Lil 'Ole XJ

[hadfield4wd]

Well this is how it started several years ago. I bought it for $500 with 232k miles everything worked but the tape deck (I don’t own any tapes anyway). AC power windows, 5 speed AX-15, 3.73 gears open/open, D30, D35.

http://i85.photobucket.com/albums/k51/hadfield4wd/Early%20Progression/kidsandjeepbeforelift2.jpg

Wheeled it for 3 years that way. Then bought a Rock Krawler 4.5 lift and put it on.

http://i85.photobucket.com/albums/k51/hadfield4wd/Early%20Progression/jeepsprings3.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Early%20Progression/jeepsprings2.jpg

Some parts I took off.

http://i85.photobucket.com/albums/k51/hadfield4wd/Early%20Progression/Jeepparts1.jpg

[hadfield4wd]

Ended up like this.

http://i85.photobucket.com/albums/k51/hadfield4wd/Early%20Progression/Jeepafterlift2.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Early%20Progression/Jeepfrontafterlift1.jpg

On 33’s

Did some trimming and made a front bumper.

http://i85.photobucket.com/albums/k51/hadfield4wd/Bumper3.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Bumper1.jpg

[hadfield4wd]

Here you can see the rockers as well.

http://i85.photobucket.com/albums/k51/hadfield4wd/Bumper2.jpg



Did a bunch of wheeling still 3.73’s and open/open.

My dad built an awesome toolbox. I carry a spare everything.

http://i85.photobucket.com/albums/k51/hadfield4wd/Box4.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Box3.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Box1.jpg

[hadfield4wd]

http://i85.photobucket.com/albums/k51/hadfield4wd/Box2.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Box6.jpg

Made a rear bumper and skid combo.

http://i85.photobucket.com/albums/k51/hadfield4wd/skid1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/skid2.jpg

[hadfield4wd]

Put a locker in the rear at Crawfords at Tellico. Still do a bunch of wheeling.

http://i85.photobucket.com/albums/k51/hadfield4wd/jeep1tellico.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/jeep2tellico.jpg


I took off the rockers and have to build new ones.

I massed parts in the garage for the axle swap for 2 years. How it sits today.

255k miles
AX-15
NP231 with sye
Custom drive shafts

Front HPD44 with:
• 5.13
• Lockright
• Alloy USA shafts
• Yukon Super Joints
• Warn Premium Hubs
• Modified Ford Radius Arms

Rear 9”
• 5.13
• Spool
• Alloy USA Shafts

36” TSL Radials Bead balanced

Still using Rock Krawler 4.5 front springs on top of the Ford mounts. Gets about 6” – 7” of lift

Rear is a bastard Rock Krawler/S-10 pack using all the long and no overload and Deaver spring liner. All for good flex. 1.5 blocks to go in to level it out.

http://i85.photobucket.com/albums/k51/hadfield4wd/finalassembly009.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/finalassembly010.jpg

[hadfield4wd]

Flexes nice and level

http://i85.photobucket.com/albums/k51/hadfield4wd/Shakedown/frontshotfullflex1.jpg

Some clearance needed.

http://i85.photobucket.com/albums/k51/hadfield4wd/Shakedown/rearstuffed1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Shakedown/clearance11.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Shakedown/rearstuffed3.jpg

[hadfield4wd]

Well I had some bad axle wrap with my custom bastard leaves. Bent my perches.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/axlewrap001.jpg

Had wavy springs. I don’t think they are supposed to be wavy like this.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/forkliftflex3.jpg

I bought a new set of BDS springs which I promptly took apart and inserted full length deaver spring liner so I didn’t want to ruin new springs. So I built a traction bar.

To get the dimensions right I had to cut a hole in the floor of the jeep.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cuttingfloor.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar3.jpg

[hadfield4wd]

Here is the bracket on the cross member.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar2.jpg

I covered it with a bread pan. Yep a bread pan works great then I sprayed it with spray on bed liner. Can hardly see it.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/loafpan2.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar7.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar9.jpg

[hadfield4wd]

Now for the axle side. I had a buddy make me a bracket because I needed it custom fit on the 9”. I also had to get a new muffler. I got the magnaflow you can see in these pics because of its size.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar6.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar10.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar11.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar12.jpg

[hadfield4wd]

Here you can see it doesn’t hang below the axle so it won’t get caught on anything.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar15.jpg

Helps protect the driveshaft.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar16.jpg

[hadfield4wd]

I also put a GLO Yoke guard on the 9”. Hangs down a little low and will be modified soon. It is ½” steel and really beefy.

Here it is next to a 5 gal bucket. For reference.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/yokeguard2.jpg

Installed.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/yokeguard3.jpg

[hadfield4wd]

Built a tire carrier.

Main structure will be 2x2 3/16 wall box.

Used a hole saw and drilled a 1 3/4'” hole then cut the remainder of the steel on the top and bottom off. Then heated it up and bent it around the DOM that will house the bushing. This will be in double sheer. Still have all the welding and grinding to do but here is progress pics.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/Hinge1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/Hinge2.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/Bushing.jpg

[hadfield4wd]

Lots of welding and grinding came to this.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/Hinge5.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/stevehinge1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/stevehinge2.jpg

[hadfield4wd]

Also did the latch.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/latchside2.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/latchside3.jpg

Bent the structure to follow the lines of the rear hatch.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/supports2.jpg

[hadfield4wd]

Here it is on the first test fit.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/Hinge6.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/latchside4.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/newpics005.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/99.jpg

[hadfield4wd]

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/992.jpg

Had to beef up the bumper.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/reinforce1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/reinforce2.jpg

[hadfield4wd]

And cut the handle for the hatch.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/Openbutton.jpg

The tire was too heavy and the bushing didn’t work so I had a bronze busing machined to fit. Keep in mind that spare is 96 lbs, I weighed it.

I also added a mount for the hi-lift.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/highliftmount.jpg

[hadfield4wd]

Final shots.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/final6.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/final7.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/Jeeptotalshot.jpg


This will be removed when the cage gets put in.

[hadfield4wd]

So here are the weights of the Jeep. Done by a race shop with individual scales.


LF – 1147lbs RF – 1121lbs Front total - 2268lbs 48.3%

LR – 1212lbs RR – 1214lbs Rear total – 2425lbs 51.7%


Total weight – 4694lbs

All that to say the Jeep is just too heavy. And the fact that 51.7% of the weight is on the rear is not to my liking. No wonder it doesn’t climb well. With the tire carrier and the tire up high and out back as soon as the nose points up the front tires have very little weight on the so the are not pulling at all. For now it stays, because it is convenient but when the cage goes in, I will remove the tire carrier and the tire will stand up behind the rear seat. I will only carry it when required for specific rides, other than that I won’t carry it at all.

Here is what I started with.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/fatty001.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/fatty002.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/fatty003.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/fatty004.jpg

[hadfield4wd]

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/fatty005.jpg

Ah. A clean slate. The box has served it purpose. When I designed it, I didn’t trailer the Jeep. I drove it everywhere. It was designed to fit 2 coolers and the Rubbermaid bin with the camping gear on it. It kept everything secure and was easy to pack. Could fit the family in it with all the gear, it was a little tight, but worked.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/fatty006.jpg

It’s just too hot to do anything else right now.

The plans are to move as much of the weight forward and low. I will put as much as I can under the seats. The parts and small tools fit in small bags. I will eliminate some items as well. Everything will be secured and the rear seat needs to remain usable. When I am done I will reweigh it on the same scales to see the difference. The tire carrier is coming off as well.

[hadfield4wd]

Well I sorted through my parts a tools. All my sockets were falling off the metal holders and were in the bottom of the tool bag. Takes forever to find what you need. Plus I figured I had too much crap.

I just dumped everything out of the bags onto the garage floor and sorted form there. Turns our I had 14 screwdrivers and 3 of them were the multi ones. Plus I had a ton of duplicate sockets. I also got tool rolls from hf (only place I could find them at the time) for my box wrenches. I ended up taking a ton of these out as there were duplicates of these as well.

I got these really cool socket holders from www.offroadtrailtools.com. The hold the sockets real well. Are flexible and came in 2 colors, so red fo rmetric and black for standard. I spoke with the owner and seemed like a great guy, starting a new business with made in the USA products.

This is still probably too many tools but at least I took a bunch out. People will still look to me for repairs as usual.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/socketholders003.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/socketholders002.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/socketholders001.jpg

[hadfield4wd]

Well many people know that the charging/electrical system on the XJ is subpar at best. When you add things like a winch it is really lacking. With the headlights, AC, radio and CB on I was down around 10 volts. The first time I kicked the winch on the Jeep stalled. I knew it was time to fix this. I got my info from here:

http://www.geocities.com/JeepI6Power/

Jon is very knowledgable and ready to help. I made all my own wires out of #1 welding wire. It is braided and makes for easier bending. All of my ends are soldered, crimped and have heat shrink. I tested my first one by putting a hook in either end and used it as a pull-up bar. It held so I think the connections are fine.

I replaced/added the following wires:

• Battery Positive to Starter
• Battery Positive to the distribution block
• Alternator output to battery positive (stock has this connected to the distribution block I skipped that and went right to the battery – ANL Isolates the alternator from the rest of system should it surge, when you bypass the distribution block it bypasses the factory protection mine is 150A because my new alternator is a 140A) [Added parts]
• Battery Negative to engine block
• Battery Negative to fenderwell [Added]
• Battery Negative to alternator case (Case bonding) [Added]
• Engine block to firewall

With the stock alternator I lose very little voltage with everything on. Maintains around 13 and I don’t have to rev the engine in order to winch. The HO alternator should also help and will be installed shortly.

Anyway here are the pics.

The first 2 are comparisons of old to new. From left to right – New wire, alternator output to distribution block, engine block to battery negative, battery positive to starter, battery positive to distribution block and Engine block to firewall.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/compare1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/compare2.jpg

Here it is next to my thumb for a size comparison

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/compare3.jpg

[hadfield4wd]

Here is the battery. You’ll notice I only had black wire so the positive I put red tape on the ends. The one red wire is for the winch.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/Injeep.jpg

Here is the 150A ANL fuse.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/fuseblock.jpg

[hadfield4wd]

Well got the winch installed. Here is the story. Got a killer deal on it from DC. It was not working. I knew that when I got it. I assumed it was at least 2 solenoids, as it didn’t operate in either direction. Turns out it was a bad motor. Warn wanted $250 for a new motor plus shipping. This would bring the cost close to $300. Warn recommended I go to a local starter/alternater repair facility to see if it could be repaired.

Enter PAR, Porters Automotive Rebuilders. I took the motor to them and they said there is a history of these motors have history of poor longevity. Here are a couple of issues with the Warn motors. One is the plastic brush holders (Mine was broken). Loosely wound field coil windings (I had a bad one as well). Plastic end cap. Low quality bearings and a reputation of armature problems. He said he had a bolt in replacement made in the USA with a full metal case, metal brush holders and larger brushes. He also said to bring the body in and he would put install the motor and remove the existing pressed in armature bearing. This motor is more powerful and should draw less amps. I’ll report on load testing. The motor is physically longer as well.

Anyway here are the pics.


http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/winch3.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/winch4.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/winch1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/winch2.jpg

[hadfield4wd]

External Fuel Pump Install

I took out the existing pickup and sending unit. It looked like this.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/Pickup1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/Pickup2.jpg

I then got a piece of 3/8” tubing. I could only find chrome, so in this case “chrome will get me home”.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/Pickup3.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/Pickup4.jpg

[hadfield4wd]

With the 3/8” tubing it was difficult to get it in the bottom grommet. That was the one left from the pump. When I pushed it in, it expanded it enough that I couldn’t get the pickup screen on. I then put the pickup screen on then inserted the tube. The screen will not fall off.

This done I switched to the wiring and cut the orange wire (Fuel Pump Hot) and soldered a longer pig tail on and used heat shrink to seal it. The ground wire I had to splice into because the fuel gauge sending unit needs the ground as well. I soldered a pig tail on to it as well.

I then installed the pickup. This is a pain in the neck and part of the reason for me going to external on my Jeep. I used Vaseline on the new gasket to hold it in place. Then installed the locking ring with a bronze drift. No sparks are wanted in this area.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/Pickupinstalled1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/pickupinstalled2.jpg

I made a bracket out of 2 x 4 3/16” angle that I had around. Cut it down to 3/4” by 4 for mounting on the skid plate. The skid plate is really beef and secure. It is 1/4” plate with 1 x 1 1/8” angle welded around for rigidity. This is then got 2 frame brackets on the front and is bolted to the bumper via tapped tabs I welded on.

I then mounted the pump (Summit Racing Part #SUM-G3138) on my bracket and installed it on my skid plate. According to the directions the pump should not be mounted below the bottom of the tank. I also installed a pre-filter (Summit Racing Part # RUS-645080). I may be changing this as it has 5/16” barbs at both ends. I had a hard time getting the 5/16” line on the 3/8” end on the pickup. The pump was supposed to have a 3/8” intake and 5/16” discharge. But it didn’t. It seems to work fine, I’ll keep an eye on the lines and change them if need be. I could also put reducers in the line. We’ll see how it does. The pre-filter has a replaceable element so I’ll be getting an extra as well as a spare pump. I installed a new factory fuel filter as well.

I then plumbed everything and wired it up. I used zip ties to make sure nothing rubbed.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/pumpmounted1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/completemounting.jpg

[hadfield4wd]

OK all. Some of you know I have been working on my hydro assist. I’ll get to that. Also many people have asked me about my OTK (Over The Knuckle) steering. It is not a true high steer, but a less expensive alternative. This will net you approximately 3” of clearance at the tie rod. First off this is on a HPD44. I ran 2 years with no assist. I had a DOM Drag link and a solid stock tie rod. The solid stock tie rod took a beating and did end up bending. I have had zero failures. Here is a pic.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tierod001.jpg

I used the typical 1 Ton steering parts. I got the TRW ones from Advance Auto and these numbers can be cross referenced at any parts store.

Here are the part numbers for the steering ends.

ES2234R (you need 2 of these) - 28.99 ea
ES2027L (one needed) - 27.99
ES2233L (one needed) - 33.99

Just so you know there is a difference between the drag link end and a tie rod end. ES2027L is a drag link end. It allows for a larger angle to be achieved.

ES2027L is the passenger tie rod end. This is originally designed for a chevy under the knuckle and the hole is drilled to a smaller taper for the wrong direction. The hole is for the steering stabilizer on a chevy. So this needs reamed from the opposite direction to accept the tie rod end. There is plenty of material to support this.

Here is what the rod ends look like. Yes I know there are no cotter pins on the castle nuts and the jam nuts need tightened, I still need to do an alignment.

Passenger side knuckle

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/rodends002.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/rodends001.jpg

Driver side knuckle

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/rodends003.jpg

[hadfield4wd]

Pitman arm

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/rodends004.jpg

My new tie rod is 1.25 .335 4130 DOM. Drilled and tapped to accept the 7/8” x 18 thread of the tie rod ends. This way there are no welds to fail.

You can go to regular DOM and weld in bungs if you want something less expensive.

The knuckles and pitman arm will also have to the reamed. The knuckles from the top down to go OTK and the pitman arm to accept the larger drag link end.

Due to me using a D44 I had to go to a longer pitman arm to match the length of the knuckle. I chose a ford drop pitman arm. Rough Country part number RC6602. It provides a 1” drop over the stock xj.

All in all I am very happy with this set up.


Next comes in the hydro assist.


I ordered this cooler from Summit

http://store.summitracing.com/partdetail.asp?autofilter=1&part=FLX%2D3818&N=700+4294924500+400226+115&autoview=sku

I have a yj box drilled and tapped for 3/8" NPT

I have the inner frame plated.

I have this Tie Rod Bracket.

http://www.ballisticfabrication.com/OD-Tube-Clamp_p_21-1474.html

I did the West Texas Pump Mod.

http://westtexasoffroad.homestead.com/powersteering.html

I have this cylinder.

http://www.surpluscenter.com/item.asp?UID=2007040810283306&item=9-4410-08&catname=hydraulic

SPECIFICATIONS
Double Acting
Bore/Stroke 1 1/2" x 8"
2,000 PSI max
Rod dia 3/4"

Ports 3/8" NPT
Retracted Length 13 1/2"
Shpg. 10 lbs.

END MOUNTINGS
Rod End Crosstube
Pin hole 3/4"
1-1/4" cross-tube width

Base End Crosstube
Pin hole 3/4"
2" cross-tube width

I will also need to do an internal stop on the cylinder for 7 1/8" travel. Some say this isn’t necessary due to the box having an internal relief when it hits the internal stops. However I have my knuckle stops hitting before the box reaches the internal stops, so if I kept turning with the assist I’d push my knuckles right off the inner-c’s eventually as the ball joints can only take so much. So I took the cylinder apart and added this metal sleeve.

Before

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cylinderinternalstop1.jpg

After

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cylinderinternalstop3.jpg

[hadfield4wd]

Also why we are on the cylinder as this axle is very tight I needed to rotate the fixed end 90 deg so I could have the hoses coming out of the top of the cylinder. I had to cut it off and re-weld it on.

Started like this.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cylinderbefore1.jpg

90 deg rotated

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cylinderafter1.jpg

Lastly on the cylinder I didn’t want to use a ¾” bolt so I sleeved the ends with bronze down to ½”

Here is a pic of the frame plating ¼”.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/steeringboxbrace3.jpg

New box bolted in.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/steeringbox1.jpg

[hadfield4wd]

Axle brackets welded on.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/bracket003.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/bracket002.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/bracket001.jpg

Cooler installed. I put it on the passenger side as it is the side with the mechanical fan and will be pulling air constantly.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cylindercooler2.jpg

The cooler is plumbed off the return line from the box to the top fitting on the cooler. The lower fitting goes to the reservoir on the pump.

[hadfield4wd]

I went to the local Parker store for the hose and ends. I may have gone a little overkill on these, but the hose is 4700lb hose reinforced with 3 layers of wire mesh. I had to cut it with a chop saw. I also used reusable ends. As a result if I have a broken line on the trail I can take out my spare line and put the ends on and call it good.

I prefilled everything I could with fluid. This would make bleeding much easier. As for fluid I have heard many things work well, but all agree that Amsoil Synthetic Power Steering Fluid works the best. Some problems are that most people go through growing pains when they first install the hydro assist and have to replace the fluid a couple times and that you can’t get it on the trail or at a part store. Well I bit the bullet and bought a case of it. This way I’ll carry my own and have enough to redo it a couple of times.

Bleeding procedure taken from here.

http://www.pirate4x4.com/tech/billavista/PR-Hydro_Steering/index3.html
Once you have everything installed and plumbed, it's time to fill and bleed. The procedure I discovered works well is:
1. Fill reservoir to just over tip of column
2. Raise front tires off ground to remove resistance
3. Turn steering wheel lock-to-lock while constantly checking the reservoir for air bubbles and level drop. Top us as necessary - be careful not to over-fill. When no more air appears to bubble out and the level remains constant, go to step 4
4. Check fluid level in reservoir, disconnect coil wire, and crank engine over to operate pump and flow fluid through entire circuit. Crank in short bursts. When no more air appears to bubble out and the level remains constant, go to step 5
5. Re-connect coil wire.
6. Check fluid level in reservoir and start engine. Operate at low rpm's at first, do not turn steering wheel. After a few seconds shut down engine and check reservoir. It will likely look like the pic at left, frothy and full of air bubbles. Allow bubbles to dissipate (can take upwards of an hour) and repeat this step until frothing does not occur.
7. Check fluid level in reservoir and start engine. Operate steering lock-to-lock while constantly checking the reservoir for air bubbles and level drop. Top us as necessary - be careful not to over-fill. When no more air appears to bubble out and the level remains constant, go to step 8
8. Top up reservoir, install reservoir cap, lower front tires to ground.
Here you can see everything installed. You can see how tight the clearances are.

Turned right

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/complete006.jpg

[hadfield4wd]

Turned left

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/complete001.jpg

Front shots

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/complete005.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/complete002.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/complete004.jpg

I just need to go through and tighten everything, align it and zip tie the lines.

[hadfield4wd]

Somewhere in there I managed to break out all my glass. I already had a plexi rear window as a result of the shakedown. I took it out and had snap in side curtains made.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/sidecurtains1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/sidecurtains2.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/sidecurtains3.jpg






Holy crap I've done a lot of stuff to this jeep.

[Scrambled]

Hey Matt glad to see your thread up. One of my favorites, shows what can be done with a lil ingenuity and not alot of $.
Might be picking your brain soon on the hydro assist set up. What are the specs on the ram you used? Bore ,shaft diameter ,stroke etc.
Who tapped the box for you?

Chris P sent me to surplus center site ALOT more reasonable than some of the aftermarket kits.

Still got plans for a cage?

Later
Sean

[FitchVA]

:2thumbsup:

[hadfield4wd]

What are the specs on the ram you used? Bore ,shaft diameter ,stroke etc.

Chris P sent me to surplus center site ALOT more reasonable than some of the aftermarket kits.


All that info is in the thread.



Who tapped the box for you?


I bought it already tapped from Tangeant Design in TN. They are now closed due to the economy.



Still got plans for a cage?


Yep. The guy who used to own Tangeant Design will be doing it. Unfortunately I spent the cage money on my wifes tranny. However he has my deposit still.

[TrailReadyMJ]

Nice Matt! I like the snap in windows :2thumbsup:

[hadfield4wd]

Put on my new Lube Locker diff gasket on the front diff. It's only been sitting on my workbench for 6 months.

Removed my cruise control.

[hadfield4wd]

Boatsides almost done.

[xjtrailrider]

PICS!!! I guess I could just drive by and look at them though:D

[xjmudman96]

I can't wait to see the boat sides!:thumb: Eventually I'd like to do that to mine.

[hadfield4wd]

Started on my boatsides. I decided to cut out my rocker to the sill. I’m never putting the doors back on so I’m not concerned what it will do to them.

Here is the starter picture. I have already cut off the rockers at this point. The rockers were down to 24”

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/boatsides007.jpg

The main piece is 2” x 4” 3/16” wall box. It was my old rockers that I cut off and removed the legs.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/boatsides004.jpg

The legs to the frame are 1 1/4” x 1 1/4” 1/8” wall square tube.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/boatsides005.jpg

There are floor penetrations and the legs are welded at these points. I don’t have pictures of this.

Here is the final picture at this point.

I gained 3 ¾” at the rocker.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/boatsides011.jpg

I still need to plate these. I’ll get that done this week.

[hadfield4wd]

Well since I had problems last trip out with valve stems getting mangled I decided to make some changes. So I unmounted all the tires, removed the valvestems. An filled in welded closed the holes. I then redrilled holes so they would stick towards the center and not out towards the face.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/rim.jpg

[hadfield4wd]

It’s nekid. Tube arrives on Tuesday. 1.5 x .120 HREW

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep001.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep003.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep004.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep006.jpg

Cut line for the comp cut

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep002.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep009.jpg

[xjtrailrider]

Looking good! i can't wait to see it all done:2thumbsup:

[Scrambled]

Let the cut off wheel magic begin.:D

Looking forward to seeing what you have in mind Matt.:thumb:

Later
Sean

[FitchVA]

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep004.jpg

is it wrong of me to want to come over and paint those nicely exposed wheel wells for you? :rotflmao5:

:2thumbsup: can't wait to see the finished project. if you need any help (besides cutting anything with a box cutter) lemme know.

[hadfield4wd]

is it wrong of me to want to come over and paint those nicely exposed wheel wells for you? :rotflmao5:



Well I'll knock the dirt off before I weld to them. Do you want to come over and wax my springs.:2thumbsup:

As this is a 2 door xj and I need access to the back seat made design a little tough. I need the access to the back seat so in the event something happens I can go back and get the kids. I understand some compromises will have to me made. As a result this is being build to withstand a rollover and protect the occupants, but very well may be unusable after the fact. I believe this will withstand many flops and easy rolls.

Design criteria:
Protect myself and the kids
Access to the back seat
Protect A pillar and rain gutter area
Incorporate the front fender area
Be able to mount front airshocks (eventually) to the front

What I will be doing is an external roof halo and A pillar. Internal B, C and D pillars. V behind the front seats and X behind the rear seats. Downbars on the windshield.

[xjmudman96]

sounds like a good design plan. I want to incorporate some tube fender type protection and tie it int0 the sliders and the front bumper one day.

[hadfield4wd]

Got the skins cut out and mocked up. Still need to cut some sort of access hole for the spring bolt. And drill some holes to plug weld it to the legs.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/boatsideskin013.jpg

[hadfield4wd]

Well I’ve been travelling a bunch and haven’t had time to pick up the tube. But I cut a bunch out of the back end.

The inside is where I want it. I’m still playing with the outside before I do a final cut. I still have to figure out what to do about the gas fill tube as well.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep011.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep013.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep015.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep012.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep016.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep014.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep017.jpg

[FitchVA]

lookin good!

could you raise the fuel filler up a few inches? there looks like there should be enough sheet metal left for it to fit

[hadfield4wd]

lookin good!

could you raise the fuel filler up a few inches? there looks like there should be enough sheet metal left for it to fit


That is kinda the plan.

I haven't cut up as far as I want yet though. I'll have to work it out.

[Scrambled]

Up a few inches maybe add a race style filler cap from summit about $28 if I remember right. Ive seen other XJ 's use 2x4 or 3x4 box tubing to build boxes for the tail lights. Use cheap trailer LED's from northern or tractor supply.

Ive got a few pieces of 4x4 box tubing you can have for the tail light boxes if you go that route.

Are you planning on street driving this anymore Matt?

Later
Sean

[hadfield4wd]

Up a few inches maybe add a race style filler cap from summit about $28 if I remember right. Ive seen other XJ 's use 2x4 or 3x4 box tubing to build boxes for the tail lights. Use cheap trailer LED's from northern or tractor supply.


I'm not gonna us box. When you see how I tub the rear out you'll see why. Stick out too much. just gonna plate it and either use the lights Steve has on his or get some Military lights.


Are you planning on street driving this anymore Matt?


It is still registered and has a current inspection. All the lights will work. Will have mirrors. However I won't drive it until I get the tires vulcanized. Maybe not even to Potts. Probably trailer to the ranger station then from there. We'll see though. I don't know if it'll pass another inspection. I'll play that by ear.

I'm just not very happy with these tires. I don't know why I am cutting them all of a sudden. I don't know if they've gotten softer. They are the radial TSL so my next tires will be Bias.

[xjmudman96]

I'm not gonna us box. When you see how I tub the rear out you'll see why. Stick out too much. just gonna plate it and either use the lights Steve has on his or get some Military lights.



.

can't wait to see that... looks good so far

[Scrambled]

Tires may be seperating internally do to age. Have you checked the date on the tires? The rock garden from the TN trip looked to be filled with alot tire killers though. I thought you were running bias ply tires already.

Looking forward to seeing what you come up with. I like a different idea or two and matt you are good at that my friend. LOL

Later
Sean

[hadfield4wd]

Tires may be seperating internally do to age. Have you checked the date on the tires? The rock garden from the TN trip looked to be filled with alot tire killers though. I thought you were running bias ply tires already.

Looking forward to seeing what you come up with. I like a different idea or two and matt you are good at that my friend. LOL

Later
Sean

The tires aren't that old 3-4 years. They are not seperating, they have a clean slice in the sidewall. And they are the radial TSL's. I wasn't the only one to lose a tire that day. Gabe lost one too.

[Scrambled]

I need to get a tire repaired as well on the blue Jeep. What shop did you find local to vulcanize?

Looking forward to the rest of the build Matt.

Later
Sean

[hadfield4wd]

Blue Ridge Tire

[Scrambled]

Thanks for the info Matt. Let the hacking continue sir. LOL

[xjtrailrider]

Matt, I saw this on NAXJA and I started to drool. Mine might look like this some day when I can afford some 1-tons under it.

http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs011.snc1/2899_564283244939_24800499_33456537_2329976_n.jpg

[hadfield4wd]

Here are the tires tsl's in the front boggers that will go in the rear.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tirestslandboggers001.jpg

I'll be cutting out the little lug totally to allow them to flex and grooving the big lug for more lateral stability. You can see the little nubbins on these.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tirestslandboggers004.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tirestslandboggers003.jpg

The TSL's will get some kind of grooving, not totally a TN cut.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tirestslandboggers002.jpg

[FitchVA]

what are the sizes of 'dem der tires?

[hadfield4wd]

36 x 12.50 x 15 TSL's measure to 36.3"
37 x 13.00 x 15 boggers measure to 36.8"

1/2" isn't going to matter

[FitchVA]

nice. :thumb:

[Scrambled]

Nice go-rounds you got there sir.:thumb:;)

Im still curious as to how you are planning the comp cut. Any more thoughts on the idea?

Later
Sean

[hadfield4wd]

Nice go-rounds you got there sir.:thumb:;)

Im still curious as to how you are planning the comp cut. Any more thoughts on the idea?

Later
Sean

Do you mean what tool will I use or how the tires will look?

Tool: Sawzall with a sharpened blade like a knife.

How they will look: I will be completely cutting off the little lug on the boggers.

Just like this. (this is not my tire)

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tirestslandboggers005.jpg

Then I'll do lateral grooves in the remaining lugs. Boggers don't flex well and they don't have much lateral support. So by cutting the lug out it helps with the flex as does the grooving. In addition the grooving helps the lateral support.

The front I'm most likely going to cut out 3/4" from the end of each center lug. To give more space between the lugs. TSL's are great tires, but when they flex over an obstacle the lugs touch each other. This will leave a gap to bite the rocks.

[FitchVA]

man, that sounds like loads of fun lol. my luck, i'd get out of synch and start cutting off the wrong lug. and not realize it till i'm 1/4 of the way done.

[hadfield4wd]

man, that sounds like loads of fun lol. my luck, i'd get out of synch and start cutting off the wrong lug. and not realize it till i'm 1/4 of the way done.


Did you think I was kidding when I said butter knives only for you?!?

You'll have a very hard time cutting tires with a butter knife.

[RUparrothead]

Did you think I was kidding when I said butter knives only for you?!?

You'll have a very hard time cutting tires with a butter knife.

:rotflmao5::rotflmao5::rotflmao5:

That made me shoot snot onto my keyboard. Thanks Matt for the laugh!

[Scrambled]

Never grooved a tire before. Any info on grooving iron, pics,where to get one?

When you get that thing back together I wanna go hit Mt City with you and Gabe.:driving:

Later
Sean

[hadfield4wd]

I goofed up on my first piece of tube.

I can use some of it though.

I did get my mini stinger bent up as this is where my front will tie in. Plus it is the only small, single plane bend on the jeep so you gotta start somewhere.

I do like the 54" handle. Makes bending easy, although I can't see the degree wheel while bending. So I gotta move around some and take it slow at the end of the bend.

[xjtrailrider]

I goofed up on my first piece of tube.

I can use some of it though.

I did get my mini stinger bent up as this is where my front will tie in. Plus it is the only small, single plane bend on the jeep so you gotta start somewhere.

I do like the 54" handle. Makes bending easy, although I can't see the degree wheel while bending. So I gotta move around some and take it slow at the end of the bend.

Get one of the kids to watch the degree wheel for you:thumb:

[hadfield4wd]

Get one of the kids to watch the degree wheel for you:thumb:

I wonder if that would be an excused absence from school. I could tell them it was math related.:D

[hadfield4wd]

Got it tacked on. I have to clean everything up before final welding.

Yes it's straight it's the camera angle. There is not enough room to get in front of it for a picture.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/stinger1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/stinger2.jpg

[Scrambled]

Id say pretty good for your first attempt at bending tube Matt.:thumb: Bend tech makes life soooo much easier, just as soon as I learn how to use it! LOL

Later
Sean

[hadfield4wd]

I ditched the bend tech ez and went to the "tube bending 101" on pirate. Really is easy. Just finished up 2 symetric compound bends, one for each side of the comp cut. Feel pretty good about it.

[hadfield4wd]

Next I wanted to tackle the comp cut area with the symmetric compound bends. I pretty happy with the results. I still need to trim the ends and tack them on. And do some final cuts to one side, bumper and hatch.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/compcut1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/compcut2.jpg

[hadfield4wd]

Well I’ve got a bunch of projects started, but I needed to further along the boatsides. I had to do some finish fitting, drill for plug welds and tack on. I am almost out of both wire and gas so I just tacked it on. Here are the pics. I’ll get the driver side done shortly then its back on the cage.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/boatsideskin14.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/boatsideskin15.jpg

[hadfield4wd]

All the access holes for the front spring are cut. Plug welds for along the legs are done. All tacked on.

Just need to finish weld and paint. I’ll do that when I’m welding the cage.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/boatsideskin16.jpg

Calling these done.

[TrailReadyMJ]

Nice Matt, I need to get on mine! Thanks for the inspiration :thumb:

[hadfield4wd]

Nice Matt, I need to get on mine! Thanks for the inspiration :thumb:

You thank me now. In 4 months you'll be angry with me for getting you started.:D

[hadfield4wd]

Finished cutting one entire bogger like this. I used a 4" grinder. Made a little smoke. I don't think my sinus's will the the same.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/boggergrooving.jpg

I got the rear comp cut fender bars tacked in. The passenger side was a little short so I cut, sleeved and added a small piece. Also had to cut my hatch.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/compcut3.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/compcut4.jpg

Also I got the front fender lower bar in place. There is still a lot to add here and it’s just tacked, but I was pretty happy with how they turned out. 3 bends on 1 plane to identical pieces.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/frontfender1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/frontfender3.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/frontfender2.jpg

[cootees]

I like that a lot.

[Scrambled]

Matt there are 2 kinds of people in this world. . . those that like the smell of burning rubber and those that dont.;)

Although that way is a lil off the norm of what I prefer. LOL

Looking good my friend.:2thumbsup:

Call if you need a hand . . . you know my schedule be gentle.:D

Later
Sean

[xjmudman96]

that looks awesome matt :2thumbsup: I assume this won't be driven on the st anymore? Or do you have alternate tail light plans?

[hadfield4wd]

that looks awesome matt :2thumbsup: I assume this won't be driven on the st anymore? Or do you have alternate tail light plans?


It's still has an inspection sticker until the middle of next summer. It'll have mirrors and tail lights.

We'll see if I can get a sticker next year. I'd like to keep it inspected if just to run Potts.

[xjmudman96]

It's still has an inspection sticker until the middle of next summer. It'll have mirrors and tail lights.

We'll see if I can get a sticker next year. I'd like to keep it inspected if just to run Potts.

sweet. thought you might be doing trailer lights or something

[hadfield4wd]

Got the roof halo, A pillar and B pillar’s tacked on. Notching owns me. Other than that pretty happy so far. I have a bunch more to add in the front fender area. Then gonna work my way back.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage002.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage005.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage004.jpg

[xjtrailrider]

Looks great Matt, I'll bring the pipe by to you Friday.

[xjmudman96]

looking good matt. idon't like exo-cages, but it looks good cause you're keeping it close to the body. i like it:thumb:

[hadfield4wd]

looking good matt. idon't like exo-cages, but it looks good cause you're keeping it close to the body. i like it:thumb:

It's not really an exo. It's a hybrid. The b pillar is actually inside the door jamb. Except for the fenders the rest will be inside the body.

[hadfield4wd]

Still making progress. I have a good feel for the notching. Finished up the roof pieces and cross ties. Got the fender bars complete. I still have one piece to add, a diagonal from the front of the lower fender bar to the node where the upper bar meets the tube. Also the piece with blue tape is a piece I need to insert into the A pillar tube with a slug, I just didn’t want to lose track of it.

Also I checked for clearance the hood does open and the windshield wipers have plenty of room.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage010.jpg

This picture shows the B pillar in the door jamb, not outside like a true exo.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage009.jpg

The windshield bars are 1” sch 40. I wanted something smaller that would be in the line of site.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage006.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage007.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage008.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage015.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage011.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage013.jpg

[xjtrailrider]

Looks like you are getting a handle on it now Matt, nice work!

[TerryD]

Looks great Matt. I checked out that Blazer you were telling me about, it's a good looking build.

[FitchVA]

looking good. looking real good. :thumb:

[Scrambled]

Looks great Matt.:2thumbsup:
You figure out what you gonna do about the fuel filler yet?

Later
Sean

[hadfield4wd]

I’ve been working on it just wanted up update the thread.

Got all the fab done. The cut the halo of so I could weld the underside of everything.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage020.jpg

I also fixed the front fender I wasn’t happy with. I determined the wheel would hit the front part of the fender bar at stuff. So I cut it off, flipped the bar and welded it back together with a slug and plug welds.

Before

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/frontfender3.jpg

After

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage019.jpg

Then Jon (xjtrailrider) came over to help me get the halo back on. Thanks Jon. Then proceded to weld everything. I’m about 40% done welding. Everything is tacked in.

I also fixed the area at the a pillar with a new piece welded on with a slug.

I’m pretty happy with it.

Here are the pics.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage024.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage025.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage026.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage027.jpg

[xjtrailrider]

looks good Matt and I'm glad i could help! Call me anytime, its a short drive:D

[FitchVA]

nice! looking real good :2thumbsup:

[rubican!]

thats awesome. I cant wait to see at crozet. Plus ive been here for 2 years and have never gotten the chance to wheel with you. Should be a good time.

[bajonesy77]

Just read the whole thing from the start, very nice.:2thumbsup: This is why I got into jeeps, I love working and building things and with a jeep.......you are never done and your jeep is the prime example, we just cant leave good enough alone(as my wife says). Excellent build!

[hadfield4wd]

Here are my cut tires. I opened up the gap between the lugs in the TSL's and made the obvious ones on the Boggers.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cuttires003.jpg

I have a heater in the garage to try to heat it up so I can paint it. I also picke up my wheel wells. I'll try to get them in tomorrow.

[hadfield4wd]

Well the plastic battery box cracked the last time out and put my battery into the fan.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/batterybox4.jpg

So I whipped this up.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/batterybox3.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/batterybox1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/batterybox005.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/batterybox006.jpg

[hadfield4wd]

Battery is in



http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/batterybox007.jpg

[xjtrailrider]

Nice work! Whats up with the smoke detector, did you almost set the house on fire?:sSc_eek2:

[hadfield4wd]

Actually its a Carbon Monoxide detector.

[OverEasy]

Even worse. The silent killer.

Love the Jeep! Looking good! I to had a experience with my battery introducing itself to my fan once. Not Good. I built a similar tray but with sides! Never happen again. ;)

[Big Red 95]

man, you are going to be able to drive that thing of cliff in the grand canyon be safe. That thing is going to be sweet when you get it done.

[hadfield4wd]

Well ready for primer.

I did really go over things and found 1 area that needed attention. The C Pillar sits on 1/4” plate that is over the frame rail portion. However I realized the area that supports the bars was just hanging out there. So I added this piece. I did this on both sides.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage035.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage031.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage037.jpg

Got my wheel wells done as well. Not perfect but will keep the rocks out.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage033.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage034.jpg

The only thing that I’m not all that happy with is the fuel filler. I have some ideas for it but they’ll come later. I’m just going to use a bungee cord now because I want to go wheeling.

[xjtrailrider]

Did you go to Crozet today? On the way home from Richmond we saw a few rigs being towed heading west on 64. They past me and I was doing 80 so I guess they were in a hurry for some reason

[xjtrailrider]

Matt, did you go with LED tail lights or stay incandescent? I will be building boxes with my new quarter guards and would like to go LED and use halogen back-up lights facing rearward and to the side but i have had trouble sourcing side marker lights that can be recessed. I don't want anything sticking outward that will catch a tree trunk.

[hadfield4wd]

I went cheap incandescent. Fitch did LED's. Look a the Gen Right LED's. They make a really nice one that includes a reverse light, side marker, turn signal and marker.

http://www.genright.com/ProductInfo.aspx?productid=LED1200

I really like these but I don't need to be DOT legal. Plus my boxes are narrower and I didn't have the room for a 4" light. I'll post pics later.

[hadfield4wd]

Final pics completed.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage049.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage047.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage046.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage039.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage042.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage043.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage044.jpg

The flop

http://www.youtube.com/watch?v=qS-cHsA-6ys

That rock landed on the weakest part. I know how to strengthen it without losing too much access. I’ll be making changes stay tuned.

[MikeB78]

The best part about that was how excited the kids were to see the flop. That would be my kids I could have totaled mine and they would have thought it was the coolest thing they had ever seen. Thats what its all about getting out and enjoying it as a family. :2thumbsup:

[imehtoh]

vERY TRUE:D.And you didn't scratch the paint...:sSc_eek2:Love the astro turf ...:wings:

[hadfield4wd]

I whipped these for cheap. I just used $8 trailer lights. I wanted them flush mounted so I sandwiched the steel between the lens and the housing. I had to add a ground wire to the main mounting pieces.

The whole thing cost me less than $20. I had the steel laying around.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/taillightboxes002.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/taillightboxes004.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/taillightboxes006.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/taillightboxes005.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/taillightboxes008.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/taillightboxes007.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/taillightboxes012.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/taillightboxes011.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/taillightboxes013.jpg

[evolution]

love the flop.. glad you was ok.. sounds like the kids had a ball.. hate you tore up the cage but they make metal everyday to fix it..:2thumbsup:

so who was the one that guessed right on the flop guessing game?

[xjtrailrider]

love the flop.. glad you was ok.. sounds like the kids had a ball.. hate you tore up the cage but they make metal everyday to fix it..:2thumbsup:

so who was the one that guessed right on the flop guessing game?

I think I won the prize...whatever the prize is:rolleyes-1:

I knew Matt wouldn't let me down:D

[hadfield4wd]

the prize is a free spot up the ledge

[jhowery]

I think you driving their rig up the ledge is a better prize.

[hadfield4wd]

I think you driving their rig up the ledge is a better prize.


That's a great idea. It'll be a self esteem booster for you Jon. When do you want me to do it?

[xjtrailrider]

That's a great idea. It'll be a self esteem booster for you Jon. When do you want me to do it?

I said 2 days right? I'm sure someone else said the first day, I think it was Rubican:D

[cootees]

I said day one. Go ahead and flop my stuff on the ledge but put some new tires on it once you are done. :)

[hadfield4wd]

Well here is the damage.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage054.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage052-1.jpg

Like a said earlier I still want access to the back seat. And the rock landed at an area that had very little support. So Chris (jeepnchris) gave me this idea. This way if I did land like that again it would have the support to withstand it as the bar comes off at a node and transfers the force to the rest of the cage.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage057.jpg

While I was at it I added some door bars. And yes I can still get in the back seat.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/doorbars008.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/doorbars007.jpg

[renegade]

looks good i see u been busy

[hadfield4wd]

I had some gussets made before Harlan and welded them in.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/100_5320.jpg

Had some damage and issues with the Jeep. I ripped off the rear hatch. I saved the lifts for a cool project though. Anybody have the little mounts that they attach to? I threw out the hatch at the campground and had my brainstorm half way home.:rolleyes-1: I blew a coolant hose and it shot coolant all over my dist and wires etc. It didn't run right after this. So it's gonna get a tune up, which hasn't been done in years. It also has a manifold gasket leak and a valve cover leak. In addition the power steering was screaming and leaking my "more expensive than gold" Amsoil, I think the pump is shot. I'll need to investigate this. So it'll get some TLC. When we towed the Jeep off the trail I knew it would bash my light boxes so I took them off. The mounting area is pretty wasted so I won't be putting them back on. I'll do something different as well and clean up the wiring to the rear, as the only thing I need is the tail lights.

http://i85.photobucket.com/albums/k51/hadfield4wd/Harlan%20Sept%202010/th_DSCN3305.jpg (http://s85.photobucket.com/albums/k51/hadfield4wd/Harlan%20Sept%202010/?action=view&current=DSCN3305.mp4)

The stinger is bent from using it as a winch point to get the other xj up so I'll need to change that and well as a fragged winch cable. I have new winch rope already, however not the hawse fairlead.

[hadfield4wd]

Putting this up so I don't forget anything.

I already have most of these parts, just need to turn the wrenches.

List of things to do (short term, the long term one is too depressing):

Plugs - Done
Wires - Done
Cap - Done
Rotor - Done
Hoses (change all and bypass heater core)
Intake/exhaust manifold gasket
Fix stinger
Install limit straps
Install new shocks - Rear Done
Fix power steering pump (don't know if it's a leak or bad pump yet)
Make new taillight mounts and remount tail lights (towing that xj destroyed the mounting of my boxes so I need to redo it. Boxes are fine since I took them off before we towed.
Fix fan switch
Install new cb
Install winch rope - Done
Buy hawse fairlead and install it - Done
Diff Guard
Buy Beadlocks
Weld beadlocks onto spare rims

[hadfield4wd]

Putting this up so I don't forget anything.

I already have most of these parts, just need to turn the wrenches.

List of things to do (short term, the long term one is too depressing):

Plugs - Done
Wires - Done
Cap - Done
Rotor - Done
Hoses (change all and bypass heater core)
Intake/exhaust manifold gasket
Fix stinger
Install limit straps
Install new shocks - Rear Done
Fix power steering pump (don't know if it's a leak or bad pump yet)
Make new taillight mounts and remount tail lights (towing that xj destroyed the mounting of my boxes so I need to redo it. Boxes are fine since I took them off before we towed.
Fix fan switch
Install new cb
Install winch rope - Done
Buy hawse fairlead and install it - Done
Diff Guard
Buy Beadlocks - Done its about time wahoo although I won't have them on before the next wheeling trip
Weld beadlocks onto spare rims

updates to the jeep

[hadfield4wd]

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/100_5427.jpg

[xjtrailrider]

I almost stopped by today, I was out driving around enjoying the snow.

[hadfield4wd]

Plugs - Done
Wires - Done
Cap - Done
Rotor - Done
Hoses (change all and bypass heater core)
Intake/exhaust manifold gasket
Fix stinger
Install limit straps - Done
Install new shocks - Done
Fix power steering pump (don't know if it's a leak or bad pump yet)
Make new taillight mounts and remount tail lights (towing that xj destroyed the mounting of my boxes so I need to redo it. Boxes are fine since I took them off before we towed.
Fix fan switch
Install new cb
Install winch rope - Done
Buy hawse fairlead and install it - Done
Diff Guard
Greas front axle Ujoints - Done
Buy Beadlocks - Done its about time wahoo although I won't have them on before the next wheeling trip
Weld beadlocks onto spare rims

Going to Crozet on Friday. I better get rocking on some of this stuff. Mainly steering and exhaust/manifold gasket.

[hadfield4wd]

Plugs - Done
Wires - Done
Cap - Done
Rotor - Done
Hoses (change all and bypass heater core)
Intake/exhaust manifold gasket - Done
Fix stinger
Install limit straps - Done
Install new shocks - Done
Fix power steering pump (don't know if it's a leak or bad pump yet) - Done Thanks Jon for the loaner ps resevoir cap. Can't believe noboy in town had one.
Make new taillight mounts and remount tail lights (towing that xj destroyed the mounting of my boxes so I need to redo it. Boxes are fine since I took them off before we towed.
Fix fan switch
Install new cb
Install winch rope - Done
Buy hawse fairlead and install it - Done
Diff Guard
Greas front axle Ujoints - Done
Buy Beadlocks - Done its about time wahoo although I won't have them on before the next wheeling trip
Weld beadlocks onto spare rims

sitting in a cabin at misty mountain campground.

[xjtrailrider]

Fix power steering pump (don't know if it's a leak or bad pump yet) - Done Thanks Jon for the loaner ps resevoir cap. Can't believe noboy in town had one.

sitting in a cabin at misty mountain campground.

:thumb: No problem neighbor! Glad you opted for the cabin, its gonna get cold tonight!

[rubican!]

last time i stayed at misty mountain the cabin didnt have power in efvery room and the hot water didnt work. I hope they fixed you up. They did give me the cabin for free though so good customer service! Have fun.

[hadfield4wd]

We got a primitive cabin. Only heat. Bathrooms were down the road. Mike was great and I was happy. Great wheeling trip. Flopped once but drove out of it. No pictures of it. It was a great time. No carnage, just tore my muffler off but I was going to replace it anyway.

[rubican!]

as long as you didn't have to service your rear diff it had to be a good day. Every 300 miles whether it needs it or not.

[hadfield4wd]

Plugs - Done
Wires - Done
Cap - Done
Rotor - Done
Hoses (change all and bypass heater core)
Intake/exhaust manifold gasket - Done
Figure out why it still runs like crap and fix it. I suspect I have water in the gas tank.
Fix stinger
Install limit straps - Done
Install new shocks - Done
Fix power steering pump (don't know if it's a leak or bad pump yet) - Done Thanks Jon for the loaner ps resevoir cap. Can't believe nobody in town had one.
Make new taillight mounts and remount tail lights (towing that xj destroyed the mounting of my boxes so I need to redo it. Boxes are fine since I took them off before we towed.
Fix fan switch
Install new cb
Unstall CB Antenea
Install winch rope - Done
Buy hawse fairlead and install it - Done
Diff Guard
Greas front axle Ujoints - Done
Buy Beadlocks - Done its about time wahoo although I won't have them on before the next wheeling trip
Weld beadlocks onto spare rims

[Scrambled]

Who machined the beadlock rings Matt they look pretty good!

Do not I repeat do not disable the heater in that thing you will regret it my friend!
Wheeling the Scrambler with the heat wide open and no doors not so bad. Wheeling lucky with no heat is not fun!!

I know you yankees are a lil more tolerant to the cold than the rest of us but think about poor Gabe.:rotflmao5:

Dropping the gas tank not so bad. If you have a suction pump remove what you can first then drop it. Mighty Vac suction pump I use is around $89 from northern tools. Works great on diffs, t-cases, etc as well. You can also get a brake bleeder kit for it,makes the job alot faster and better results.

Another thing that makes it easier is a tank dolly. Pick a floor jack remove the cup fab a balanced brace to support the tank. Makes it alot easier to remove tank and comes in handy putting cross members, skid plates,etc in by yourself.

Give me a call if you cant figure out why its not running right and I bring the scanner over. Cant make it till after the first though.

Later
Sean

[hadfield4wd]

Who machined the beadlock rings Matt they look pretty good!


They are Aero Race Wheels. I got them through Trailhead Customs. Aero is big in the Cricle Track parts. The only have 13" and 15". But you can get their wheels already beadlocked in 5x4.5 and 5x5. Which has almost every Jeep made since 1988 covered. They are also much lighter than other weld on options. Most 1/4" weld on options are 20 - 28lbs. Then add this to a 20lb rim and you have some serious rotational mass to break things. These rings are only 7lbs with hardware.



Do not I repeat do not disable the heater in that thing you will regret it my friend!
Wheeling the Scrambler with the heat wide open and no doors not so bad. Wheeling lucky with no heat is not fun!!

I know you yankees are a lil more tolerant to the cold than the rest of us but think about poor Gabe.:rotflmao5:


Well my exhaust runs under the passenger side it gets mighty hot. I've melted shoes. Plus Gabe is from NY he can handle it.


Dropping the gas tank not so bad. If you have a suction pump remove what you can first then drop it. Mighty Vac suction pump I use is around $89 from northern tools. Works great on diffs, t-cases, etc as well. You can also get a brake bleeder kit for it,makes the job alot faster and better results.

Another thing that makes it easier is a tank dolly. Pick a floor jack remove the cup fab a balanced brace to support the tank. Makes it alot easier to remove tank and comes in handy putting cross members, skid plates,etc in by yourself.


I know how to do it, it's just a pain. Have you seen my gas tank skid? Anyway if I drop the tank it won't go back into the stock spot. And I don't have the time right now to do what I want with it. I'm thinking about jumping my fuel pump and draining it that way. But I don't want to do that until I can fill it with good gas. So for now it has dry gas in it.



Give me a call if you cant figure out why its not running right and I bring the scanner over. Cant make it till after the first though.


Thanks for the offer.

[Scrambled]

Sounds like your "radiant" heat system works pretty good if your melting shoes my friend.:harhar:
Even without carpet it shouldnt get that darn hot if running correctly. Sounds like it's running quite rich to generate that much heat from the cat. Would explain some of your driveability issues you been facing lately. Out of curiosity you have a heat shield still on the rig?

Cant say I blame you for not wanting to drop the tank and the skid more than once!
The dolly makes it easier throw one together when you get a chance. Made mine out of scrap square tubing even used it to put an axle back in a couple times.

Dont forget to add a fuse to the jumper when you jump the tank circuit . . . that can become an expensive mistake. LOL

You planning on custom tank when you pull the old one or fuel cell?

Later
Sean

[hadfield4wd]

Sounds like your "radiant" heat system works pretty good if your melting shoes my friend.:harhar:
Even without carpet it shouldnt get that darn hot if running correctly. Sounds like it's running quite rich to generate that much heat from the cat. Would explain some of your driveability issues you been facing lately. Out of curiosity you have a heat shield still on the rig?

No heat shields or carpet and the cat is about 1/8" from the floor. Its always been this hot inside. At least for the last 4 years. the running issue is only the last 2 trail rides. Pretty sure its bad gas. I just need to take some out to see. Idles great.



You planning on custom tank when you pull the old one or fuel cell?

Well I'd like a high zoot fuel cell, however going with the fact that I'm cheap means I'll just put my exisitng tank in the back.

On a happy note the beadlocks are welded up and the rims are completely painted. 3 coats. They are drying in my office where its warm. Also got all my tires unmounted on from the old rims. Should have these done next week

[Scrambled]

Well time to make use of all that wasted radiant energy and install a burrito cooker under the seat. I bet by lunch time you would have a frozen burrito just about perfect. :yup:;)

I understand being cheap( I prefer the term cost effective though) but factory fuel tank in the back just looks like poop.


Im running into a similar problem with the tank on the Commando to clear the 4 link and shocks.

Maybe get some dimensions and see what Chris would charge to TIG weld a custom tank out of aluminum?
His fab work is top notch!:2thumbsup:

[hadfield4wd]

I understand being cheap( I prefer the term cost effective though) but factory fuel tank in the back just looks like poop.


Um have you seen what the rest of my jeep looks like?



Maybe get some dimensions and see what Chris would charge to TIG weld a custom tank out of aluminum?
His fab work is top notch!:2thumbsup:

If I was going to do this I would just get a fuel cell with all the pickups etc. But to put one in right with working fuel gauge and tip valve is $500. Just not gonna do it. Plus you won't see my tank in the rear. It'll be covered. Plus when I do this I'll stretch the rear.

[hadfield4wd]

Well I have needed beadlocks for a long time. Just about every trip I lose a bead or bend a rim or both. I have had an extra set of rims around the house in order to get a weld-on kit. However I have a problem with the weld-on kits. They all are very heavy. Anywhere from 20-28 lbs. Added to a rim and you’re talking about a close to 40lb rim. I already break shafts so that much added rotational mass would only add to the situation.

So I have spent a lot of time looking into the different options. I thought about going to aluminum rims and internal beadlocks like the Inner Air locks. But I felt I’d need a strengthening ring to weld to the outer lip so I didn’t break a rim. That is when I stumbled on Aero Race Wheels (www.aeroracewheels.com). I purchased mine through www.trailheadcustoms.com. They build wheels for dirt track cars. They only come in 15”. They have a DIY kit that is relatively inexpensive and is very light comparatively. The DIY kit they sell is only 7.2lbs with hardware, which is amazing. Also because the outer ring has a shape to it, you don’t need to worry about coning or centering the tire. Also if you want to go even lighter they have an aluminum outer ring that will save you another 1.5lbs. Anyway here is a chart that I did to compare the weights.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/Beadlock-1.jpg

You can see that buy going aluminum I wouldn’t save any weight. I weighed my rims after I welded the beadlocks with the hardware and they are right at 28lbs. Now keep in mind there is a lot of variation in rim weights. The unbeadlocked steelies I took off were considerably heavier than what I started with. They weighed in at 26lbs. So I had a net gain of 2.5lbs per wheel. I’m pretty happy with this.

Ok back to Aero. I was very pleased with the quality. The inner ring holes all had nutserts installed so no need to use a box wrench on a nut on the back side when torqueing down the bolts.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/100_5427.jpg

One thing I was surprised by was that the inner ring only had 16 nutserts and holes and the outer ring had 32 holes. If I had read their webpage better I would have seen this. The other thing I was surprised about was that the bolts were 5/16’s and not 3/8’s like most other manufacturers recommend. In addition the bolts were just case hardened and not grade 8. So I went to the local Fastenal and bought 64, grade 8 5/16’s flange bolts. I spoke with tech support at Aero and they don’t think the number or size of the bolts will make a huge difference for my application. The bolt heads are protected from rocks by the ring and they use this setup on 800hp sprint cars. They did suggest checking the torque regularly as most of their users change tires every week. Only time would tell.

The powder coating on the outer rings is very good. These are 1/8” but with the pressed outer, that adds a lot of strength over a flat piece of steel like most DIY kits. There is also a mounting flange for a mud cover that I’m not using and was tempted to cut off. Maybe I’ll do that at a later date. In addition all my valve stems had to be relocated. With the beadlocks on they pointed directly at the inner ring. It would make it virtually impossible to fill with air. So I used a solid rod to fill the gap and welded the holes closed. Then I redrilled holes out of the way.

The welding was pretty easy. I took my time and prepped everything well. Ground the rim and the inner ring then wiped them down with acetone. Due to the fact that these are not ¼” thick they sit further down in the rim than other DIY kits so I tacked them in then very carefully cut 3/16” off of the rim. This way the weld surface was flush. Here are the pictures completed and mounted on the Jeep.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/Beadlocks.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/100_5486.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/100_5487.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/100_5485.jpg

If you’re interested in Aero Race Wheels they don’t sell directly you have to go through a vender. You can e-mail Josh at Trailhead Customs for pricing.

josh@trailheadcustoms.com

Also on a side note they have complete beadlock rims in 5 x 4.5 and 5 x 5. The 2 most popular Jeep bolt patterns. They have various backspacing and colors. They are also really light at 23lbs each.

[hadfield4wd]

Plugs - Done
Wires - Done
Cap - Done
Rotor - Done
Hoses (change all and bypass heater core)
Intake/exhaust manifold gasket - Done
Figure out why it still runs like crap and fix it. I suspect I have water in the gas tank.
Fix stinger
Install limit straps - Done
Install new shocks - Done
Fix power steering pump (don't know if it's a leak or bad pump yet) - Done Thanks Jon for the loaner ps resevoir cap. Can't believe nobody in town had one.
Make new taillight mounts and remount tail lights (towing that xj destroyed the mounting of my boxes so I need to redo it. Boxes are fine since I took them off before we towed.
Fix fan switch
Install new cb
Unstall CB Antenea
Install winch rope - Done
Buy hawse fairlead and install it - Done
Diff Guard
Greas front axle Ujoints - Done
Buy Beadlocks - Done its about time wahoo although I won't have them on before the next wheeling trip
Weld beadlocks onto spare rims - Done

[FitchVA]

looking good matt.

[Scrambled]

Um have you seen what the rest of my jeep looks like?

OK that one is just way to easy so Im gonna let it go.;)

If I was going to do this I would just get a fuel cell with all the pickups etc. But to put one in right with working fuel gauge and tip valve is $500. Just not gonna do it. Plus you won't see my tank in the rear. It'll be covered. Plus when I do this I'll stretch the rear.

My biggest concern with it is not looks but saftey as Im sure you have thought of as well. Cant just throw a fuel cell in the back and load up the kids and drive down 81. Not Gonna Happen.:sSc_eek2:
Im planning on using sending unit from existing tank and filler tube from early CJ and have Chris fab one out of aluminum to fit my needs.
Thoughts?

The beadlocks look great btw!:2thumbsup: Very thorough write up ,looks like you did your homework as usual bro.

Later
Sean

[hadfield4wd]

Whats unsafe about a fuel tank vs a fuel cell in the rig? Keep in mind it's open, and doesn't go on the highway. It's really no different than a fuel cell. Also with several rolls and flops I know mine doesn't leak.

Fabbed tanks are nice and can be fit into places others can't, but aren't really any safer. If I ever did a cell I'd call these guys for the pickup. They'll do it in any cell.

http://www.pirate4x4.com/forum/showthread.php?t=918970&highlight=

[Scrambled]

[QUOTE=hadfield4wd;11637]Um have you seen what the rest of my jeep looks like?

Ok that one is just too easy so Im gonna let it be. LOL

I though you had planned on keeping the XJ "street legal" for awhile longer?

If you have minimal street usage in mind I suppose it would be fine.

I saw an XJ based buggy at Big Dogs this year that had actually done a great job recessing and reusing the fatory tank in the rear. Wish I had got a couple pics of it now.:rolleyes-1:

Thanks for the link:2thumbsup:, I shouldnt have to go that far though with the Commando's set up as the Howell kit is pretty easy to plumb.

Im doing a lil reasearch on baffles for the custom tank we have planned. Cant decide whether I really need em or not? Oh well I keep researching I guess.


Later
Sean

[hadfield4wd]

I though you had planned on keeping the XJ "street legal" for awhile longer?

If you have minimal street usage in mind I suppose it would be fine.


No more ont he street, unless we get a couple feet of snow. My insurance company was going to drop my unless I took it off the policy. Also I would have a really hard time getting a sticker for it. So I turned in the tags. It's a trailer queen only.




I saw an XJ based buggy at Big Dogs this year that had actually done a great job recessing and reusing the fatory tank in the rear. Wish I had got a couple pics of it now.:rolleyes-1:


I'm not gonna recess mine. I've seen a bunch done this way. I want mine fully in the back because I can then stretch the rear.

[cootees]

No more ont he street, unless we get a couple feet of snow. My insurance company was going to drop my unless I took it off the policy. Also I would have a really hard time getting a sticker for it. So I turned in the tags. It's a trailer queen only.

How did the insurance company know what you were using it for?

[hadfield4wd]

How did the insurance company know what you were using it for?

Well we switched company's (for a number of reasons) and they asked if any of our vehicles were changed from stock configuration. I said yes then they asked for a list of modifications. I wasn't going to lie so I told them. They then sent the agent out to take pictures. It was downhill from there. I tried to get some offroad insurance etc to no avail. Keep in mind if you have modifications to a vehicle and you don't tell them, they won't insure it for those. So if you have a winch and it gets stolen they most likely won't pay for it. They have to know what they are insuring. Same with stereo's. Otherwise as far as they are concerned they are just insuring a stock vehicle.

[rubican!]

i really like those beadlocks. Might look into seeing what it would take to convert my cragars once i get my new rims in. Of course it would get old changing tires everytime you wanted to go wheeling. But those def make me want to hang on to my cragars.

[hadfield4wd]

Keep in mind they only come in 15". I'm 99% sure 15's will fit on a JK rubi. I could weld on other DIY beadlocks if you're interested. If you want to go to 15's then it would be less expensive to buy their rims. Trust me on this on. You don't want to swap tires on rims. It's a real pain. When I unmounted my tires I broke my HF manual tire mounter on the last one and had to take it off with my tire spoons. Talk about a pain.

If you're going to do it get a set of wheeling tires and a set of driving tires. Have them both mounted. Then put your beadlocks oun your trailer and drag them with you.

[hadfield4wd]

Plugs - Done
Wires - Done
Cap - Done
Rotor - Done
Hoses (change all and bypass heater core)
Intake/exhaust manifold gasket - Done
Figure out why it still runs like crap and fix it. I suspect I have water in the gas tank.
Fix stinger
Install limit straps - Done
Install new shocks - Done
Fix power steering pump (don't know if it's a leak or bad pump yet) - Done Thanks Jon for the loaner ps resevoir cap. Can't believe nobody in town had one.
Make new taillight mounts and remount tail lights (towing that xj destroyed the mounting of my boxes so I need to redo it. Boxes are fine since I took them off before we towed.
Fix fan switch
Install new cb
Unstall CB Antenea
Install winch rope - Done
Buy hawse fairlead and install it - Done
Diff Guard - Done what a pain. The bottom 3 bolts were worn down so I had to weld a bolt onto each one hten get them out.
Greas front axle Ujoints - Done
Buy Beadlocks - Done its about time wahoo although I won't have them on before the next wheeling trip
Weld beadlocks onto spare rims - Done


Really knocking the list out.

[cootees]

Well we switched company's (for a number of reasons) and they asked if any of our vehicles were changed from stock configuration. I said yes then they asked for a list of modifications. I wasn't going to lie so I told them. They then sent the agent out to take pictures. It was downhill from there. I tried to get some offroad insurance etc to no avail. Keep in mind if you have modifications to a vehicle and you don't tell them, they won't insure it for those. So if you have a winch and it gets stolen they most likely won't pay for it. They have to know what they are insuring. Same with stereo's. Otherwise as far as they are concerned they are just insuring a stock vehicle.


Thats crazy. I have switched insurance a few times in the past few years and not once have I been asked about modifications. Only thing i have told them is the 4runner is just a weekend pleasure vehicle.

[hadfield4wd]

Plugs - Done
Wires - Done
Cap - Done
Rotor - Done
Hoses (change all and bypass heater core)
Intake/exhaust manifold gasket - Done
Figure out why it still runs like crap and fix it. I suspect I have water in the gas tank.
Fix stinger - Done
Install limit straps - Done
Install new shocks - Done
Fix power steering pump (don't know if it's a leak or bad pump yet) - Done Thanks Jon for the loaner ps resevoir cap. Can't believe nobody in town had one.
Make new taillight mounts and remount tail lights (towing that xj destroyed the mounting of my boxes so I need to redo it. Boxes are fine since I took them off before we towed.
Fix fan switch
Install new cb
Unstall CB Antenea
Install winch rope - Done
Buy hawse fairlead and install it - Done
Diff Guard - Done what a pain. The bottom 3 bolts were worn down so I had to weld a bolt onto each one hten get them out.
Greas front axle Ujoints - Done
Buy Beadlocks - Done its about time wahoo although I won't have them on before the next wheeling trip
Weld beadlocks onto spare rims - Done

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/100_5512.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/100_5514.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/100_5515.jpg

[hadfield4wd]

Plugs - Done
Wires - Done
Cap - Done
Rotor - Done
Hoses (change all and bypass heater core)
Intake/exhaust manifold gasket - Done
Figure out why it still runs like crap and fix it. I suspect I have water in the gas tank. - In progress
Fix stinger - Done
Install limit straps - Done
Install new shocks - Done
Fix power steering pump (don't know if it's a leak or bad pump yet) - Done Thanks Jon for the loaner ps resevoir cap. Can't believe nobody in town had one.
Make new taillight mounts and remount tail lights (towing that xj destroyed the mounting of my boxes so I need to redo it. Boxes are fine since I took them off before we towed.
Fix fan switch - Done
Install new cb
Install CB Antenea - Done
Install winch rope - Done
Buy hawse fairlead and install it - Done
Diff Guard - Done what a pain. The bottom 3 bolts were worn down so I had to weld a bolt onto each one hten get them out.
Greas front axle Ujoints - Done
Buy Beadlocks - Done its about time wahoo although I won't have them on before the next wheeling trip
Weld beadlocks onto spare rims - Done


I was able to drain the tank pretty easily. I tried to siphon it, but apparently I suck at it (pun intended). My manual pump wouldn't do it. So I just jumped my fuel pump and had the line go into a 5 gallon can. Then I put it in my van. We'll see if it's bad gas, but I don't think so. I think it's a pickup problem. I didn't have time to pull the pickup as my son had bball and my daughter was in district band. I need to go back and grind some off my diff guard. It hangs below the casting and it is leaking so I need to pull it and torque it right. I hope I didn't ruin my lube locker gasket by welding to the bolts, but I had no other way to get them out. Also last time at Crozet with the new pump it didn't turn fast enough so I'll have to do the valve mod in the pump. All in all making forward progress.

[xjtrailrider]

Did you eliminate the ballast resistor from the fuel pump circuit? I'll bet you don't see any difference in performance but I think your fuel pump is gonna love it! I ditched mine on the 90 XJ 4 years ago when I installed the new fuel pump and it has worked great.

[hadfield4wd]

No I didn't. I don't like to make changes to things while I'm trouble shooting. Once I get it running like it should I'll be making the change. I was amazed how much fuel that thing pushed. I basically emptied my gas tank of 15 gallons of fuel in 20 minutes. That was 12 volts directly from the battery.

[hadfield4wd]

Plugs - Done
Wires - Done
Cap - Done
Rotor - Done
Hoses (change all and bypass heater core)
Intake/exhaust manifold gasket - Done
Figure out why it still runs like crap and fix it. I suspect I have water in the gas tank. - Done for now
Fix stinger - Done
Install limit straps - Done
Install new shocks - Done
Fix power steering pump (don't know if it's a leak or bad pump yet) - Done Thanks Jon for the loaner ps resevoir cap. Can't believe nobody in town had one.
Make new taillight mounts and remount tail lights (towing that xj destroyed the mounting of my boxes so I need to redo it. Boxes are fine since I took them off before we towed.
Fix fan switch - Done
Install new cb
Install CB Antenea - Done
Install winch rope - Done
Buy hawse fairlead and install it - Done
Diff Guard - Done what a pain. The bottom 3 bolts were worn down so I had to weld a bolt onto each one hten get them out.
Greas front axle Ujoints - Done
Buy Beadlocks - Done its about time wahoo although I won't have them on before the next wheeling trip
Weld beadlocks onto spare rims - Done
Modify stock PS pump for faster steering


Did you eliminate the ballast resistor from the fuel pump circuit? I'll bet you don't see any difference in performance but I think your fuel pump is gonna love it! I ditched mine on the 90 XJ 4 years ago when I installed the new fuel pump and it has worked great.

Well I got time to pull the pickup which is what I suspected as the issue. I figured the tube I had replacing the pump was rusted or something. Turned out it was perfect. Jsut as new as the day I put it it 3 years ago.

So because Jon is usually right about these things I ditched the ballast resistor. So I have a full 12v going to the pump. I did call summit and they said that 6v would cut everything down and shorten the life of the pump. I do carry a spare so I going to see what it does. I won't know until next wheeling trip, whenever that is. If it dies out again I'll throw the new pump on. Since it's external I figure I can do it in 15 minutes. I added a couple to my list, but it's almost done. I need to pick up my CB from Phil and get it in.

[hadfield4wd]

Plugs - Done
Wires - Done
Cap - Done
Rotor - Done
Hoses (change all and bypass heater core)
Intake/exhaust manifold gasket - Done
Figure out why it still runs like crap and fix it. I suspect I have water in the gas tank. - Done for now
Fix stinger - Done
Install limit straps - Done
Install new shocks - Done
Fix power steering pump (don't know if it's a leak or bad pump yet) - Done Thanks Jon for the loaner ps resevoir cap. Can't believe nobody in town had one.
Make new taillight mounts and remount tail lights (towing that xj destroyed the mounting of my boxes so I need to redo it. Boxes are fine since I took them off before we towed. - Done
Fix fan switch - Done
Install new cb
Install CB Antenea - Done
Install winch rope - Done
Buy hawse fairlead and install it - Done
Diff Guard - Done what a pain. The bottom 3 bolts were worn down so I had to weld a bolt onto each one hten get them out.
Greas front axle Ujoints - Done
Buy Beadlocks - Done its about time wahoo although I won't have them on before the next wheeling trip
Weld beadlocks onto spare rims - Done
Modify stock PS pump for faster steering - Done

Well I just need to put the new CB in. The front diff gasket is leaking where I put the diff guard on. I just bolted it on and I didn't torque them like Lube locker says. I did ahve to weld bolt heads to the existing worn down bolts to get them off because they were so worn down from rocks. I hope I didn't ruin the lube locker. I'll take it off this week. I'll also clearance the diff guard a little bit as it seems to hang down a little lower than the diff. I'm pretty sure I've worn away a bunch of material off the diff.

Also as I have the mounts made the tail lights still don't work. It seems I have a bunch of wiring issues in the back. Theres about 20 wires in the loom and none seem to do what the diagram says they are supposed to do. So the next thing to tackle is just to rewire the back. There is so much there I don't need. All I need is stop, taillights and fuel pump. This thing still has all the speaker wires, defrost, rear wiper etc, etc, etc. It's a mess. So we'll see I'm not in a rush to do this. I hate wiring. Maybe I'll bride Gabe with beer and food to get him to come over to help.

Wheeling in 2 weeks. Still no tow rig, but I did make a low ball offer on one so we'll see.