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Unread 10-12-2008, 10:47 PM   #1
DutchVDub
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1992 YJ Wrangler 
 
Join Date: Jun 2008
Location: Firestone, CO
Posts: 37
My build thread

I figured I would not only introduce myself but my current build as well.

First me,
My name is Richard and I'm a 25yo E5 in the COARNG. I work full time for the NG as Federal technician rebuilding HMMWV diffs and repairing military equipment, mainly HMMWV's. I've been into wheeling since I tried turning my 84 S-10 2wd longbed into a pre-runner back when I was 16yo. I've since owned wheeled 2 Zuki Samurai's and loved the hell out of them.

I sold my second Zuki when I shipped for Iraq back in 06 and upon my return I decided that with the family starting a Zuki would be a bit on the small side unless I were to make it a trailered trail rig (something I'm very against). I was originally going to go back to the way of the bowtie but I was also lazy and didn't feel like dealing with a SAS. Thus the Jeep Cherokee XJ was purchased. I purchased my 99 XJ Sport for 5000$ and added some 32x11.5 BFG M/T's and a Rusty's 4.5" SA lift. Loved the Jeep and while I was able to wheel it quite a bit stock i never made it out to the trail with the lift. Some 17yo kid decided to run light in a Bronco and total it for me.

Thats when I decided to go cheap and found my current 92 XJ Laredo. Bought it for 800$ off some hippy in Boulder, added a 4.5" RC SA lift, the 32's from the 99 XJ, an 8.25 w/ 3.55 gears from an auto, welded the spiders on the 8.25, and regeared the front D30 w/ used 3.55's. Well now that I've wheeled the piss out of it in cheap Jeep mode its time for a serious revision. thus the build thread.

Now for pics.

Wheeling my 1st Zuki (88 Samurai w/ no mods) at Spring Creek:






My 99 XJ w/ lift and tires:


My 99 XJ wrecked :



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Unread 10-12-2008, 10:49 PM   #2
DutchVDub
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1992 YJ Wrangler 
 
Join Date: Jun 2008
Location: Firestone, CO
Posts: 37
My 1992 XJ stock:



My 92 XJ as of last week:



The build thus far:

Had to remove a few bits:








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Unread 10-12-2008, 10:49 PM   #3
DutchVDub
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1992 YJ Wrangler 
 
Join Date: Jun 2008
Location: Firestone, CO
Posts: 37
A few bits waiting to go in:








Old rims/tires:


New rims/tires:




Welded 27spline 8.25 after a summer of really hard wheeling and abuse:




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Unread 10-12-2008, 10:49 PM   #4
DutchVDub
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1992 YJ Wrangler 
 
Join Date: Jun 2008
Location: Firestone, CO
Posts: 37














Waggy D44:


The parts hauler:


Tera 4:1, TNT belly pan, and SYE awaiting install
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Unread 10-12-2008, 10:49 PM   #5
DutchVDub
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1992 YJ Wrangler 
 
Join Date: Jun 2008
Location: Firestone, CO
Posts: 37
Herculiner for the floorpan and Rustoleum for the exterior, axles, and New LA's:


To clean the floor with afterwards:


New 8.8 on top, old 8.25 on bottom:




No more axle:


The Waggy D44 being inspected:


So the plan is this:

Drivetrain:
Waggy D44 w/ TNT Truss, 4.56 gears, PowerTrax No-Slip locker, late 70's F150 hubs and brakes, 5x5.5 bolt pattern

Explorer 8.8 w/ TNT Ubolt eliminators, 4.56 gears, PowerTrax No-Slip locker, SpiderTrax 5x4.5 to 5x5.5 adapter/1.5" spacers

Np231 w/ Teraflex 4:1 kit, Advance adapters SYE

Tom Wood's custom rear CV driveshaft

Stock 4.0 and AX-15

Suspension:
Front: 6.5" Rusty's Springs, TNT Belly pan and Y-Link LA's

Rear: 4" BOR super flex leaf springs, 1.5" shackles (already have on, plus 1.5" TNT Ubolt eliminators equal 7" of lift)

Exterior/chassis:
painted w/ rustoleum flat green, TNT uni-frame stiffners, custom rocker guards, Rusty's flexible cutout flares (already installed), Detours XJ Backbone for front bumper

Interior:
CB radio, Herculined floor, new head unit (damaged mine while washing the interior)

Additional repair items to be done:
new fuel pump, new water pump, new rear main seal, replace all ujoints in front driveshaft

I'm hoping to get done in time for Novemeber to Remember. Wish me luck.

I have almost all the parts I need either here or enroute, just need to source a few odds and ends.
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Unread 10-12-2008, 10:57 PM   #6
4pointOH1998
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Join Date: May 2008
Location: Waterville/Bangor, MAINE
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That's pretty sweet man. Welcome to Jeepforum

Going to be following this one
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Fighting the rust since April '08...
A Maine XJ Nightcrew!
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Unread 10-12-2008, 11:04 PM   #7
NiCk-
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1998 XJ Cherokee 
 
Join Date: May 2008
Location: Memphis, TN
Posts: 561
good luck. Hope this one doesn't get totaled
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RC 4.5" with ADJ. Trac Bar
33" BFG All Terrains on Cragar Soft 8's
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Unread 10-12-2008, 11:35 PM   #8
jebmccall
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damn you got plenty of spare axles, lol nice build up man
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Unread 10-13-2008, 09:47 AM   #9
DutchVDub
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1992 YJ Wrangler 
 
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Location: Firestone, CO
Posts: 37
oh i'll be selling axles at a buy 1 get 2 free rate soon enough. one is the D35 that came in it, another is the 8.25 I originally swapped in, there is a bare d30 housing i was going to use to build into a super30, then there is the 8.8 thats going in the back, and a waggy d44 for the front. soon the stock d30 will be on the floor too.
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Unread 10-15-2008, 11:16 PM   #10
DutchVDub
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1992 YJ Wrangler 
 
Join Date: Jun 2008
Location: Firestone, CO
Posts: 37
Ok so yesterday I got some more work done.



First the wife helped me remove the front bumper in prep. for the Detours Backbone that is on the way.













Then I removed my faulty leaf spring that was causing my XJ to lean. RC had actually sent me a replacement no questions asked a few months ago but I never put it on.









(notched the pinch weld because it annoys me how it gets in the way of that bolt)













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Unread 10-15-2008, 11:16 PM   #11
DutchVDub
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Join Date: Jun 2008
Location: Firestone, CO
Posts: 37
Then I had to take a break for some nourishment.

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Unread 10-15-2008, 11:56 PM   #12
XJKipp
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1995 XJ Cherokee 
 
Join Date: Dec 2007
Location: Gainesville, GA
Posts: 252
wow, what a build man! Lookin like you're going to have sweet set up when its "done", I wish I had a collection of parts like that...
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31x10.50 BFG M/T KM2...see specs

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Unread 10-16-2008, 12:04 AM   #13
DutchVDub
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1992 YJ Wrangler 
 
Join Date: Jun 2008
Location: Firestone, CO
Posts: 37
After the mourishment my son wanted some love, and to steal my hat.





My buddy Matt after helping me pull the T-Case.





The T-Case and TeraLow kit side by side.





And the AA SYE





Test painted some of the Jeep because I was bored.





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Unread 10-16-2008, 12:07 AM   #14
DutchVDub
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1992 YJ Wrangler 
 
Join Date: Jun 2008
Location: Firestone, CO
Posts: 37
I also received my 4.56 gears for both the D44 and 8.8, along with my RE HD Trac Bar w/ brace and RE GENII sway bar disco's











Old Rusty's HD T-Case crossmember









Random pics









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Unread 10-16-2008, 12:16 AM   #15
omz
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sick!

I'm tracking this thread for sure. love the caddy and urS4 too! Tell me how the green turns out I have been kicking around spray bombing mine green.
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