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post #1 of 283 Old 12-04-2011, 03:40 PM Thread Starter
dukie564
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1995 XJ Cherokee 
 
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Project Danger Cart XJ

Well...it's about damn time I started one of these...

Forgive me, but the I probably have about 5 pages of stuff to post up from the past few years to get me to where I am now, and the build will be kind of slow from there on out.

The goal I have for this jeep is to have a build done right the first time around. I've had quite a few YEARS in researching exactly what I want to do.

Sooo...without further adeu...the Danger Cart (i hope some people get the reference).


1995 XJ Cherokee Sport
4.5" Homebrew Lift, 4.0L HO I-6, AX-15, NP231, D30(Open)/C8.25(Locked)
33x12.5 Mickey Thompson Baja MTZ Tires, 309,000 mi and runnin' strong
http://www.jeepforum.com/forum/f22/p...rt-xj-1297118/
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post #2 of 283 Old 12-04-2011, 03:40 PM Thread Starter
dukie564
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1995 XJ Cherokee 
 
Join Date: Jun 2008
Location: Aberdeen
Posts: 2,832
So...this is what I started with. A 1995 Cherokee Sport, flame red, bone stock with a sagging ***. 4.0L H.O., Np231 and AX-15 (god I love it being a 5-speed). D30 front and c8.25 rear. 196,xxx miles on original engine and transmission.

It was in pretty bad shape when I got it - busted out rear window, non-functioning radio, no rear brakes, and packed to the roof with trash and junk.

Spent about 2 days and 6 contractor bags cleaning it out. Replaced the window and rear brakes, and gave it a thorough wash and wax, as well as a shampoo. Cleaned up pretty damn good - but those tires have GOT to go





The legendary 4.0L


And installed a new head unit

1995 XJ Cherokee Sport
4.5" Homebrew Lift, 4.0L HO I-6, AX-15, NP231, D30(Open)/C8.25(Locked)
33x12.5 Mickey Thompson Baja MTZ Tires, 309,000 mi and runnin' strong
http://www.jeepforum.com/forum/f22/p...rt-xj-1297118/
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post #3 of 283 Old 12-04-2011, 03:41 PM Thread Starter
dukie564
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1995 XJ Cherokee 
 
Join Date: Jun 2008
Location: Aberdeen
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First mod - like I said - tires had to go

235/75R15 Destination M/Ts - so sexy



1995 XJ Cherokee Sport
4.5" Homebrew Lift, 4.0L HO I-6, AX-15, NP231, D30(Open)/C8.25(Locked)
33x12.5 Mickey Thompson Baja MTZ Tires, 309,000 mi and runnin' strong
http://www.jeepforum.com/forum/f22/p...rt-xj-1297118/
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post #4 of 283 Old 12-04-2011, 03:41 PM Thread Starter
dukie564
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1995 XJ Cherokee 
 
Join Date: Jun 2008
Location: Aberdeen
Posts: 2,832
Then I decided I was tired of the stock airbox, so I picked up an intake off ebay for like $35. I made a shield too, but don't have a picture. Works pretty awesome. Great butt dyno impact




OOO Shiny!!!

1995 XJ Cherokee Sport
4.5" Homebrew Lift, 4.0L HO I-6, AX-15, NP231, D30(Open)/C8.25(Locked)
33x12.5 Mickey Thompson Baja MTZ Tires, 309,000 mi and runnin' strong
http://www.jeepforum.com/forum/f22/p...rt-xj-1297118/
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post #5 of 283 Old 12-04-2011, 03:42 PM Thread Starter
dukie564
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1995 XJ Cherokee 
 
Join Date: Jun 2008
Location: Aberdeen
Posts: 2,832
and.....then I moved to Maryland. For those that don't know Maryland's safety inspection is a PITA, but you only have to do it once.

Well...I failed both the safety and emissions. Brakes, sway bar links, and biggest of all my exhaust was totally shot.

So....ordered up a Flowmaster Super 40, and Magnaflow hi-flow cat, and a custom mandrel bent 2.5 tailpipe from Mandrel Bending Solutions in Odenton, MD.

Sounds awesome

http://youtu.be/HUQXXPi-D4A
http://youtu.be/DGVjRtpS0a0

1995 XJ Cherokee Sport
4.5" Homebrew Lift, 4.0L HO I-6, AX-15, NP231, D30(Open)/C8.25(Locked)
33x12.5 Mickey Thompson Baja MTZ Tires, 309,000 mi and runnin' strong
http://www.jeepforum.com/forum/f22/p...rt-xj-1297118/
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post #6 of 283 Old 12-04-2011, 03:43 PM Thread Starter
dukie564
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1995 XJ Cherokee 
 
Join Date: Jun 2008
Location: Aberdeen
Posts: 2,832
next on the list - mucho maintenance. Diff fluids, tranny fluid, and transfer case fluid change, new valve cover gasket, and new spark plugs





And some paint to spice things up!



1995 XJ Cherokee Sport
4.5" Homebrew Lift, 4.0L HO I-6, AX-15, NP231, D30(Open)/C8.25(Locked)
33x12.5 Mickey Thompson Baja MTZ Tires, 309,000 mi and runnin' strong
http://www.jeepforum.com/forum/f22/p...rt-xj-1297118/
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post #7 of 283 Old 12-04-2011, 03:43 PM Thread Starter
dukie564
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1995 XJ Cherokee 
 
Join Date: Jun 2008
Location: Aberdeen
Posts: 2,832
oh...and I peeled back the carpet to find this...(see the leaf?)
Temporarily patched with sheet metal, silicon bath caulk, and self tapping screws



1995 XJ Cherokee Sport
4.5" Homebrew Lift, 4.0L HO I-6, AX-15, NP231, D30(Open)/C8.25(Locked)
33x12.5 Mickey Thompson Baja MTZ Tires, 309,000 mi and runnin' strong
http://www.jeepforum.com/forum/f22/p...rt-xj-1297118/
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post #8 of 283 Old 12-04-2011, 03:44 PM Thread Starter
dukie564
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1995 XJ Cherokee 
 
Join Date: Jun 2008
Location: Aberdeen
Posts: 2,832
Picked up some cheap Harbor Freight driving lights, and installed some H4 conversions



1995 XJ Cherokee Sport
4.5" Homebrew Lift, 4.0L HO I-6, AX-15, NP231, D30(Open)/C8.25(Locked)
33x12.5 Mickey Thompson Baja MTZ Tires, 309,000 mi and runnin' strong
http://www.jeepforum.com/forum/f22/p...rt-xj-1297118/
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post #9 of 283 Old 12-04-2011, 03:46 PM Thread Starter
dukie564
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1995 XJ Cherokee 
 
Join Date: Jun 2008
Location: Aberdeen
Posts: 2,832
I had my first wheeling outing coming up, so I decided to make my jeep a little more trail/water friendly.

First was a vent extension for the rear differential. I used a one-way fuel filter and some clear line. Installed behind the driver's taillight - much higher than the stock vent.
Full writeup here: http://www.jeepforum.com/forum/f11/h...-vent-1137497/


And then my current most favoritist mod - COWL SNORKLE!
Used the stock airbox and filter, 3" ID PVC pipe, and a stock air tube
It works fantastic. I never intend to submerge my jeep above the cowl, and didn't want a snorkel running up the side of my jeep - so it works perfect. It's a true CAI also. Tested it with a garden hose on full blast in the cowl - not a drop entered the airbox
Full writeup here: http://www.cherokeeforum.com/f67/my-...snorkle-67919/




1995 XJ Cherokee Sport
4.5" Homebrew Lift, 4.0L HO I-6, AX-15, NP231, D30(Open)/C8.25(Locked)
33x12.5 Mickey Thompson Baja MTZ Tires, 309,000 mi and runnin' strong
http://www.jeepforum.com/forum/f22/p...rt-xj-1297118/
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post #10 of 283 Old 12-04-2011, 03:46 PM Thread Starter
dukie564
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1995 XJ Cherokee 
 
Join Date: Jun 2008
Location: Aberdeen
Posts: 2,832
I was tired of my speakers crackling...or not working, so I snagged a set of 4 6.5" JVCs off crutchfield for $60. Installed 2 of them first in the rear speakerbar.

Little bit of trimming required to fit them, but nothing major. Also tore the sagging fabric off, sanded it down really well, and spent about 4 days priming, wet-sanding, painting, wetsanding, etc. About 16 hours into this - came out great!

More pictures and writeup here: http://www.jeepforum.com/forum/f11/r...heavy-1104865/

With the fuzzies removed:

Painted:

Speaker Installed:


Looking and Sounding good:

1995 XJ Cherokee Sport
4.5" Homebrew Lift, 4.0L HO I-6, AX-15, NP231, D30(Open)/C8.25(Locked)
33x12.5 Mickey Thompson Baja MTZ Tires, 309,000 mi and runnin' strong
http://www.jeepforum.com/forum/f22/p...rt-xj-1297118/
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post #11 of 283 Old 12-04-2011, 03:47 PM Thread Starter
dukie564
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1995 XJ Cherokee 
 
Join Date: Jun 2008
Location: Aberdeen
Posts: 2,832
Went wheeling for my first time in mud (had previously gone in snow).
Green Ridge State Park ORV. Nothing crazy - some small rocks and a LOT of water - sooo glad I had that cowl snorkle

...didn't save my alternator though...RIP. Had to change it mid way back to my house...that sucked.







1995 XJ Cherokee Sport
4.5" Homebrew Lift, 4.0L HO I-6, AX-15, NP231, D30(Open)/C8.25(Locked)
33x12.5 Mickey Thompson Baja MTZ Tires, 309,000 mi and runnin' strong
http://www.jeepforum.com/forum/f22/p...rt-xj-1297118/
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post #12 of 283 Old 12-04-2011, 03:48 PM Thread Starter
dukie564
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1995 XJ Cherokee 
 
Join Date: Jun 2008
Location: Aberdeen
Posts: 2,832
Made a friend - when wheeling again in White Marsh and Chesapeake City. No breakage!






1995 XJ Cherokee Sport
4.5" Homebrew Lift, 4.0L HO I-6, AX-15, NP231, D30(Open)/C8.25(Locked)
33x12.5 Mickey Thompson Baja MTZ Tires, 309,000 mi and runnin' strong
http://www.jeepforum.com/forum/f22/p...rt-xj-1297118/
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post #13 of 283 Old 12-04-2011, 03:48 PM Thread Starter
dukie564
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1995 XJ Cherokee 
 
Join Date: Jun 2008
Location: Aberdeen
Posts: 2,832
Got ambitious one day - borrowed an angle grinder, and then this happened





1995 XJ Cherokee Sport
4.5" Homebrew Lift, 4.0L HO I-6, AX-15, NP231, D30(Open)/C8.25(Locked)
33x12.5 Mickey Thompson Baja MTZ Tires, 309,000 mi and runnin' strong
http://www.jeepforum.com/forum/f22/p...rt-xj-1297118/
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post #14 of 283 Old 12-04-2011, 03:49 PM Thread Starter
dukie564
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1995 XJ Cherokee 
 
Join Date: Jun 2008
Location: Aberdeen
Posts: 2,832
Went wheeling again. For real this time. Place called Trails Rd in PA with about 15 other jeeps. First time on the rocks. Blew the seals on my 230,xxx mile steering box on the way down - made for a fun day of gaining lower arm strength trying to steer around rocks







1995 XJ Cherokee Sport
4.5" Homebrew Lift, 4.0L HO I-6, AX-15, NP231, D30(Open)/C8.25(Locked)
33x12.5 Mickey Thompson Baja MTZ Tires, 309,000 mi and runnin' strong
http://www.jeepforum.com/forum/f22/p...rt-xj-1297118/
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post #15 of 283 Old 12-04-2011, 03:50 PM Thread Starter
dukie564
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1995 XJ Cherokee 
 
Join Date: Jun 2008
Location: Aberdeen
Posts: 2,832
sooo...yeah. Blown steering boxes are no fun. I drove 2 hours home with no power steering. Filled it up the next day and surprisingly it worked! Very slow leak however - had to add fluid almost every day and the pump was NOT happy about it. I priced up reman steering boxes online, but didn't like the cost impact. I had picked up a v8 ZJ tie rod a few weeks earlier, so I figured it was the best time to do a full steering overhaul (minus the pump, which I hoped would be still good even after the stress the blown box had put on it.)

So the plan -

Steering box from a 98/99 V8 Dodge Durango 4x4 - same mounting pattern as a XJ box, but with a bigger (stronger) cylinder.
V8 ZJ Tie rod - a full 1/4" larger diameter than the stock XJ bar. and solid instead of tubular.
Energy Suspension poly bushings and boots all around (tie rods and sway bar)
C-ROK inner spacer / reinforcement plate
Add a 7/8" bolt to the spacer plate though the frame tow hole
full cleaning, sanding and painting
Grade 8 Bolt upgrades
Power Steering Cooler

Full Writeup and afterthoughts can be found here: http://www.jeepforum.com/forum/f11/d...ughts-1191132/

C-ROK plate - VERY beefy!


Junkyard components:


Shiny:


That's a big difference!


Well that looks...moist


That sucked:


New vs Old: noticeably bigger and therefore sexier in jeep speak:


Well that just looks...wrong


here we go - plate and position adjustment washers


Box in! connecting the steering shaft to the box on my back, while holding it up with one hand was NOT fun...


Power Steering Cooler mounted and plumbed up


All done:



Soooo much better - can turn the wheels with my pinkie!

1995 XJ Cherokee Sport
4.5" Homebrew Lift, 4.0L HO I-6, AX-15, NP231, D30(Open)/C8.25(Locked)
33x12.5 Mickey Thompson Baja MTZ Tires, 309,000 mi and runnin' strong
http://www.jeepforum.com/forum/f22/p...rt-xj-1297118/
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