'99 Sport Build Thread: Grocery Haulin' With Panache - Page 4 - JeepForum.com
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post #46 of 347 Old 07-21-2011, 01:04 PM Thread Starter
PhilipJ
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The only bad thing about the 242 is that the parts are becoming more rare, so the $500 kit is actually $900 ($400 core charge). However, sending in any 242 mainshaft or tail housing is worth $200 each. So if you can track down some spares or have another vehicle to drive, sending the parts in first will cut out some of that initial cost.

Just be careful removing the oil slinger from the end of the tail housing; it chips very easily because it's aluminum. I punched a little chunk off the end of mine in the process. Thankfully they let me send the one from the kit back and re-machined my original (free!) to accept a new seal, so I got the full core refund.

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post #47 of 347 Old 07-21-2011, 02:17 PM
sirlasvegas
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This thread is awesome! Great build!
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post #48 of 347 Old 07-21-2011, 03:16 PM Thread Starter
PhilipJ
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Took the XJ on its first real maiden voyage last weekend. I would have had some good video, but stupid me didn't notice that my GoPro was set on 'snapshot' mode instead of 'camera'. So when I hit the start button and heard it beep I thought it was recording 2+ hours of video. All I got was a still shot of the sky from when I was mounting it on the roof.

Oh well, it's a close ORV area and I always run it several times per year. I'll get some video next time and you'll see how rocky, tight and twisty some of the trails here can really be. Or just youtube 'Evans Creek' sometime if you're bored. Meanwhile, here's some carnage:


Oops. Coming up a steep and very tight s-turn, I couldn't see a damn thing in front of me. I thought I would clear the root sticking out, but my mental feelers were still in 'Wrangler' mode (plus I had no spotter since I was the lead). The panel was cracked and pitted to hell anyway and I had enough free ebay bucks to get a new one and some smoked signal lenses to be installed next week. Just need to find some matching paint...or maybe I'll just do it black, even though it'll look weird.



There were lots of pivot turns, but only on the driver side for some reason



And a lot of mean rocks
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post #49 of 347 Old 07-21-2011, 09:42 PM
jj88jeep
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Quote:
Originally Posted by PhilipJ View Post
The only bad thing about the 242 is that the parts are becoming more rare, so the $500 kit is actually $900 ($400 core charge). However, sending in any 242 mainshaft or tail housing is worth $200 each. So if you can track down some spares or have another vehicle to drive, sending the parts in first will cut out some of that initial cost.

Just be careful removing the oil slinger from the end of the tail housing; it chips very easily because it's aluminum. I punched a little chunk off the end of mine in the process. Thankfully they let me send the one from the kit back and re-machined my original (free!) to accept a new seal, so I got the full core refund.
Thanks for the heads up! maybe I'll try tracking a spare t-case down for future use.
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post #50 of 347 Old 07-22-2011, 06:07 PM Thread Starter
PhilipJ
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Finally threw on the front flares today. I haven't ordered the rears yet, that's a whole other animal I'll tackle since I have to cut-n-fold the quarter panels for my bumper anyway.

Despite the massive instructions, the install was pretty easy. Remove old crap, loose fit new mounts and drill a few holes, make some lines, cut, clean, install new mounts and flares.

Before


Cutting


One side done


Other side done


Nice and clean after a much needed bath
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post #51 of 347 Old 07-22-2011, 06:41 PM
jj88jeep
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NICE!!! Really like that style of flare!!!
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post #52 of 347 Old 08-02-2011, 01:23 AM
rulppa
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This is getting nice, cant wait to see it with new bumpers. I love the flares!
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post #53 of 347 Old 08-07-2011, 07:43 PM Thread Starter
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AJ's SlikRok bumper has arrived! Very easy install although there were some tight tolerances, but nothing that couldn't be solved with a little reaming from the power drill. Also mounted the winch and installed C-Rok's power steering box brace.

Frame-side shot


After some prep with the flapper wheel


Welded-through recovery tabs. I don't think these will come out easily.


Underside of the winch plate. The two front mounts have to be done with a wrench as a socket won't fit, I chalk that up as a good theft-deterrent.


Nutserts in the frame rail for lower mounts


New brackets mounted and my ghetto temporary license plate rigging to stay legal


C-Rok brace vs stock (wimpy, wimpy, wimpyyyy)


Boring out stock mounting holes and tapping in crush-sleeves for the brace


All bolted up, synthetic line spooled on tight. Also a new header panel that needs to be painted and smoked-out turn lenses installed.

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post #54 of 347 Old 08-07-2011, 09:01 PM
Mark-96-XJ
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not sure how much i would trust a steering stabiliser

1999 XJ Classic, Auto, Power everything, 3 inch, GY Wrangler Radial 31's

1996 XJ 5 Speed, 100% Herculined, Rough country 4.5, BFG A/T 33's

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post #55 of 347 Old 08-07-2011, 09:33 PM Thread Starter
PhilipJ
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I only wrote it that way once as a joke, because that's how it was spelled on the box.
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post #56 of 347 Old 08-07-2011, 09:54 PM
mg2000xj
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This is an awesome XJ! Great work, cant wait to see it with the rear bumper on too.

-Morgan
'00 Silverstone 2 Door XJ
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post #57 of 347 Old 08-07-2011, 10:11 PM
MagicNelson
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That bumper looks really good!!
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post #58 of 347 Old 08-07-2011, 10:57 PM Thread Starter
PhilipJ
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Thanks! I like it, too. It's very sleek and isn't all gaudy like most big-name stuff out there and its quality is just as good if not better. There was a long lead time in waiting for it, but well worth the delay to me.

If anyone's curious, it weighs 72 lbs and I rattle-canned it with Rustoleum Hammered finish.
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post #59 of 347 Old 08-08-2011, 01:24 AM
GregB_00XJ
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Wow lots of progress, very nice!!

2000 Jeep Cherokee Classic XJ - 2005 Jeep Grand Cherokee LTD 5.7L WK - CDN M101 1/4 Ton Trailer


____=__=
l l ,[_____],
l---- L -[]lllllll[]-

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post #60 of 347 Old 08-08-2011, 08:16 PM
KINGSB
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Looks like a nice build so far!

1998 Jeep Cherokee - 2.5 Inch Old Man Emu Lift - BF Goodrich All Terrains - All Mopar Accessories
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