Budget, what budget?....build.

[Firemanray]

Just joined recently so I decided to bring my build thread with me. I bought this very clean '98 early this year with a lot of the mods I wanted already on it. The price was awesome so I pounced.

Here is what it looked like when I bought it:
http://i223.photobucket.com/albums/dd11/firemanray21/0531101039.jpg

This is a project for me and my 13 yo son to work on together. He has since laid claim to it for his own.

The first thing I did was put a new Tom Woods front shaft in ( the slip yoke on the old one was shot ). Then some new u-joints in the front axle. Then a test drive:
http://i223.photobucket.com/albums/dd11/firemanray21/0703101042.jpg

The next item was the 10,000# Warn winch I traded for. It was suppose to bolt right into the ARB bumper. Well it was an older model I guess, after much tape measure work it was determined that it would NOT in fact fit inside the bumper. Let the fun begin.

This is the "before" picture of the bumper:
http://i223.photobucket.com/albums/dd11/firemanray21/beforebumper.jpg

Next I made room for the winch on top of the bumper and built a mounting flange for it:
http://i223.photobucket.com/albums/dd11/firemanray21/newmount.jpg

Now the winch is mounted and the fairlead was attached after building brackets for it:
http://i223.photobucket.com/albums/dd11/firemanray21/Jeep010.jpg

I think I like the winch up high so it will stay out of the mud and water. The only drawback is at 70 mph + the engine starts getting a little hot due to the restricted airflow through the radiator. (Wasn't a problem before the winch was mounted). I can live with it since I don't drive that fast much anyway.

Stay tuned, next is the wheel swap, fender and bumper trim.

[Firemanray]

Well a couple of weeks into this new project I found one of the wheels cracked. I wanted something that stuck out more anyway soooo.... now I have an excuse to buy these:
http://i223.photobucket.com/albums/dd11/firemanray21/newwheel.jpg

I loved the look after the install but turning sharp was impossible, time to man up, break out the plasma cutter and make some big fender openings.
Off with the flares, cut the front along the body line then cut and fold the rear. Now we have this beast:
http://i223.photobucket.com/albums/dd11/firemanray21/DSC01047.jpg

Heres a couple of shots of the bumper trim:
http://i223.photobucket.com/albums/dd11/firemanray21/Jeep011.jpg

http://i223.photobucket.com/albums/dd11/firemanray21/Jeep013.jpg

http://i223.photobucket.com/albums/dd11/firemanray21/Jeep015.jpg

Then my son went out in the yard to flex it a little:

http://i223.photobucket.com/albums/dd11/firemanray21/DSC01051.jpg

Coming up next I start building sliders.

[bigjim350]

Very nice looking Jeep. Can't wait to see it in person. Maybe we could build some sliders for mine while we are at it. Do you still have the old wheels?

[Firemanray]

Yes I have the wheels, The cracked one still worked fine, I just liked having an excuse to put the wide ones on.

I've got a full compliment of metal working equipment and love to fabricate. Also have lot's of down time during the winter. It would only take a day to fab up some nice sliders. I'll get the pics posted soon.

[Mudderoy]

Thanks for joining and especially for posting up all the fun stuff. :camera: :popcorn:

[bluedragon436]

Welcome to xjtalk... Aweswome looking rig... Wish I could have found a rig that was already started for a good price.. What is the backspacing on those Cragar rims that you installed??

[Firemanray]

Thanks for joining and especially for posting up all the fun stuff. :camera: :popcorn:

Your welcome, I like pictures better than a bunch of typing :D


Welcome to xjtalk... Aweswome looking rig... Wish I could have found a rig that was already started for a good price.. What is the backspacing on those Cragar rims that you installed??

Thanks, the back spacing is 4", it moved the tires out at least 3" from where they were.

Dover Del., I have a friend that was stationed there. He moved back here about a year ago. C-5 pilot, now he's back flying for Cont... oh well, United, whatever.

[nismo5]

nice lookin jeep real clean and great that your kid likes to work on it with ya good times

[Firemanray]

Thanks nismo.


Well now for the sliders. They are nearly finished but I been busy with other things so they have to wait.

Here is a series of pictures from lay out to mock up:
http://i223.photobucket.com/albums/dd11/firemanray21/Slider001.jpg

http://i223.photobucket.com/albums/dd11/firemanray21/Slider002.jpg

http://i223.photobucket.com/albums/dd11/firemanray21/Slider003.jpg

http://i223.photobucket.com/albums/dd11/firemanray21/Slider004.jpg

http://i223.photobucket.com/albums/dd11/firemanray21/Slider006.jpg

http://i223.photobucket.com/albums/dd11/firemanray21/Slider005.jpg

Maybe I'll get them mounted some time soon.

[cantab27]

nice looking jeep ,, like the arb front bar ,have one on my pos ... welcome to xjtalk as well mate

[bluedragon436]

Yeah I like the ARB setups... I just wish they weren't so expensive to purchase...

[Mudderoy]

Yeah I like the ARB setups... I just wish they weren't so expensive to purchase...

ARB was my first choice, but I'm really glad I went with something custom.

[4.3LXJ]

Love the fab stuff. Keep it up. It is the truly cheap way to go.

[drew91xj]

jeep looks clean.... dont wory the cuting and fab has just began lol

[XJ4IV]

Ray, Ive yet to meet you but Im looking forward to hanging out with you and putting our metal working skills and ingenuity together and making some cool stuff... I wish I could score a deal on a nice bender and a tube notcher so I can get this freaking EXO underway
I already have enough pipe to do the lower sides from bumper to bumper I just need the roof coverage as well as the up rights ... let me know if youve got a bender Ill come with pipe and BREW of your choice!!! or cash if you prefer

[Firemanray]

jeep looks clean.... dont wory the cuting and fab has just began lol
The clean look is over, after some hard wheeling without proper bump stops I've got 4 bend fenders. Also tweaked the whole back cab section dropping off of a creek bank to hard.


Ray, Ive yet to meet you but Im looking forward to hanging out with you and putting our metal working skills and ingenuity together and making some cool stuff... I wish I could score a deal on a nice bender and a tube notcher so I can get this freaking EXO underway
I already have enough pipe to do the lower sides from bumper to bumper I just need the roof coverage as well as the up rights ... let me know if youve got a bender Ill come with pipe and BREW of your choice!!! or cash if you prefer
I love to fab stuff, just don't have enough hours in the day to build some of my ideas. I would like a good pipe bender myself. I hope to build a full cage in mine someday ( that time thing again ).

[BrianXJ]

Very nice looking XJ. Nice pics

[PolarXJ]

nice looking jeep. keep up with the fab. :)

[Firemanray]

Well I finally finished my sliders and mounted them. It's been almost 6 months since I first started fab'n them. Here's how it ended up.

I decided the sliders needed to be extended out further than the original design so I built a "spacer" bar that would be welded to the back of each slider before it was mounted:
http://i223.photobucket.com/albums/dd11/firemanray21/DSC010822.jpg
I welded elevator bolts to the spacer bar, these would be attached to the flange at the bottom of the rockers.

Next I welded the spacer to the rockers:
http://i223.photobucket.com/albums/dd11/firemanray21/DSC010892.jpg
Now the rocker is ready to install.

Coming up next, frame rail sliders.


.

[Firemanray]

With the sliders finished it was time to make a tough mount to support them. I had this large structural steel 3/16" thick angle laying around:
http://i223.photobucket.com/albums/dd11/firemanray21/DSC010902.jpg

My "frame" rails have taken a beating and as you all know they are not the toughest thing to be sliding over rocks, logs, stumps, hummers etc. I decided to use this angle on my frame rails and make sliders for them as well as the rockers. This gave me a very tough platform to attach my sliders to.

I decided to just thru bolt the angle to the existing frame rail in order to allow removal for further modifications later on.
http://i223.photobucket.com/albums/dd11/firemanray21/DSC010882.jpg
I studied the frame and found some points were thicker than others due to the number of metal layers used to make the frame. I tried to utilize these points for the attachment.

Finally I bolted the sliders to the rocker flange and welded bracing between the frame sliders and the rockr sliders. This thing is tough now, and I have a heavy duty mounting surface for more under armour.
http://i223.photobucket.com/albums/dd11/firemanray21/DSC010872.jpg
http://i223.photobucket.com/albums/dd11/firemanray21/DSC010862.jpg

My mig started acting up as I neared completion, the tip is about wore out and I didn't have a replacement. I did manage to get it welded. What fun laying underneath trying to lay a bead.


.

[Firemanray]

No pictures here but the catylatic converter was rattling so bad you couldn't hear yourself think. I cut it out and gutted it then welded it back in, sounds great now!!

[modestmar00xj]

yeah good work guys! i like the sliders! welcome to xjtalk!

[Firemanray]

Oh I forgot to add pictures of the finished product (needs paint):
http://i223.photobucket.com/albums/dd11/firemanray21/DSC010812.jpg

[XJ4IV]

might later wanna flip em over so the sliding portion is higher like JUST below the door opening... for clearance reasons but I really like the design overall

[Firemanray]

I've been wanting to mount a switch inside the cab to run the winch. The group of guys I wheel with are great, I hardly ever have to get out in the mud and hook the winch when I'm stuck. It would be much easier to just run the winch from a permantly mounted switch.

I don't have pictures of this mod but I'll give some details.
The easiest part of the switch add is wiring at the winch itself. Using a 2 conductor 12 guage wire I attached one wire to solenoid pack where the existing "up" control wire is attached. Then I did the same for the "down" control wire. I then routed the wiring thru the engine compartment and fire wall, under the dash, and down the inside of the console.

I did not want the winch to be powered up except when needed. My rear defroster has never worked, however, the control switch and timer still work. I tied into the output from the defroster switch and ran the "hot" wire under the console along with the control wires.

I then installed a momentary 3 position toggle switch in the console along the edge of the e-brake slot just under the arm rest (I will post a picture of this later). I hooked the wiring to the switch so that when the switch is pulled up the winch spools in and down spools out. This switch location allows me to have fingertip control over the winch with my arm resting on the console (lazzzzyyy).

The cool thing about this set up is you power up the interior switch using the rear window defrost switch and the automatic timer will shut it off a little while later so you don't forget to "power down". Also the exterior switch still operates as normal.

Disclaimer: DO NOT!!! Try to use both interior and exterior switches simultaneously. There is no means to prevent the winch from trying to run both directions at the same time. You WILL let the magic smoke out, and it cannot be put back in!



.

[bigjim350]

No pictures here but the catylatic converter was rattling so bad you couldn't hear yourself think. I cut it out and gutted it then welded it back in, sounds great now!!

If this sets off your Check Engine Soon light, I know of a little trick to fix it. Just did it on my Dads ZJ and it worked great. But being a legal no no, I won't post it up here.

[Firemanray]

If this sets off your Check Engine Soon light, I know of a little trick to fix it. Just did it on my Dads ZJ and it worked great. But being a legal no no, I won't post it up here.

Anything at all to do with spark plug accessories?

[bigjim350]

Yep worked great :D

[Firemanray]

I've been wanting to mount a switch inside the cab to run the winch. The group of guys I wheel with are great, I hardly ever have to get out in the mud and hook the winch when I'm stuck. It would be much easier to just run the winch from a permantly mounted switch.

I don't have pictures of this mod but I'll give some details.
The easiest part of the switch add is wiring at the winch itself. Using a 2 conductor 12 guage wire I attached one wire to solenoid pack where the existing "up" control wire is attached. Then I did the same for the "down" control wire. I then routed the wiring thru the engine compartment and fire wall, under the dash, and down the inside of the console.

I did not want the winch to be powered up except when needed. My rear defroster has never worked, however, the control switch and timer still work. I tied into the output from the defroster switch and ran the "hot" wire under the console along with the control wires.

I then installed a momentary 3 position toggle switch in the console along the edge of the e-brake slot just under the arm rest (I will post a picture of this later). I hooked the wiring to the switch so that when the switch is pulled up the winch spools in and down spools out. This switch location allows me to have fingertip control over the winch with my arm resting on the console (lazzzzyyy).

The cool thing about this set up is you power up the interior switch using the rear window defrost switch and the automatic timer will shut it off a little while later so you don't forget to "power down". Also the exterior switch still operates as normal.

Disclaimer: DO NOT!!! Try to use both interior and exterior switches simultaneously. There is no means to prevent the winch from trying to run both directions at the same time. You WILL let the magic smoke out, and it cannot be put back in!



.


Well I thought I would just come back and edit this but I guess I'm to late.

Here are pictures of the switch. The reason the lable is upside down is so the operator can read it sitting in the driver seat.
http://i223.photobucket.com/albums/dd11/firemanray21/0126111452.jpg
http://i223.photobucket.com/albums/dd11/firemanray21/0126111452a.jpg

[bigjim350]

Well that should come in handy quite a bit. I know I've been hooked to the buisness end of that winch before.

[j&d Greens]

I like your son's future Jeep Ha, Ha. The more you do to it the more it will be harder to let go of. Can't wait to see what you do next. :popcorn:

[Firemanray]

Ok so it's been a while, time for an update.
I bought a set of swampers off of Rene (with wheels) and installed them:
http://i223.photobucket.com/albums/dd11/firemanray21/0421111929.jpg
(Had the doors off at the time) My son really liked the look of the wheels, I didn't, so I put them on my other wheels:
http://i223.photobucket.com/albums/dd11/firemanray21/IMG_3596-1.jpg
And as a compromise I put the doors back on since he didn't like the "no door" look.

I replaced the steering damper and 1 tie rod end then did a "tape measure" alignment.


.

[Firemanray]

Next thing was to build a place to carry the spare tire without caving in the roof. So we built the long awaited roof rack:
http://i223.photobucket.com/albums/dd11/firemanray21/IMG_3594-1.jpg

We designed the rack to have an integrated light bar and an area in the back for tool boxes or coolers:
http://i223.photobucket.com/albums/dd11/firemanray21/rack.jpg

Here are some other shots of the rack:
http://i223.photobucket.com/albums/dd11/firemanray21/IMG_3595-1.jpg
http://i223.photobucket.com/albums/dd11/firemanray21/IMG_3597-1.jpg

We both really liked the outcome of this project. We have more plans when we add lights so I'll wait 'till then to show 'em.

[4x4Dalton]

Sweet lookin rack Ray. Hey when ya can bro send me the dimensions of that I really like the looks of that :thumbsup:

[cantab27]

nice work ray....um ya might have trouble fitting ya spare......like the colour of the house in the background..............

[Firemanray]

nice work ray....um ya might have trouble fitting ya spare......like the colour of the house in the background..............

I need to put a wheel in it alright. The house has GREEN and RED on it!! Had to get the RED in there somehow!

[steph74]

Very nice work.

I really like the sliders and the roof rack....
When you find the time, I would love to know how you attached it to the gutter ? It is not clear to me from the pictures....

[Firemanray]

Sweet lookin rack Ray. Hey when ya can bro send me the dimensions of that I really like the looks of that :thumbsup:

I'll get it drawn up and post it for you.

[Firemanray]

Very nice work.

I really like the sliders and the roof rack....
When you find the time, I would love to know how you attached it to the gutter ? It is not clear to me from the pictures....


I used a small turnbuckle with a hook on each end. I drilled a hole in the rack and one in the gutter directly below it. Insert turnbuckle and tighten with wrench. Done!

[bigjim350]

The xj is looking good Ray. When ever you get sick of those 10" soft 8's I will swap ya my 8" soft 8's.

[XJ4IV]

Next thing was to build a place to carry the spare tire without caving in the roof. So we built the long awaited roof rack:
http://i223.photobucket.com/albums/dd11/firemanray21/IMG_3594-1.jpg

We designed the rack to have an integrated light bar and an area in the back for tool boxes or coolers:
http://i223.photobucket.com/albums/dd11/firemanray21/rack.jpg

Here are some other shots of the rack:
http://i223.photobucket.com/albums/dd11/firemanray21/IMG_3595-1.jpg
http://i223.photobucket.com/albums/dd11/firemanray21/IMG_3597-1.jpg

We both really liked the outcome of this project. We have more plans when we add lights so I'll wait 'till then to show 'em.

well I guess I found my other swamper that I gave to rene... :hmmmm2:

[4.3LXJ]

Next thing was to build a place to carry the spare tire without caving in the roof. So we built the long awaited roof rack:
http://i223.photobucket.com/albums/dd11/firemanray21/IMG_3594-1.jpg

We designed the rack to have an integrated light bar and an area in the back for tool boxes or coolers:
http://i223.photobucket.com/albums/dd11/firemanray21/rack.jpg

Here are some other shots of the rack:
http://i223.photobucket.com/albums/dd11/firemanray21/IMG_3595-1.jpg
http://i223.photobucket.com/albums/dd11/firemanray21/IMG_3597-1.jpg

We both really liked the outcome of this project. We have more plans when we add lights so I'll wait 'till then to show 'em.

That tire must be aired down for wheeling :rolleye0012:

[Firemanray]

Well it's been a long hot BUSY summer. I haven't done much to my Beast but here is a taste of this weekends project:
http://i223.photobucket.com/albums/dd11/firemanray21/Radiator.jpg

I will try to do some kind of write up as I install this stack of goodies!!

[cantab27]

that would be good ray,,, am fitting a cooler when i swap over trans, plus taking all cooling gear out and replacing all i have too.... has boiled last couple of runs ,,,well not the last run ..but summer it boiled good twice..

[4.3LXJ]

Should I just say, keep her cool ray?

[eking81]

nice build i like the sliders they look like over kill lol
the rack is also nice i like how you added mess to hold the boxes and whatever

[Firemanray]

I haven't updated this in a while but today I started replacing the AAL stock springs with a set of Rusty's I bought a year ago. Since I have a total of 4" of lift using 1" shackles and 3" AAL I decided to just use a 3" Rusty's spring. I am also adding a 6* shim to the spring pack to help with pinion angle:
http://i223.photobucket.com/albums/dd11/firemanray21/004-1.jpg

While in the process of doing this upgrade I discovered some other issues. First the rear shock stroke is to short for the lift. I have been wanting to re-locate the shock mounts to the axle to give me more ground clearance under the axle. No time like the present. I cut the shock mounts off of the axle and cut a matching radius in them so I can weld them back to the axle tube eliminating the low hung stump hangers:
http://i223.photobucket.com/albums/dd11/firemanray21/005-1.jpg

As I test fit the springs I discovered they are shorter length than the stock ones and not only is my axle going to move forward almost an inch, my shackle will be almost vertical. So now I am going to build some shackle re-location boxes while I'm doing the rest of the stuff.

[Mudderoy]

Why would the springs be shorter? It doesn't sound right to me.

[Firemanray]

Why would the springs be shorter? It doesn't sound right to me.

They should measure shorter eye-to-eye, un-installed because the arch is much greater than the stock spring. My concern is from the front eye to the tie bolt is almost 1" shorter on the new spring. Problem is I've had these over a year and I own them. I'll make them work. Since I haven't done a SYE yet moving the axle forward a little will insure I don't pull the shaft out of the tranny in an extreme droop situation. Thinking about it they may engineered that way just for that reason. We'll see how it turns out in the end.

[Firemanray]

I got the rear springs in without the re-location boxes. Once they flatten out they fit fine. The PO had used a combo of AAL and extended shackles to do the 4.5" lift. He told me it was a 3" AAL and a 1.5" shackle. As it turns out it was the opposite so now I have 6.5" lift in the rear. I need this thing to be ready for a wheel'n trip in a couple of weeks soooooo.... I built these for the front:
http://i223.photobucket.com/albums/dd11/firemanray21/Jeep004.jpg
NOW the whole thing is up to 6.5" lift. Definately wasn't in the plans!!
http://i223.photobucket.com/albums/dd11/firemanray21/65lift.jpg
I didn't like the look of it so I added a 1" block to the back. ( No pics yet.) The stance looks much better and no the 1" block WILL NOT have any adverse effect on the suspension.

[Firemanray]

Since I went up another couple of inches I decided to put the front sway bar back on. That required me to build these quick disco's:
http://i223.photobucket.com/albums/dd11/firemanray21/Jeep001.jpg
I used quick clip pins on both ends with anti-vib springs:
http://i223.photobucket.com/albums/dd11/firemanray21/Jeep003.jpg
http://i223.photobucket.com/albums/dd11/firemanray21/Jeep005.jpg
Tomorrow my new shocks get here and I can try this beast out!

[cantab27]

coolies ray ...gonna go bigger in the shoe department,,,(tires)

[Firemanray]

coolies ray ...gonna go bigger in the shoe department,,,(tires)

I've got the 12.5 x 33" Super Swampers for off road, they're to rough for highway use. I'm thinking maybe selling all my tires and getting some 35" radial swampers.

[msmoorenburg]

I've got the 12.5 x 33" Super Swampers for off road, they're to rough for highway use. I'm thinking maybe selling all my tires and getting some 35" radial swampers.

Let me know I maybe in the market for some "Highway Tires" It would be nice to hear the radio again

[bluedragon436]

You don't like the gentle hum of some nice tires, Matt?? LOL..

[msmoorenburg]

You don't like the gentle hum of some nice tires, Matt?? LOL..

oh i love it just not 38 miles 1 way to work at 75mph :rolleye0012:

[4.3LXJ]

I am ready for some quieter tires too, and mine certainly are not Swampers or Boggers.

[4.3LXJ]

Let me know I maybe in the market for some "Highway Tires" It would be nice to hear the radio again

The answer to that is an amp and larger speakers:rolleye0012:

[Firemanray]

I finished the lift upgrade and put the swampers back on. It rides great, I can actually drive it at highway speed with the swampers now. I took some poser shots of my new found flex:
http://i223.photobucket.com/albums/dd11/firemanray21/poser3.jpg
http://i223.photobucket.com/albums/dd11/firemanray21/poser4.jpg

[cantab27]

nice job ray, its looking good...

[bigjim350]

Yep now its time to put that newly found flex to use.

[Firemanray]

Well folks I haven't been around here for a while due to "life". Now it's less than 1 month until my son turns 16. I've put the Xj into hiding to do my own version of "pimp my ride" for my son. After wheeling the poor thing to death for the last 3 years it has come time to build a "mall crawler" (or high school parking lot crawler, you choose). Currently it sits in the shop completely stripped, no interior, no glass (except w/s) waiting for a color change and interior upgrade. I will try to post pictures as I go along. He's gonna be one lucky kid when he gets this thing back!! Stay tuned.

[4.3LXJ]

Welcome back Ray

[bigjim350]

Can I pick the color :D

Sent from my nerdy smartphone

[bluedragon436]

He will certainly be a lucky kid... Look forward to seeing how this rebuild goes, and pics of his reaction when he sees what he got!!

[Carves]

:popcorn:

[cantab27]

howdy ray ..welcome to xjtalk..yell out if ya need a hand with color choice

[Firemanray]

Can I pick the color :D

Sent from my nerdy smartphone

As long as it's tahiti pearl black with blue pearl mixed in it to give it a blue sparkle, YEP! (his pick, already ordered). :D

[4x4Dalton]

Welcome back Ray. Can't wait to see the XJ transformation


Sent from my bulletproof iPhone using the Flapmyjaws app :)

[bigjim350]

As long as it's tahiti pearl black with blue pearl mixed in it to give it a blue sparkle, YEP! (his pick, already ordered). :D

Uhhhh yeah thats what I was gonna suggest.

[XJ Wheeler]

Lol, good to see ya back on Ray. Smart kid, chose to put some blue in the mix so it will last. :D Keep the posts coming, but next time... WE WANT PICS!

[Firemanray]

Been real busy, here's some pics of operation "Black Ops":
http://i223.photobucket.com/albums/dd11/firemanray21/0119131820_zps3fbd4e92.jpg
http://i223.photobucket.com/albums/dd11/firemanray21/0121131442_zps03654948.jpg
http://i223.photobucket.com/albums/dd11/firemanray21/0121131442a_zps5c4db833.jpg
http://i223.photobucket.com/albums/dd11/firemanray21/0121131443a_zps1c6cbea1.jpg
http://i223.photobucket.com/albums/dd11/firemanray21/0121131443_zps7f22fa95.jpg

[XJ Wheeler]

Looking good, nice progress.

[cantab27]

nice work ray

[msmoorenburg]

ok ok when can i drop off the 97?

[4x4Dalton]

Lookin good Ray.


Sent from my bulletproof iPhone using the Flapmyjaws app :)

[Firemanray]

Got the doors on and body lines correct, ready to wet sand and paint:
http://i223.photobucket.com/albums/dd11/firemanray21/0125131918_zpsfa915a1f.jpg

[Firemanray]

Well here it is, I haven't taken time to post the "progress" pictures but this is the final outcome:
http://i223.photobucket.com/albums/dd11/firemanray21/0205131622_zpsf5579119.jpg

[XJ Wheeler]

Wow, man. I think you gotta name that thing Black Beauty. Cuz it is GORGEOUS! Very nice job, especially with how hard black is to get right.

[msmoorenburg]

another one converted to the dark side :sign0181:

[Brasscatz]

Wow! I'll be over as soon as I can to pick up my Jeep! Thanks for working on it and fixing it up for me ;)

Seriously though, NICE! I like that bumper/grill guard you got. Where did you get it?

[XJ Wheeler]

Wow! I'll be over as soon as I can to pick up my Jeep! Thanks for working on it and fixing it up for me ;)

Seriously though, NICE! I like that bumper/grill guard you got. Where did you get it?

That's an ARB, got one on my brothers xj and moms zj. If we ever get these meet and greets going you can check out his.

[Firemanray]

Wow! I'll be over as soon as I can to pick up my Jeep! Thanks for working on it and fixing it up for me ;)

Seriously though, NICE! I like that bumper/grill guard you got. Where did you get it?

You'll have to fight my son for it!!! The bumper is an ARB as stated but it has been modified to handle that big winch. The winch is an older model Warn 10,000# and it would not fit inside the bumper as the bumper was designed. I took the middle crossbar out and beefed up the bumper so the winch would fit.

The ARB is quiet expensive, it was on the Xj when I bought it otherwise I would have gone with something a little easier on the pocket book.

[Firemanray]

My son has been driving Mama's car for the last couple of weeks which has been to long. Today I finished the "Black Ops" project and went by the school and swapped vehicles without him knowing it. He came home all smiles!!! Worth every minute of it.

[bluedragon436]

I can imagine he would have loved every second of the surprise as well as the drive home!! The rebuilt XJ looks awesome...

[XJ Wheeler]

That's just plain AWESOME! Good job bud.

[Brasscatz]

My dad used to do that with my old Trans Am when I couldn't get it started on cold mornings. He'd drive it up to school and take his truck back. I think you deserve "Father of the Year" award! Little things like that go a long way in a father/son relationship. Nicely done good buddy! :thumbsup: Oh, got any more pictures of that sexy Jeep? :D

[hitman44]

by far my fav build thread thus far. not only is the jeep awesome, but getting to share it with your son and in the end getting to see his face when he found out it was really his is what its really all about!! i cant wait to do the same with my son. building the jeep together and when he turns 16 (got some time still lol) getting to pass it on to him.
great build and keep up the good work

[Firemanray]

Well it's been a while since I updated this build. Nothing has changed much in the last year since I gave the Xj to my son. He did grenade the motor back in June 2013, nothing left to rebuild. Matt gave me a good core and I had Thunderbolt motors rebuild it since I was so busy working. It took 2 months to put back together because I was so busy. New motor runs great. I would recommend Thunderbolt if anyone needs to have an engine rebuilt.

Here are a couple of shots of the #6 cylinder and the head:
http://i223.photobucket.com/albums/dd11/firemanray21/0709132030_zpsf72af7ce.jpg (http://s223.photobucket.com/user/firemanray21/media/0709132030_zpsf72af7ce.jpg.html)
http://i223.photobucket.com/albums/dd11/firemanray21/0709132031_zpsdec3e70f.jpg (http://s223.photobucket.com/user/firemanray21/media/0709132031_zpsdec3e70f.jpg.html)

[Firemanray]

More recently he's been wanted some "racing" seats to replace the boring factory seats. Since he's over 6' now legroom has become a problem. We ordered some seats w/ covers from Summit Racing and so far we've built a new seat platform using the original rails for the driver side.
http://i223.photobucket.com/albums/dd11/firemanray21/0124141519_zps02b4b4bc.jpg (http://s223.photobucket.com/user/firemanray21/media/0124141519_zps02b4b4bc.jpg.html)

This was a "fab-as-you-go" project, there is no way this side of a cad program to design a rail system to fit the crazy set up in an Xj. If you ever have your seat out look at it from the front or back, the rails sit WAY to one side. Since we had to fab new mounts we moved the seat back 1" from the original location to accommodate his long legs. Also since we used the original rails the seat is still fully adjustable.
http://i223.photobucket.com/albums/dd11/firemanray21/0130141729_zpsa710dcab.jpg (http://s223.photobucket.com/user/firemanray21/media/0130141729_zpsa710dcab.jpg.html)
http://i223.photobucket.com/albums/dd11/firemanray21/0130141736_zpsf078122e.jpg (http://s223.photobucket.com/user/firemanray21/media/0130141736_zpsf078122e.jpg.html)
http://i223.photobucket.com/albums/dd11/firemanray21/0130141728_zps0ea2d9f0.jpg (http://s223.photobucket.com/user/firemanray21/media/0130141728_zps0ea2d9f0.jpg.html)

We had to extend the end of the seat belt bracket that attaches to the seat rail in order for the seat belt to clear the raised sides of the seat. I didn't get a picture of that but when we do the passenger side I will.

The pictures are all kind of dark since we the seat and the interior are dark colors, but here is the final product:

http://i223.photobucket.com/albums/dd11/firemanray21/0130141736a_zpsa0bd439f.jpg (http://s223.photobucket.com/user/firemanray21/media/0130141736a_zpsa0bd439f.jpg.html)
http://i223.photobucket.com/albums/dd11/firemanray21/0130141736b_zpsc7a4151c.jpg (http://s223.photobucket.com/user/firemanray21/media/0130141736b_zpsc7a4151c.jpg.html)

The ultimate plan is to "cage" this thing and put 5 point harnesses in. Just takes time.

[bluedragon436]

Looking good Ray...

[Brasscatz]

Very nice, I'm diggin the seats

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

[Firemanray]

I realized when updated another of my build threads that I haven't updated any of them in almost a year. Time flies when your......busy!!
Anyway the Xj has once again been retired from street use and is strictly off road use now. (My son got a new car = safer, better mileage). We did finish putting both of the racing seats in and more recently we replaced some front suspension components.
http://i223.photobucket.com/albums/dd11/firemanray21/jeepstuff_zps267343e4.jpg (http://s223.photobucket.com/user/firemanray21/media/jeepstuff_zps267343e4.jpg.html)

The front differential was shot from nearly 5 years of hard mudding and off roading. We had an axle from under the '88 (RIP) so we installed it under the '98 when we added those parts.

[Firemanray]

The original ARB bumper had a horrible effect on approach angle so we swapped the bumper that was on the '88, moved the winch, and added synthetic winch rope.
http://i223.photobucket.com/albums/dd11/firemanray21/IMG_7928_zps2ec849f7.jpg (http://s223.photobucket.com/user/firemanray21/media/IMG_7928_zps2ec849f7.jpg.html)

[Firemanray]

We haven't done much to the Xj except wheel it for the last couple of months. We've got a couple of events coming up that we're going to take the Xj and the crawler to, so it was time to clean up the carnage. Here's the list from this last week:
Install Lokka locker in front diff.
Replace axle shaft u-joints.
Replace wheel bearings.
Replace power steering pump.
Replace alternator.
Add larger tranny cooler.
Convert old tranny cooler to steering cooler.
New battery cables.
New tranny fluid. (Cooked the fluid last trip out.)
Remove radiator and clean mud from cooling fins.

I didn't take a lot of pictures, nothing real exciting to see.
http://i223.photobucket.com/albums/dd11/firemanray21/Mobile%20Uploads/20150318_111622_zpsd1jh5j4d.jpg (http://s223.photobucket.com/user/firemanray21/media/Mobile%20Uploads/20150318_111622_zpsd1jh5j4d.jpg.html)
http://i223.photobucket.com/albums/dd11/firemanray21/Mobile%20Uploads/20150318_111602_zps2ozclkoc.jpg (http://s223.photobucket.com/user/firemanray21/media/Mobile%20Uploads/20150318_111602_zps2ozclkoc.jpg.html)
http://i223.photobucket.com/albums/dd11/firemanray21/Mobile%20Uploads/20150321_133556_zpspkf1cssh.jpg (http://s223.photobucket.com/user/firemanray21/media/Mobile%20Uploads/20150321_133556_zpspkf1cssh.jpg.html)
http://i223.photobucket.com/albums/dd11/firemanray21/Mobile%20Uploads/20150321_134625_zpstf36y93b.jpg (http://s223.photobucket.com/user/firemanray21/media/Mobile%20Uploads/20150321_134625_zpstf36y93b.jpg.html)

[denverd1]

You're front lock go in and perform without issue? Abes issue had me wondering...

[Firemanray]

Installation was a breeze. It locks and unlocks fine on stands in the shop. I haven't driven it yet. We'll be at Barnwell Mountain again on April 3 and 4. I'll know more about how it acts then. You should come hang out with us.

[prcjeep]

Still got that arb front bumper???

[denverd1]

Installation was a breeze. It locks and unlocks fine on stands in the shop. I haven't driven it yet. We'll be at Barnwell Mountain again on April 3 and 4. I'll know more about how it acts then. You should come hang out with us.

I think I will! I'll get my ducks in a row well in advance this time.

your trans survive the overheat? how did that happen?

[Firemanray]

I think I will! I'll get my ducks in a row well in advance this time.

your trans survive the overheat? how did that happen?

Zach was playing in the mud in 2 HI with 33" swampers on 3.55 gears then climbed a sandy hill. Trany doesn't like being leaned on that hard. We'll see if it holds when we come to BM week end after next.

[denverd1]

Zach was playing in the mud in 2 HI with 33" swampers on 3.55 gears then climbed a sandy hill. Trany doesn't like being leaned on that hard. We'll see if it holds when we come to BM week end after next.

Zach loves him some 2 HI thats for sure! I may post our trip on local forum to see if we can get a couple more out there, cool?

[Firemanray]

Zach loves him some 2 HI thats for sure! I may post our trip on local forum to see if we can get a couple more out there, cool?

Bring it!!! It will be a sight to see. My daughter is bringing one of her college friend who has NEVER been off the pavement in her life. We'll put her in the back seat of the crawler and do "De Woody", all on go-pro of course!

[denverd1]

Bring it!!! It will be a sight to see. My daughter is bringing one of her college friend who has NEVER been off the pavement in her life. We'll put her in the back seat of the crawler and do "De Woody", all on go-pro of course!

haha!! thats going to be awesome. Need to mount another one facing rear to really document the experience!

[denverd1]

2 guys with pretty built rigs are tentatively coming so far

[Firemanray]

Easter weekend 2015, one for the history books! We had a blast wheel'n but did we ever destroy some stuff! Both axle shafts, the new locker, rear drive shaft, all grenaded, tore the steering box loose on the frame rail, and to top that off I just heard that one of my guests has a mild concussion from getting hit in the head by a tree limb that found it's way into the roll cage on the crawler. Man that was a blast! I finally started looking at the damage this evening.:D

Some pictures:
http://i223.photobucket.com/albums/dd11/firemanray21/20150409_155807_zpsrqkinnzf.jpg (http://s223.photobucket.com/user/firemanray21/media/20150409_155807_zpsrqkinnzf.jpg.html)
http://i223.photobucket.com/albums/dd11/firemanray21/20150409_155746_zpsxm9kitfp.jpg (http://s223.photobucket.com/user/firemanray21/media/20150409_155746_zpsxm9kitfp.jpg.html)
http://i223.photobucket.com/albums/dd11/firemanray21/20150409_155736_zpso6hlfesf.jpg (http://s223.photobucket.com/user/firemanray21/media/20150409_155736_zpso6hlfesf.jpg.html)
http://i223.photobucket.com/albums/dd11/firemanray21/20150409_155755_zpsxblfwryt.jpg (http://s223.photobucket.com/user/firemanray21/media/20150409_155755_zpsxblfwryt.jpg.html)

[4.3LXJ]

Even the locker?

[Firemanray]

Even the locker?

Yep sheared all the little pins that are held in place by the springs. I haven't pulled it out to see what the malfunction is but it made a mess. My son was driving when all this happened, my wife was with him, she says he wasn't doing anything crazy. We all know "crazy" is a relative term.:D

[4.3LXJ]

Yes, relatives. Sounds like it runs in the family

[denverd1]

Yep sheared all the little pins that are held in place by the springs. I haven't pulled it out to see what the malfunction is but it made a mess. My son was driving when all this happened, my wife was with him, she says he wasn't doing anything crazy. We all know "crazy" is a relative term.:D

what??? It looked like the wheel ujoints took most of the the beating... when Zach does something, he does it right!

[Firemanray]

While I'm waiting on parts to fix the locker and axles I fixed the steering issues, permanently! I welded the frame back together and then fabbed up a steering box brace. It ties into the steering box bolts on the driver side and crosses over to the passenger side and bolts in where the sway bar originally bolted on.

I started with a heavy piece of DOM tubing I had that was an exact fit on the lower snout of the gearbox. from there I worked my way out to both attachment points. I don't think the steering box will EVER move again.

http://i223.photobucket.com/albums/dd11/firemanray21/Mobile%20Uploads/20150413_155507_zps455jm3ch.jpg (http://s223.photobucket.com/user/firemanray21/media/Mobile%20Uploads/20150413_155507_zps455jm3ch.jpg.html)
http://i223.photobucket.com/albums/dd11/firemanray21/Mobile%20Uploads/20150413_160030_zpsjggnt3rt.jpg (http://s223.photobucket.com/user/firemanray21/media/Mobile%20Uploads/20150413_160030_zpsjggnt3rt.jpg.html)
http://i223.photobucket.com/albums/dd11/firemanray21/Mobile%20Uploads/20150413_155956_zpsgiwwxloh.jpg (http://s223.photobucket.com/user/firemanray21/media/Mobile%20Uploads/20150413_155956_zpsgiwwxloh.jpg.html)
http://i223.photobucket.com/albums/dd11/firemanray21/Mobile%20Uploads/20150413_155931_zpsazh20kn5.jpg (http://s223.photobucket.com/user/firemanray21/media/Mobile%20Uploads/20150413_155931_zpsazh20kn5.jpg.html)

[Firemanray]

With all the carnage from Easter weekend there are a lot of parts on order. While I'm waiting on everything to be delivered I started on the roll cage. So far I've completed the main hoop and have the layout done for the rear hoop. Nuff said here are the pictures:
Main loop layout:
http://i223.photobucket.com/albums/dd11/firemanray21/Mobile%20Uploads/20150415_140547_zpszujqrxvo.jpg (http://s223.photobucket.com/user/firemanray21/media/Mobile%20Uploads/20150415_140547_zpszujqrxvo.jpg.html)

Seat support / harness bar:
http://i223.photobucket.com/albums/dd11/firemanray21/Mobile%20Uploads/20150415_151002_zpslibx8asa.jpg (http://s223.photobucket.com/user/firemanray21/media/Mobile%20Uploads/20150415_151002_zpslibx8asa.jpg.html)

Mocked up in the cab with the some triangulation installed:
http://i223.photobucket.com/albums/dd11/firemanray21/Mobile%20Uploads/20150415_160357_zpsfie6j0e5.jpg (http://s223.photobucket.com/user/firemanray21/media/Mobile%20Uploads/20150415_160357_zpsfie6j0e5.jpg.html)

Rear hoop pattern drawn out:
http://i223.photobucket.com/albums/dd11/firemanray21/Mobile%20Uploads/20150415_160449_zpsnmgkxxzk.jpg (http://s223.photobucket.com/user/firemanray21/media/Mobile%20Uploads/20150415_160449_zpsnmgkxxzk.jpg.html)

[4.3LXJ]

Nice looking cage so far. I think I need a bender too :D

[denverd1]

Looking great!!!

[Firemanray]

Rear hoop nearly finished.
http://i223.photobucket.com/albums/dd11/firemanray21/Mobile%20Uploads/20150416_165445_zpsr3ffk6ku.jpg (http://s223.photobucket.com/user/firemanray21/media/Mobile%20Uploads/20150416_165445_zpsr3ffk6ku.jpg.html)

[4.3LXJ]

looking real nice Ray

[Firemanray]

Well after a major design change the back loop is done. A strong cage will have as many nodes as possible together to transfer the forces through the cage and not dissipate the energy by bending a bar. My first design had nodes scattered all over the place which would result in major deformation of the cage in a hard crash. This design should work much better.

Since the Xj has a paper thin body and sub-frame I added the long flat bar to the bottom of the legs to spread the weight over the floor area. This will be mounted under the carpet and have a similar backing plate on the exterior of the cabin. I plan to do all the main hoops this way.

http://i223.photobucket.com/albums/dd11/firemanray21/back%20loop_zpsuionadhp.jpg (http://s223.photobucket.com/user/firemanray21/media/back%20loop_zpsuionadhp.jpg.html)

[Firemanray]

Since the front loop has to accommodate leg room for the rear passengers it presents some real challenges to make it as strong as it needs to be. I've added 2 more vertical supports from the floor to the center crossbar to help transfer any impact through the cage with minimal deformation. These bars arch forward and down right between the back of the console and the seats. There will be a flat bar between each outside legs similar to the rear hoop. The real challenge begins when I finish welding this thing and put it back in. It has to come in the back hatch and over the back seat. It barely fits!
http://i223.photobucket.com/albums/dd11/firemanray21/front%20loop_zpsqnjnaofb.jpg (http://s223.photobucket.com/user/firemanray21/media/front%20loop_zpsqnjnaofb.jpg.html)

[bluedragon436]

Man I think I need to take a trip to TX to pick up a roll cage for my XJ.. I'd hate to see what any "fab shop" near me would charge and it wouldn't even come out close to that nice looking or functionality!!

[Firemanray]

The cage is finally finished (for now). I may put an "a" pillar loop in it later but I'm out of time for now. We've got a bunch of repairs to complete before we leave for the Wounded Warriors event next week.
http://i223.photobucket.com/albums/dd11/firemanray21/Mobile%20Uploads/20150421_180636_zpskqkgmuuv.jpg (http://s223.photobucket.com/user/firemanray21/media/Mobile%20Uploads/20150421_180636_zpskqkgmuuv.jpg.html)
http://i223.photobucket.com/albums/dd11/firemanray21/Mobile%20Uploads/20150421_180715_zpsrydda4ek.jpg (http://s223.photobucket.com/user/firemanray21/media/Mobile%20Uploads/20150421_180715_zpsrydda4ek.jpg.html)
http://i223.photobucket.com/albums/dd11/firemanray21/Mobile%20Uploads/20150421_180709_zpsk3ec3xcm.jpg (http://s223.photobucket.com/user/firemanray21/media/Mobile%20Uploads/20150421_180709_zpsk3ec3xcm.jpg.html)
http://i223.photobucket.com/albums/dd11/firemanray21/Mobile%20Uploads/20150421_180621_zpsqty5be9n.jpg (http://s223.photobucket.com/user/firemanray21/media/Mobile%20Uploads/20150421_180621_zpsqty5be9n.jpg.html)

[denverd1]

Looks awesome Raymond!! Honestly that's as far as I would take it. Any more steel is a head banging issue in my book. Those warriors will be nice and secure

sent from my Samsoon S5 from the bottom of a mud hole

[autotech98]

Wow awesome ray !

Sent from my SAMSUNG-SGH-I547

[Firemanray]

The cage is padded, the harnesses in, the doors off, all the drive line and suspension carnage is repaired, we are ready to wheel again!
http://i223.photobucket.com/albums/dd11/firemanray21/Mobile%20Uploads/20150428_195144_zpsw3l7cvrx.jpg (http://s223.photobucket.com/user/firemanray21/media/Mobile%20Uploads/20150428_195144_zpsw3l7cvrx.jpg.html)

[4.3LXJ]

:congrats:

[Pookapotamus]

That is one sweet looking cage! Paint it yellow!!!!

[Firemanray]

Look like I'm fixing to put some massive axles under the Xj. I'm trading for these "tonz" this weekend.
http://houston.craigslist.org/pts/4961997645.html

[JENSSEN]

That is one sweet looking cage! Paint it ORANGE!!!!


Fixed it for you :)

[denverd1]

Look like I'm fixing to put some massive axles under the Xj. I'm trading for these "tonz" this weekend.
http://houston.craigslist.org/pts/4961997645.html

Oh snap!!! I was trying to keep up with you on our builds!! that just went out the window.

Ha! Tell Zach have fun trying to spin the caps off those joints!!

[xj-jake]

So much work and so much fun. I'd be interested to see how the transformation to tons goes. I'll be following.

[Firemanray]

Well the trade fell apart so we're back to square one. Given the awesome performance from the Xj at Hidden Falls this weekend I'm going to build the 8.25 and the D30 up and torture them. It'll be cheaper in the long run and I can get some really strong parts for the stock axles.

[xj-jake]

Bummer about the deal falling apart. What are you thinking about doing to the 30?

[Firemanray]

Bummer about the deal falling apart. What are you thinking about doing to the 30?

Chromos or maybe some (real expensive) rcv axles, trusses, 4:56 gears, locker (type TBD),tube seals, all new moog ball joints, knuckle over steering.

[bluedragon436]

Sorry to hear about the tons deal falling through... What OTK steering setup are you looking at going with, or are you planning on building your own setup?? Look forward to seeing more as the build progresses!!

[Firemanray]

Sorry to hear about the tons deal falling through... What OTK steering setup are you looking at going with, or are you planning on building your own setup?? Look forward to seeing more as the build progresses!!

I think I'll just build my own. It should be cheaper.