96 xj

[xjmudman96]

I had no idea what would be in the cards for this heep when I got it. My intention was to trade my full size gas-guzzler chevy in for something I could hawl my rugrats around in. But what I got was a new addiction:yup:

As of now I have installed the following:

3" Zone add a leaf and new coils
33x10.50 BFG mudders
Airaid intake and trottle body spacer
yakima crossbars and load warrior basket
4 auxilary lights
midland cb and firestick anteanna
homebrew T-case drop out ot body lift blocks
stinger style brush guard/skid plate off a toyota
removed rear sway bar
cut out fenders ( too much) :mad:
curt tubular hitch with slide in shackle mount
jvc cd/mp3 kicker 12 and pioneer ampwith copacitor
I think I'm up to 4 power steering pumps now as well


working now on tearing out seats and carpet to reinforce floorboards, then I'm going to spray some kind of liner in. Haven't decided what kind yet.
Pics coming soon

[xjmudman96]

I took advantage of the warm weather today and got started on strippingn it down
http://i459.photobucket.com/albums/qq314/xjmudman96/100_0309.jpghttp://i459.photobucket.com/albums/qq314/xjmudman96/100_0315.jpghttp://i459.photobucket.com/albums/qq314/xjmudman96/100_0319.jpghttp://i459.photobucket.com/albums/qq314/xjmudman96/100_0318.jpg
That's alot of rust, and alot of ginding and welding. But I enjoy this so much. It's especially nice to be able to not depend on this jeep for primary transportation. More pics coming...

[Scrambled]

Hey Kevin looks like you got some metal work to do bro.
Try the Herca-liner kit ,as far as DIY bedliners go it's my favorite. Remember to scuff and degrease the floor before you start. The more time you spend on prepping the surface the better the outcome and longevity of the coating. Once youv'e done a good cleaning of the surface scuff it all with a scotch pad remove any debris then wipe it all down with acetone.

Later
Sean

[xjmudman96]

This is what's interferring wiyh my 4x4 shifting. The floor panel has rusted away where the linkage was bolted and the lever won't stay in the bracket. I think I'm gonna try to get a new bracket to bolt to the metal I replace. Whoever had this thing before me must of had to drive through the swamp everyday. http://i459.photobucket.com/albums/qq314/xjmudman96/100_0314.jpg

this is the tierod/drag link I'm gonna try to stick inhttp://i459.photobucket.com/albums/qq314/xjmudman96/100_0305.jpg

You can't really tell from the pic, but it is much thicker than the o.e. ones.
this is why I'm replacing themhttp://i459.photobucket.com/albums/qq314/xjmudman96/100_0302.jpg<a href="http://s459.photobucket.com/albums/qq314/xjmudman96/?action=view&current=100_0303.jpg" target="_blank">http://i459.photobucket.com/albums/qq314/xjmudman96/100_0303.jpg

[xjtrailrider]

Kevin, whats up with that "pinched spot" on the DL, that would worry me some. You may want to sleeve that area or something.

http://i459.photobucket.com/albums/qq314/xjmudman96/100_0305.jpg

[cootees]

That is substantially a larger portion of rust than I had to deal with. Never the less I feel your pain. Thats not a fun task to do.

The only suggestion I have for you is that if you are not going to buy a premolded floorpan then get yourself an air nibbler from harbor freight($20) it will make cutting the sheet metal so much easier.

[xjmudman96]

The pinched spot is where the stablizer ties in @. As for the task of removing the rusted areas I just using an angle grinder. Then once I've got all the trash out I'm gonna just piece in sheet metal. Yeah, this is alot of work I know, but I don't have the $ to buy a pre-molded anything:D so I gotta do what I am allowed finacially. I got a good friend down at R>C> restoration in salem that I'm gonna stop by and talk to this week, hopefully he can give me some ideas. I think I'm gonna have to drop the gas tank in order to get the cargo area welded, without blowing myself up. :yup:
http://i459.photobucket.com/albums/qq314/xjmudman96/100_0320.jpg
You can see the gas tank right under where I'll have to patch. what do you guys think, should I drop it?

[cootees]

I would drop it if I were you. If you are using an angle grinder to cut that stuff out. the gas tank sits butted up to the floor pan and it would be too easy to slice it and throwing sparks there would not be pretty.

I used two angle grinders when I was cutting mine out. One with a cutting wheel and one with a grinding wheel to grind down the spot welds on the unibody. Once the spot welds are ground off, it should be fairly easy to pull up large sections of the floor.

[xjtrailrider]

The pinched spot is where the stablizer ties in @.


OK, but is it solid stock there?

I like the stock steering with a heavier tie rod, works good for me and others

I picked up the Big Daddy tie rod for $99 and even though it was a PITA to install, its pure beef!

[Scrambled]

I've got the tie rod and drag link from Big Daddy off road on the Scrambler and I love them.
As Jon put it they are Beef. As far as the gas tank goes definately drop it before you start.

How bout some more info on the steering set up. That fold in the DL concerns me.

Later
Sean

[xjtrailrider]

How bout some more info on the steering set up. That fold in the DL concerns me.


Me too, I don't wanna see anyone get hurt

[rubican!]

i was up at old dominion the other day to see about some seats and theyhad a couple XJ's. If anything else you could get a stock one off of one of them for cheap.

[xjmudman96]

i was up at old dominion the other day to see about some seats and theyhad a couple XJ's. If anything else you could get a stock one off of one of them for cheap.

That would be like giving up on on her. I just can't do it. It might take me all spring and half the summer, but I'm not willing to let her die just yet buddy. :boohoo:

[xjmudman96]

Iguess I'm maturing in the 4x4 world. I am selling my sub and amp for money to order some AJ's rockrails:thumb: Is that growth or what you guys?:)

[Scrambled]

Now your sarting to get it.:yup:

Subs come after armor ,gears ,lockers etc. And eventually they go by by cause they take up to much room.

It just gets worse from here Kevin. Welcome to our addiction.:D

Later
Sean

[xjtrailrider]

Funny, I just put a sub in mine. Its a old Sparkomatic bass tube that I cut short so I could squeeze it in the back. It sounds like but though!

I just like my Bluegrass and Hank Jr to have a little bump :boohoo::clap2:

[xjmudman96]

I just like my Bluegrass and Hank Jr to have a little bump :boohoo::clap2:[/QUOTE]

Hey, there aint nothin wrong with bassy bluegrass!:2thumbsup:

[xjmudman96]

I decided to take you guys advice ( as usual) and while the weather permitted today I got my explosive hazard down to a minimun. :D

http://i459.photobucket.com/albums/qq314/xjmudman96/100_0338.jpg

http://i459.photobucket.com/albums/qq314/xjmudman96/100_0339.jpg

http://i459.photobucket.com/albums/qq314/xjmudman96/100_0340.jpg

Now I can really start operating! I might just strip the whole cargo area and try to cut and fit one solid piece back in. I was planning on just doing little patch work here and there, but this is a whole lot of rust. I don't just want to put a bandage on this thing, I'd like know that once I'm done I can wheel this thing pretty hard for a long time without having to revisit this style project.

[xjmudman96]

well I've made a little progress. I got all the pans fitted to go down and got some all thread to hang my gas tank back up with. I started to buy new hanging straps, but low budget motivated me to try and re-surface the old ones. It worked out great, they look like new ones now. The tricky part is gonna be getting the t-case shifter linkage bolted back on to the new metal. I will take some pics this weekend. It's just been too cold out there:rolleyes-1:

[xjmudman96]

Wow, I'm glad this almost done. It's been tough not being able to go wheelin the past couple weeks. I got the floors ready for liner now. I think I'm gonna go with the duplicolor stuff @ advanced. I haven't heard any negative feedback about it, and it's half the cost of Herc. I may regret it, but once again my low budget is motivating me.
Here are some pics of my new floor all sealed up and ready to roll...

http://i459.photobucket.com/albums/qq314/xjmudman96/thejeepbuild004.jpg http://i459.photobucket.com/albums/qq314/xjmudman96/thejeepbuild003.jpg http://i459.photobucket.com/albums/qq314/xjmudman96/thejeepbuild002.jpg http://i459.photobucket.com/albums/qq314/xjmudman96/thejeepbuild001.jpg

Not too many flops on this project so far. I forgot that I had to get to my gas tank spout so had to cut an access hole out
http://i459.photobucket.com/albums/qq314/xjmudman96/thejeepbuild006.jpg

Also I got a little "trigger happy" with the seam sealer and didn't notice it was dipping down on my tire
http://i459.photobucket.com/albums/qq314/xjmudman96/thejeepbuild011.jpg

I also got some new stickers in the mail last week!! ( i have a bit of a sticker problem ) check it out..
http://i459.photobucket.com/albums/qq314/xjmudman96/thejeepbuild009.jpg http://i459.photobucket.com/albums/qq314/xjmudman96/thejeepbuild010.jpg http://i459.photobucket.com/albums/qq314/xjmudman96/thejeepbuild008.jpg

The next thing to do is of course hang my gas tank back up. I also have to relocate the transfer case shifter linkage.
http://i459.photobucket.com/albums/qq314/xjmudman96/thejeepbuild007.jpg

[xjtrailrider]

Nice work Kevin. When my Heep needs floors I'll give you a call:D

[95greenrio]

I used the Duplicolor bedliner on my YJ but there's Herculiner on there now haha. I think my problem was mainly poor preparation though, that was the first semi-major project I did on my Jeep and I had no idea what I was doing. The Duplicolor doesn't have as much texture as Herculiner and there is a noticeable difference between the roll on Duplicolor and the spray can stuff, the spray can stuff kind of looks like a powdercoat and the roll on just looks like rubberized paint. Good luck with the lining and remember good preparation is key, I spent three days cleaning mine out and getting it ready to put on the Herculiner last summer and it turned out great.

[TrailReadyMJ]

Looks great Kevin!

I too had issues with the Duplicolor stuff in my old XJ, but also didn't do a ton of prep. I won't use their roll on anymore, but I kinda like the spray on stuff for bumpers, sliders, etc... That's just because it's easy to touch up, and beating them on rocks will end up taking the finish off, no matter what you use.

Either way, the MJ will probably be getting Herc in the cab and bed (Actually using bedliner as bedliner? That will be a first for me :D ).

As mentioned the Duplicolor is almost more of a paint, where the Herc is much thicker and can easily be textured depending on the applicator you use. It also gives off more fumes, which means there is a stronger chemical reaction going on while drying/curing, generally making it a stronger product.

You will also need fewer coats with the herc to get a nice thick layer, so in the end, it probably wouldn't cost much more.

Oh, and whatever you do, don't get it on your "hootus"! http://www.explorerforum.com/forums/showthread.php?t=18595

[xjtrailrider]

Oh, and whatever you do, don't get it on your "hootus"! http://www.explorerforum.com/forums/showthread.php?t=18595


:rotflmao5:Thats some funny chit there! I didn't read all 13 pages of posts but dang....I'm still laughing at the 3 pages I did read!

I also found it amusing and disturbing that people actually spend money building up and lifting Exploders. I've had 2 and they are/were JUNK.

[hadfield4wd]

Don't relocate that shifter. The xj shifter sucks. You'll be further ahead getting this one from Novak.

http://www.novak-adapt.com/catalog/kit_sk2x.htm

[xjtrailrider]

Don't relocate that shifter. The xj shifter sucks. You'll be further ahead getting this one from Novak.

http://www.novak-adapt.com/catalog/kit_sk2x.htm

Thats on my list as well but it keeps getting knocked down for other things, I want one though.

[Scrambled]

Looking good Kevin. Glad to see you are almost ready for the trail again. I've used the Herca-liner on a few projects and had great results. Never used the dupli-color stuff thoug.

Later
Sean

[xjmudman96]

I have decided to go with Herc. I was planning on it from the beginning, but tried to save a few bucks. After reading up on the dupli-crap it won't give me the texture I'm looking for.
I'm not relocating the shifter, just re-mounting the linkage bracket. But with the T-case dropped down an inch now I think it will be a little farther down the hump. I got my gas tank in today thanks to Brandon, so I went to start it up and discovered my battery is toast. Then I tried to yank it out and the post tried to come out along with the connector. I am budgeting in an optima next month. :yup:
http://i459.photobucket.com/albums/qq314/xjmudman96/thejeepbuild012.jpg

For now I am going to take a break from all this jeep crap and do a little bit of nothing. Gotta keep some kind of a balance.

[hadfield4wd]

I'd put carpet back on your floor. It gets way hot in my jeep.

Also dump a mixtore of water and baking soda on the battery terminal. That'll take care of the corrosion. Coat it with vaseline when you put the new one on.

[TrailReadyMJ]

Also dump a mixtore of water and baking soda on the battery terminal. That'll take care of the corrosion. Coat it with vaseline when you put the new one on.
X2. A good ol' can of cola works great as well (any soda, the more fizz the better). Just wash it off when you're done so things don't get sticky.

[YJeXtreme]

Go for the herculiner kit, Advance has it on sale right now for 69.99 that's $30 cheaper than autozone, Believe sale is good until 3/25 from what an employee/friend told me.

[xjmudman96]

I'd put carpet back on your floor. It gets way hot in my jeep.

Yeah, I've noticed the heat factor. I drove it to work today to show the guys there what I'd done so far and on the way back home today it got kinda toasty:Hot03: I guess I'll just have to go doorless on those hot days on the trail :wings:

[xjmudman96]

Here is what I thought was gonna be the worst part of gettin my heep back together. It turned out to be fairly easy with a little help from a friend @ Advance. I got sway-bar link bushings for a hayndai accent and some long grade 8 bolts, some washers and nuts and it works better than it ever has.

http://i459.photobucket.com/albums/qq314/xjmudman96/000_0001.jpg

http://i459.photobucket.com/albums/qq314/xjmudman96/000_0002.jpg

http://i459.photobucket.com/albums/qq314/xjmudman96/000_0003.jpg

I probablly could have gotten shorter bolts, but Hey, It works

[xjtrailrider]

I have no carpet or even herculiner, it gets hot in the summer(until I turn on the AC:D)

But the parts Cherokee is donating some carpet and better looking seats.

[xjmudman96]

Well I finally talked my boss into letting me use the shop to finish this project, so where is your power now rain??:harhar: I have to go back today and put everything back together, will have pics up later on this evenig. Definately impressed with the Herculiner, looks very thick and durable.

[xjmudman96]

http://i459.photobucket.com/albums/qq314/xjmudman96/100_0462.jpg

http://i459.photobucket.com/albums/qq314/xjmudman96/100_0460.jpg

http://i459.photobucket.com/albums/qq314/xjmudman96/100_0461.jpg

http://i459.photobucket.com/albums/qq314/xjmudman96/100_0467.jpg

http://i459.photobucket.com/albums/qq314/xjmudman96/100_0465.jpg

http://i459.photobucket.com/albums/qq314/xjmudman96/100_0466.jpg

http://i459.photobucket.com/albums/qq314/xjmudman96/100_0468.jpg

http://i459.photobucket.com/albums/qq314/xjmudman96/100_0472.jpg

http://i459.photobucket.com/albums/qq314/xjmudman96/100_0473.jpg

http://i459.photobucket.com/albums/qq314/xjmudman96/100_0474.jpg

This was a fun project that I would do to any trail jeep I get in the future. It was nice to have help as always (thanks Brandon!) Like I've heard many times, prep is the key, and we prepped it well. I only used one kit too! I bought an extra quart just in case but I guess I will do the bottom on the outside with that. I did notice that my water pump bearing is squeaking now so I ghess that's my next project.

[xjtrailrider]

Good work Kevin!

Do you need any parts for the 96 while i have this parts XJ here? I will be done with parting it out by next weekend if I get good weather.

[RUparrothead]

what type of prep work is needed for the herculiner? I want to do the bed on my truck and any helpful advice is appreciated:driving:

[xjmudman96]

Good work Kevin!

Do you need any parts for the 96 while i have this parts XJ here? I will be done with parting it out by next weekend if I get good weather.

does the parts jeep have a factory cargo rack? If so I need the passenger front retainer clip that goes into the front track. Oh,, and a water pump but I seen you were already moving the motor. What about the dash facing?

[xjmudman96]

what type of prep work is needed for the herculiner? I want to do the bed on my truck and any helpful advice is appreciated:driving:

they give you a scotch pad in the kit to "scuff" up the surface, but we used an orbital sander with 80 grit on most of it to speed things up. Then I vaccumed all the dust up and wiped it all down with Acetone. By this point I had to take a break. Even with the bay door open those fumes had me out there :sFun_tease: But the applying it was just like painting, You do a light first coat that basically primes the surface. Then when it starts to dry you add a second coat, which really sets it off. The really cool thing about this stuff is that @ anytime after it has dried you can touch it up. Just wipe a little acetone on it and let it dry. It will bond to itself. So if I want to make it even thicker down the road it's not a problem.Isn't this supposed to go in product reviews?

[xjtrailrider]

does the parts jeep have a factory cargo rack? If so I need the passenger front retainer clip that goes into the front track. Oh,, and a water pump but I seen you were already moving the motor. What about the dash facing?

The rack is toast due to the roll over, I have a black dash bezel in excellent condition-$15

[Scrambled]

Looking good Kevin:2thumbsup: Aren't you glad we talked you into the herc kit?;)
What did you do to fill the gap at the back of the cargo area?
Tell Brandon I said hi see you on the 25th bro.:D

Later
Sean

[xjmudman96]

What did you do to fill the gap at the back of the cargo area?


we used some thin (26 G) metal and pieced it in to fill in the gaps. It turned out that you can't even really tell I messed with it. Thanks for the persuation bro :yup:

[xjmudman96]

Well I finally got my first coat of armor on today. I wanted to buy some AJ's super rails, but as usual money was tight. So I spent 70 bucks on steel and got my father-in-law (who welded for Norfolk Southern 30+ years) to help me.

http://i459.photobucket.com/albums/qq314/xjmudman96/100_0648.jpg

This was all stack welded so it should hold up up better than the steel itself

http://i459.photobucket.com/albums/qq314/xjmudman96/100_0647.jpg

I we;ded the end caps @ home with my littke flux welder. These were the prettiest beads I've laid yet.

http://i459.photobucket.com/albums/qq314/xjmudman96/100_0651.jpg
http://i459.photobucket.com/albums/qq314/xjmudman96/100_0652.jpg

All painted up and mounted
http://i459.photobucket.com/albums/qq314/xjmudman96/100_0656.jpg
http://i459.photobucket.com/albums/qq314/xjmudman96/100_0658.jpg
http://i459.photobucket.com/albums/qq314/xjmudman96/100_0659.jpg

I'm still gonna weld the sides of the angle to the unibody frame, and probably a piece of plate from tube to tube and to the pinchweld, but I put a highlift under these and jacked them up then shook the crap out of the jeep. Seems to be holding good
http://i459.photobucket.com/albums/qq314/xjmudman96/100_0657.jpg
I kow that they are a little bit short too, but I will just have to keep that in mind when I'm coming off a rock. Maybe a little more skinny peddle is in order:wings:

[xjtrailrider]

They look like they will be fine, I would definitely bolt them to the frame rails though. All you need now is that new rear bumper that is sitting in my way....cough-cough.

[xjmudman96]

All you need now is that new rear bumper that is sitting in my way....cough-cough.

yeah, I apologize Jon. I'll call you today and get out there asap.

[hadfield4wd]

I'm still gonna weld the sides of the angle to the unibody frame, and probably a piece of plate from tube to tube and to the pinchweld, but I put a highlift under these and jacked them up then shook the crap out of the jeep. Seems to be holding good


Definately secure to that pinch seam. The forces of lifting are nothing compared to that tire dropping off a rock and slamming on that rock rail. The will move and will bend the rocker. My rocker is bent from the rails and they are welded to the pinch seam. Although I do hit a little hard occasionally



I kow that they are a little bit short too, but I will just have to keep that in mind when I'm coming off a rock. Maybe a little more skinny peddle is in order:wings:

The shortness won't matter. Usually the rocks won't get up that tight. Plus you'll be able to trim more without cutting the rock rails.

All in all looks good.

[xjmudman96]

yessssssssssssssss! I have the rock god's approval on my fabrication:2thumbsup: I do have my eye on a good peice of 3/16 plate I'm hoping to get. It's like 10'x6', so I might try to make some skids too. This crap is so addictive.

[Scrambled]

Looking good Kevin:2thumbsup:

Definately tie them into the pinch seam. I still have all the measurements from when I built mine on the old XJ.

Best ones I've seen for an XJ though are the ones Jon has on his rig. If you can tie them into the rear spring hanger and front control arm mount.

Later
Sean

[YJeXtreme]

Looking good bro! Yes this is ADDICTIVE... just wait til I get shop room for mine, and see what's in store during it's build.

[xjmudman96]

Well, I went and tested out my rocker protection and it seems to be doing it's job. I did weld a piece from the seem under the rockers and to the pipe brackets. seems to be pretty stiff now. Thanks for all the help guys. Hope to see a bunch of you'all on the 27th ...:driving:

[xjmudman96]

I got some spacers for the front and some blocks for the rear. New to me longer shocks too. I anticipate an overall 2'' of added lift with all this. the back springs sag. from stock height I should have about 5'' . But the control arms I planned on using aren't going to work, so this may take more time than I planned.

I was trying to straighten out my brake lines, as someone suggested to me, and broke one of them:( so now I have to fix that too.
http://i459.photobucket.com/albums/qq314/xjmudman96/100_0884.jpg

[xjmudman96]

I got the new brake line in and finished the lift. I used stock arms for a dodge ram to push my front axle forward about an inch and a half. I had to do some serious re-decorating to make it work. I'll have some pics up soon.

[hadfield4wd]

Sweet. Be careful with that block in the rear. Mine was nothing but trouble. XJ springs are fairly soft and the extra leverage will cause wrap. I busted ujoints/driveshafts because of the wrap. A cheap lift caused about $700 in repairs. Not including building the traction bar.

[xjmudman96]

yeah I put some shims under the blocks yesterday. It set my angle almost perfect, I don't really feel a whole lot of vibe. I wheeled it today (lightly) and seen that my flex line feeding the rear brakes is a little too tight than I like, so I got one off a ram I'm going to swap in. All said I'm pleased with the flex I have now with no rubbing!:thumb: just on the lower arm when I turn.

Here you can see where I had to use a comealong to get the last bolt in my upper arm.
http://i459.photobucket.com/albums/qq314/xjmudman96/100_0905.jpg

[xjmudman96]

I did some more fender trimming and i'm thinking of getting some fender flares. pacer makes those "flexy flares" that you just screw or bolt on.for a fraction of the price for bushwackers. I think the surface mount would look good and enable me to keep them high off the wheel...http://www.jcwhitney.com/Rubber_Fender_Extensions_Fender_Flares?ID=12;0;0;0 ;100002;ProductName;0;0;0;0;2008750;0;0

http://i459.photobucket.com/albums/qq314/xjmudman96/kdubzjeeppics002.jpg

[rubican!]

http://rustysoffroad.com/mm5/merchant.mvc?Screen=PROD&Store_Code=rustys&Product_Code=RA-FLR1-XJ&Category_Code=BODY

I think these are sweet for the price.

[hadfield4wd]

http://rustysoffroad.com/mm5/merchant.mvc?Screen=PROD&Store_Code=rustys&Product_Code=RA-FLR1-XJ&Category_Code=BODY

I think these are sweet for the price.


I like those as well. He may have cut too much for them though if you compare the fenders. Oh and you don't need flares. They just get in the way.;)