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~Artec JK 1 TON SWAP~Engo winches available at www.rockridge4wd.com! Free shippMagnaflow SS Cat Back Exhaust System, Street, High Clearan

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Unread 08-18-2010, 09:25 AM   #1
xjcrawler736
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1990 XJ Cherokee 
 
Join Date: Mar 2007
Location: Harleysville, Pa
Posts: 176
1990 XJ - That was then, this is now....

I had a build thread in the Cherokee forum but I don't think it really fits well there. So I will share it with all the the Jeep Forum world.

Here goes.

Well like everyone else I started out with a stock XJ. 1990 XJ Sport that I got for $400. Didn't run because the guy I bought it from had did a motor swap and didn't get the distributor in the right gear. So the timing was really off.

I put a Rough Country 6.5" lift on it and some 33" Super Swamper SSR's



And like always that wasn't cutting it. So I moved over to a Ford HP44 and Ford 9" and 36" Super Swamper SX's. Needed more gearing so I did a 231 doubler and a flipped D300. So I then had a 4 speed transfer case with a doubler low of 7.15 to 1.



Now that I had the axles and tires I started to get jealous of all the CJ's with their open tops. So I started the chop. And bent up a 6 point cage with a lot of triangulation.



But its never enough. I needed a better suspension. I got rid of the leafs in the back and did a rear 3 link with stock XJ coils in the rear.

Trail 5 Hill Climb at Rausch Creek



Some others may have seen when I was in JP.




I started doing harder and harder trails and kept breaking D44 axle shafts. So I bit the bullet and did the D60/14bolt swap. Threw in some 35 spline shafts from Ten Factory. Turned the front into a 3 link and the rear to 4 link. Also upgraded the Rough Country shocks to some 2.5" High Temp Res. shocks from FOA. And because running 36's on Tons is just silly I went out and got myself a set of 38.5" Maxxis Creepy Crawlers and made myself some beadlocks.

In Johnson Valley wheeling the week of King of the Hammers






But guess what....It wasn't enough. I got the Ultra 4 racing bug after watching a couple King of the Hammers races and helping build some top notch race buggies.

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Unread 08-18-2010, 09:28 AM   #2
xjcrawler736
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Custom crossmember for the front that will house a 9000lb Warn that I will use for recovery and a suck down winch.

Also full hydro for the steering. All PSC parts. 2.5x8" double ended ram, orbital, cooler, pump, high steer and so on.





After it is all said an done I will be looking at the following

XJ based tube buggy
Engine - Turbo 4.6L stroker
Trans - AW4 with a large cooling system
Transfer Case - 231 doubler, D300 with 32 spline outputs
Axles - D60/14bolt with chromoly shafts 4.56 gears
Shocks - Front - Bilstein 2.5" 9100 Series Coilovers with valved reservoirs
Shocks - Rear - Bilstein 2.0" 9100 Series Coilovers with reservoirs
Bilstein Air bumps all around





Bent up the mount for the ram


Started working on the crossmember/bumper


My helper


Nearly finished product


Rear view of how I did the clevis mounts. Cut square holes and dropped the clevis in about 1/4" and welded them from behind. I will then weld the fronts tonight.
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Unread 08-18-2010, 09:34 AM   #3
xjcrawler736
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I did get the rest of the holes drilled for the winch. Welded the front of the D-ring mounts and welded in studs to bolt down the fairlead.

Everything is super tight. I really have limited room in more ways then one. When I get everything mounted up tonight I will shoot some pictures of how close everything is.










My order from PSC should be here today. So I will be able to start working on the steering. I also put through an order from Ruffstuff for some new hiems, 14 bolt pinion guard and some other little tabs.

I am really shooting to get it up and running this weekend. But I am going to need some help. Hopefully I can get some people to come over and lend me a hand.

And just for added effect. Here are some of the pictures from my trip from Pennsylvania to Johnson Valley, CA to wheel and support or team in KOH.


2700 miles one way with this


The race buggy (blew the motor when testing)


Our group out wheeling


Fixing one of the other XJ's that broke a 35 spline stub shaft and a D300 rear output at the same time.


Plenty more photos on my photobucket if you guys are interested.
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Unread 08-18-2010, 09:35 AM   #4
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Pulled apart the pump and tapped it for a -10 fitting.



Orbital mount


The PS reservoir I made.


Took the Jeep to Clark Industrial to get all the hydro lines made






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Unread 08-18-2010, 09:36 AM   #5
xjcrawler736
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More



We had everything we needed. :flipoff2:



Both Jeeps done.


Quick flex test to make sure no lines get pinched and are plenty long.



And No-bs's jeep from another thread on Jeep Forum's


Now I just need to finish up some welds and do a couple other little things with the steering and it is 100% done.




BTW....FULL HYDRO IS AMAZING. ok i'm done.
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Unread 08-18-2010, 09:37 AM   #6
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Bumper in done.






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Unread 08-18-2010, 09:37 AM   #7
ibjeepin95
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A real build. I like!
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Unread 08-18-2010, 09:40 AM   #8
xjcrawler736
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Buttoned a lot of stuff up and here is how it sat before leaving for Rausch Creek



The trip itself.

The Jeep did great except I had a couple problems. 3 broken u-joints at the same joint. Destroyed 2 suspension mounts and smashed one of my rear FOA's. Overall great weekend but lots of trail fixes. Got to wheel with some of the best Ultra 4 and WErock drivers in the country.

Pics from the weekend. I am working on the videos.

EZ Rick playing around on Crawler Ridge


Erik Miller doing the same

Doug from Extreme Axle Sales rolled over

Shram after doing an endo. Notice the stinger.

Rachel driving the XJ






Playing capture the cone on Big "O" trail.

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Unread 08-18-2010, 09:41 AM   #9
xjcrawler736
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More from the trip...



More pictures from this past weekend



This is what has been happening to my joint at the D60










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Unread 08-18-2010, 09:42 AM   #10
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This one cracks me up.






Mike with his first flop. (he dropped coverage on it when we got home :laughing


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Unread 08-18-2010, 09:43 AM   #11
xjcrawler736
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After the trip the XJ went under the knife. There isnt much left. haha







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Unread 08-18-2010, 09:47 AM   #12
xjcrawler736
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Tim from Liquid Iron is helping me out with some new link mounts. I sent Tim some CAD drawings and within an hour he had them boxed and out for shipping.
LiquidIronIndustries

I am going a bit of a different direction with the mounts so I don't have to worry about ripping anything apart like I did before. Should look pretty trick.




reworked the rear end last night and cut about 7" out of it. It just looked too long. Before everything is finally welded in I cut it all up and rebuilt it.




Got a couple big things that help me move forward with the design.





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Unread 08-18-2010, 09:48 AM   #13
xjcrawler736
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More tube work







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Unread 08-18-2010, 09:50 AM   #14
xjcrawler736
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The rear suspension link mounts are all setup and ready to be fully welded. And the subframe is being completed. Building a 3" subframe under this thing really helps with suspension geometry, drive line angles, and space for exhaust and other little things under the floor.

At full bump the skid plate will be about 13-14" off the ground. And at ride height it will be about 21" off the ground. A bit lower then I am used to but it is well worth the benefits. Rear will have 10" of uptravel and the front will have about 7".

Rear lower frame mount.



And got to back home so I can prep it to go down to Liquid Iron.

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Unread 08-18-2010, 09:50 AM   #15
xjcrawler736
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Did a lot of work on the XJ down at Liquid Iron this weekend. Put down about 20 or so hours of work on it.

What we got done

Roof bars
Windshield bars
Window bars
X behind the seats
center console bars/dash bar
Boat sides
Front push bar
Front end bars
Some of the subframe
Trans mount
Shock mounts in the rear










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