[HankyDanky]

Ok, so heres the story. Had a 1990 wrangler when I was in Highschool and loved the thing. Replaced EVERYTHING except for the brakes. All upgrades, was bone stock when I got it, lifted it 4" and got 33" BFG's. Kc Highlights, new seats, carpet, misc interior parts, ect..... Well to make a long story short since it was my DD and I was seeming to be woking on it every weekend from Heavy wheeling I had to part with it and get something with better Gas milage and more room. So got a 2001 Honda Accord. Couple years went by and I was starting to want a jeep again more and more. Was very limited on funds especially since the new jeep was going to be just used for off-roading/camping. Searched all the news papers, craigslist and a bunch of other places. Figured if I was going to get something cheap I would be replacing aaaalot of stuff but was ok with that since I had another car and had nothing but time to work on it. Found a Jeep Cherokee for $500, still ran, had been sitting for a couple years, 2" rancho BB lift already installed. Could it be true?? Called the guy right away and the next day I was there with a car dolly ready to tow it away. Needed a new battery, fuel pump, and battey cables and the thing started right up. Compression across the board was better than I could hope for and the 4x4 worked like a champ. Now it was a cherokee limited so it had all power options as well, windows still worked, needs door acctuators, but other than that it was in great condition in the inside, leather interior that looked like it had not been touched other than the drivers seat. I Will keep updating with new progress!

Here are a couple Photos right when I got it home.




Its being painted black with the roll on method and is actually coming out great. Cut the back panel waaay out to make room for the new 33's (soon).








New MC and Brake booster from a 96 Grand Cherokee (Dual Diaphram instead of the crappy single). Along with the new K&N Air Filter.

[HankyDanky]

Had to replace the O-rings on the fuel injectors and the quick disconnect today and got around to bleeding the brakes. I have brakes again!

[chrisjep97]

that black paint job looks great!

[1990JEEPXJ]

how hard was the new brake MC/booster install?

[HankyDanky]

Originally Posted by 1990JEEPXJ

how hard was the new brake MC/booster install?

Like everything it had its complications. Biggest problem for me was finding the brake line adapters and the brake lines. Then you have to get a flaring tool kit and make your own brake lines since each side needs to be double flared. Unless you can find double flared brake lines. Took a couple hours to install and bleed the system but was defiantly worth to upgrade too since I had to replace the booster anyways.

Here is the write up that I used for the Idea, part numbers and whatnot.
http://www.madxj.com/MADXJ/technical/technicalfiles/ARbrakeBoosterUpgrade/BrakeBoosterUpgrade.htm

Edit: Got the MC and the Booster off ebay for 20 bucks and I got the brake line adapters at NAPA, just give them the part number that is in the write up above for the plews and edelmann ones. It says that they were blue fitting but mine were gold (brass fittings I believe). I used a little teflon tape inbetween all the brake lines and the adapters just to make sure they sealed nice and tight. Put them in the first time and each brake line was leaking at one side. So had to re-flare the brake lines. I got three feet of standard 3/16 line from napa and cut them into 2 12" sections. Reason being I knew I would have to do the flares a couple times (and I did have to alot) but just take your time on them and get them right so you dont have to take it all apart again. Hope this helps!

[1990JEEPXJ]

thanks. i have the horrible ABS and have been thinking about doing this swap

[HankyDanky]

Originally Posted by chrisjep97

that black paint job looks great!

Thanks! But I will say that if I had to do it again then I would choose a different color. Black shows to many imperfections in the body that take aaaaalot of time to get each and everyone out. As far as the whole painting process it was actually pretty fun. Still got a couple more things to do with the paint and already have about 40+ hours into the paint and prep alone. But for only about $75 in materials it came out great!

These are some of the sites I used for info on the roll on paint job.
http://www.rickwrench.com/index79master.htm?http://www.rickwrench.com/50dollarpaint.html
http://earlyxj.com/paint.htm

Also there is a guy on the mopar forums who did an excellent job of this, read the entire forum because it tells you alot! - http://board.moparts.org/ubbthreads/showflat.php?Cat=0&Number=2331682&page=0&fpart=1&vc=1

[aircruiser]

looking good man. that paint job almost looks factory

[CTXJ90]

how nice are those leather seats in the limiteds. I got my 90 xj for free but it also needs a paint job. Yours looks great though what tires are you thinking about running?

[HankyDanky]

Originally Posted by aircruiser

looking good man. that paint job almost looks factory

Yeah I was waaay suprised how nice it actually came out. And I only went up to a 600 grit so far. Going to do a little more painting and sanding when I get the chance but for now its ok.

Originally Posted by CTXJ90

how nice are those leather seats in the limiteds. I got my 90 xj for free but it also needs a paint job. Yours looks great though what tires are you thinking about running?

They are not to bad, havent gotten a chance to go wheeling since I have had it but just put everything back together this morning actually so after I register it and get insurance then its going to tonto national forest for a bit of wheeling!! The roll on paint job was super easy, but takes alot of time. Pretty cheap and if you have the time and the patience to do it I say go for it. I was going to do orange or yellow because they dont show so many imperfections but i just put some extra work into the black and still came out good... As far as tires, I am getting moto metal 16x9 rims (http://www.wheelsforless.com/search_result.asp?Description=Black&Product_ID=mm95169) and then 33x12.50 goodyear wrangler mt/r. Would have gotten them already but going back to TN for 3 weeks to see family and my cousins wedding so thats going to take quite a bit of cash.

[HankyDanky]

Been a while since I have updated so thought I would put up pictures of my Sanden OnBoard Air System. Ran 5ft of copper to the underside of the jeep to the One way valve, Filter and then to the tank.

Thought it would be the best place to mount it, out of the way.


Inline Oiler


Got the tank hooked up!


Switch for the pressure switch, just something temporary.


Pulling air from the front to keep the compressor a little bit cooler.


Fuel/air filter.


Copper to the air hose, helps cool it down quite a bit.

[OregonGrown]

i've been thinking about making my a/c compressor do that to. the thing that worrys me about it is that compressor is disighned to be oiled by oil being carried by the refrigerant. without oil running through the pump it's only a matter of time before it fails. keep us posted on how it works over time I left my pump in even though I gutted the rest of my a/c system i figured i'd at least give it a try

[HankyDanky]

Originally Posted by OregonGrown

i've been thinking about making my a/c compressor do that to. the thing that worrys me about it is that compressor is disighned to be oiled by oil being carried by the refrigerant. without oil running through the pump it's only a matter of time before it fails. keep us posted on how it works over time I left my pump in even though I gutted the rest of my a/c system i figured i'd at least give it a try

Well its the refrigerant that lubricates the compressor, but if you look in the second picture I have an in line oiler that goes into the compressor. It slowly lets in compressor oil so that it does not freeze up. Had it on for a couple weeks and have used it quite often (just because I have it now ) But so far so good. Was not to hard to put in and have already used it for quite a bit of stuff. If you do not plan on using the ac then I say that this mod is well worth your time and money.

[bebout]

can you give a little more detail on this set up?

[HankyDanky]

Originally Posted by bebout

can you give a little more detail on this set up?

Well as far as the parts list...

VIAIR 2.5 Gal Air Tank - Autoanything.com - Sure you could find one cheaper though, ebay.

Kilby Pressure switch - http://www.knowwhere2jeep.com/catalog/product_info.php?products_id=5279

In line Oiler - http://www.jackssmallengines.com/ch_air_lubricator.cfm

Polyconn Manifold - http://www.northerntool.com/webapp/wcs/stores/servlet/product_6970_200339554_200339554

Safety Relief Valve - Cant remember where I got it but it releases all the air at 175 PSI if need be.

Got the 3/8 hose, clamps, air accessories tool kit, 1/4 NPT to 3/8 barb (alot of them), one way check valve, reducers (various ones to 1/4 NPT), Teflon tape (use on everything!), a couple 3/8 to 3/8 barb, 4 1/4 NPT plugs for the tank and one on the manifold, 10ft of copper hose (used only 5 ft), 1/4 NPT copper hose connector. All from Home Depot

1/4 NPT Air/fuel filter (Kobalt) - From Lowe's - They have these at home depot as well, just didn't see them and headed to Lowe's. Don't think they are by cobalt though.

Mini air filter 3/8 barb, 10 amp switch with 16GA wire, in line fuse - Auto zone

There are a couple other little things I am sure but that is just about everything I used (just did this all from memory). Except for the reducers on the AC compressor. Just depends on what you want to use. Ex old ac hose, 90* elbow, existing fitting. Overall I am super happy with the set up, take about 1 min 20 sec to fill from 0-155 PSI for the tank and have not timed filling up the tires but it is just as quick as the ones at the gas station. You have to run it at idle or I find that it still warms up the metal Items very quickly which could lead to leaks in the air hose. Copper seems to help quite a bit, at least thats what I like to think.