10-2014, 08:39 PM

Very nice build, but I gotta ask, in some pics "Overrock" is up on the fenders, and in some it's just above the rockers across both doors, personally I like it on the doors, but what is with that?

And where did you get the new turn signals? Methinks they might look good on my build.

XJ Wheeler

04-10-2014, 09:14 PM

Man, gettin it done! And fast!

Nice work, turning into quite the beast.

Sent via messenger pigeon - i talk, he types.

JRW7072009

04-11-2014, 10:17 AM

Thank you everyone its been a lot of work in a short time but I am excited for it to get done.

Very nice build, but I gotta ask, in some pics "Overrock" is up on the fenders, and in some it's just above the rockers across both doors, personally I like it on the doors, but what is with that?

And where did you get the new turn signals? Methinks they might look good on my build.

Just before I started the build I put the big stickers across the bottom, however they where not straight the guy I got them from did not line up the line and the offroad.com to the Over Rock part. I didn't catch it until I was putting on the second sticker so I tried to fix it but it didn't work out.

So in the middle of the build I decided to peel it off... I plan to do some big ones across the bottom again when I have the money.

The lenes I bought through Transamerican Wholesale but you can get them through eBay and 4WD.com
CRO56000111C
http://www.4wd.com/Jeep-Lighting-Jeep-Lighting-Accessories/Side-Marker-Lens.aspx?t_c=14&t_s=67&t_pt=5033&t_pn=CRO56000111C
CRO56000110C
http://www.4wd.com/Jeep-Lighting-Jeep-Lighting-Accessories/Side-Marker-Lens.aspx?t_c=14&t_s=67&t_pt=5033&t_pn=CRO56000110C

NW99XJ

04-11-2014, 10:53 AM

JRW7072009

04-12-2014, 09:50 AM

http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed27_zps2dc20dc5.jpg
Ok, obviously this is part of some sort of gear install kit....
But can you give me the break down of what I'm looking at, where you got it from, and how much?
The thought of doing my own gears has always been appealing, I just haven't had (what I heard were) the necessary tools... these look like said tools.
I have the dial gauge and mount, and all that, but these look to be a critical part of what is needed to do a gear swap.
Thanks in Advance.
Nice build BTW.

As far as I know there are two types of bearing pullers and this is the one we used at 4 Wheel Parts usually called a Clamshell style, its very handy for pulling off the bearings from both the carrier and the pinion with a very low risk of damaging the bearing. The other one I have used a few times is a bearing splitter style.
Shown here, you need a press to use this one.
http://www.northerntool.com/shop/tools/product_200416268_200416268?cm_mmc=Google-pla-_-Metal%20Fabrication-_-Shop%20Presses-_-154940&ci_src=17588969&ci_sku=154940&gclid=CKbCh8eY270CFZZqfgodlGIA-g

The white yellow and black clam shells are what you put around the bearing, they taper and are different diameters on both sides for different types of bearing. The tall black thing of the left is what you use to run them off with the impact gun. The silver piece in the middle is usually used when you are pulling the carrier bearings off and is not needed when you pull the pinion bearings.

I'll snap some pics as I'm using it for ya! I purchased it from Transamerican Wholesale its a G2 brand and you can pick them up from 4wd.com or 4 Wheel Parts.

G/280-BRGPLLR
http://www.4wd.com/G2-Clamshell-Bearing-Puller.aspx?t_pn=G%2f280-BRGPLLR

JRW7072009

04-22-2014, 09:58 AM

Here are a few shots of it in action. I am pulling off the bearings from the carrier.
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed49_zpsc7bf63ac.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed49_zpsc7bf63ac.jpg.html)

Here is how it looks getting it set up. (It should have the bearing race on it to help protect it when its being pulled off I forgot it here)
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed50_zpsd8b2a8a9.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed50_zpsd8b2a8a9.jpg.html)

From there you just run the bolt down with an impact gun and it does all the work.
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed51_zps5b5e843f.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed51_zps5b5e843f.jpg.html)

http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed52_zpsa7932004.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed52_zpsa7932004.jpg.html)

JRW7072009

04-22-2014, 10:00 AM

Here are a few shots of the work.
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed53_zpsd69d6345.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed53_zpsd69d6345.jpg.html)

http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed54_zps86dd1609.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed54_zps86dd1609.jpg.html)

A new addition to the garage.
http://i588.photobucket.com/albums/ss323/jrw7072009/WhiteXJ94/unnamed55_zpsa6c95418.jpg (http://s588.photobucket.com/user/jrw7072009/media/WhiteXJ94/unnamed55_zpsa6c95418.jpg.html)

4.3LXJ

04-22-2014, 10:04 AM

Thanks Joey. I like the way that puller works. How much for that?

JRW7072009

04-22-2014, 10:14 AM

G2 offers one for about $412
http://www.4wheelparts.com/Drivetrain-Differentials/G2-Clamshell-Bearing-Puller.aspx?t_c=12&t_s=237&t_pt=10113&t_pn=g%2f280-brgpllr&utm_source=google&utm_medium=froogle&utm_campaign=product&emlprox=out&ppcfon=1&gclid=CPyM17ax9L0CFcRefgodQHgAKA

Yukon Gear offers two for $389 & $464
http://www.ringpinion.com/b2c/PartsList.aspx?SearchMode=Cat&CatID=59&MakeID=2&ModelID=254&Side=Front&DriveType=4WD&DiffID=136

You can pick one up on eBay for around the $250 range, and they look to be the same as the others...

They are pricey but if you are doing a lot of gears they are worth it. You can get a bearing splitter for quite a bit less for the DIY guys that may only be doing a couple gear jobs here and there.