Another XJ on 1 Tons Build Thread - JeepForum.com
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post #1 of 24 Old 04-21-2015, 03:07 PM Thread Starter
AKIQPilot
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Another XJ on 1 Tons Build Thread

Ok. My Son in Law has finally started his build. This one is going to be nice, not like my weekend, slam bam build. He doesn't get on this forum much so I will do my part and try to document the progress.

Son in laws name is Kody so I will likely refer to him by name or SIL.

This is going to be 4 linked front and rear, HP 60 in front, Sterling 10.5 in rear, 44" ag tires, full hydro, Wheelbase stretched about 18 inches.

We picked up this '99 last year for $700. It had a bad TCM that was causing some electrical problems and it had a crack in the head between 3&4. $40 for a new TCM and about $500 for a new head with all the goodies to bolt it on.

Rig has under 90,000 miles on it. Runs perfect and it's virtually spotless inside and out. Not a speck of rust anywhere but the drivers door skin has a little wrinkle in it.









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post #2 of 24 Old 04-21-2015, 04:28 PM
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How the hell did someone manage to crack the head on a 99 before reaching 100k miles.

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post #3 of 24 Old 04-21-2015, 04:39 PM
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This thing is going to be a beast!

2001 Silverstone Metallic Classic XJ

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post #4 of 24 Old 04-21-2015, 04:55 PM Thread Starter
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Quote:
Originally Posted by Motorcharge View Post
How the hell did someone manage to crack the head on a 99 before reaching 100k miles.
Not sure but glad they did because between that and the bad TCM I was able to talk the guy down from $2800 to $700. The thing was stuck in 4th gear. The exhaust smelled like coolant.

I said to the guy. The tranny is likely ruined, that will cost me $1500 to have fixed. The head is cracked, thats another $600. I can only offer you $700 for this thing even though it's pristine. He said, "thats the same thing the transmission shop told me and you are the only guy to even make an offer. I'll take $700"

Loaded it on the trailer and drug it home.


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post #5 of 24 Old 04-21-2015, 08:25 PM
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This'll be a fun one. Awesome haggling skills for a worthy grab to monsterize',

D3<!L!>3D
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post #6 of 24 Old 04-21-2015, 08:49 PM Thread Starter
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Here's what about 1500 lbs of unnecessary crap looks like.









Mid way through Day one of the build.



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post #7 of 24 Old 04-21-2015, 09:22 PM Thread Starter
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Most of the big junk is now gone time to start preparing the chassis for plating.





These should fit no prob, right?



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post #8 of 24 Old 04-21-2015, 09:39 PM
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Quote:
Originally Posted by akiqpilot View Post
most of the big junk is now gone time to start preparing the chassis for plating.

These should fit no prob, right?
right!!

D3<!L!>3D
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post #9 of 24 Old 04-21-2015, 09:59 PM Thread Starter
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Uh oh. What do we have here.



Tacked into place.







Seal welded.



And now fully welded out.



Both sides are now complete from the front bumper to the forward leaf spring perch. Still need to plate the inside of the frame in strategic locations for the 4 link mounts.


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post #10 of 24 Old 04-21-2015, 10:04 PM
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Damn! talk about digging right in!

~Mike~


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post #11 of 24 Old 04-22-2015, 11:55 AM Thread Starter
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Time to start trimming fenders and making new inner fender wells.





Marked out the cut line for the inner fender.



Inner fenders gone....





Made templates for the new inner fenders.





New inner fenders all shaped and welded into place.



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post #12 of 24 Old 04-22-2015, 12:16 PM Thread Starter
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So now it was time to tidy up some loose ends under the hood.

We removed all of the air conditioning components except the compressor. The evaporator, the condenser, all the lines, all the electrical controls are now gone.

Cruise control actuator and wiring is now gone.

EVAP solenoid and all the EVAP lines and components are now gone. Plugged the EVAP port on the intake manifold.

All of the antilock brake mechanisms and wiring are now gone. Built brake line adapters to connect the metric thread of the master cylinder together with the SAE threads of the brake lines going to each front wheel and the rear.

Relocated the coolant overflow bottle to the passenger side firewall.

Built a battery tray to move the battery between the compressor motor and the firewall.

Removed all unnecessary wiring from the fuse/relay panel and remounted it.

Removed about 10' of unneeded vacuum lines and relocated the ball canister.

Removed all of the wiring behind the grill. Dissected the wiring harness on the driver side and removed all the unnecessary wiring for the antilock brakes and all the windshield washer wires and hoses.

Relocated the ECU to a more strategic place close to the master cylinder.

Cut the bottom off the airbox and made a new floor for it out of 22 gauge. Mounted the airbox back in it's stock location.

Almost everything under the hood is done, next up is the PSC full hydraulic steering install.

Once we are completely happy with how everything fits we will disassemble everything and paint the new sheet metal of the inside and outside of the fender wells.


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post #13 of 24 Old 04-22-2015, 01:02 PM Thread Starter
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So, on Day 2 it was time to start on the rear fenders...........

The plan was to move the rear axle back about 10". That may get revised a little as we run the numbers through the 4 link calculator but the rear is getting stretched somewhere between 8" and 10".

Took the torch to the sheet metal and started whacking. The rear door makes it a challenge for a nice looking shape to the fender. We drew a line and Kody started chopping steel.



Inner and outers are now gone.





Tried to stay with the body lines of the rear hatch and maintain some level of structural integrity for the hatch. We didn't want for a little bump to the back corner to damage the way the hatch closes or seals.



Bent up some 16 gauge steel and made a new inner fender. All tacked into place.







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post #14 of 24 Old 04-22-2015, 01:12 PM Thread Starter
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Now both rear fenders are finished. Fully welded up inside and out.









Even the rear seat belt anchors are welded back in place.



Sometimes welding this light sheet metal together leaves less than the most beautiful welds.

Once Kody is completely done welding everything, body, frame, fenders, stiffeners, crossmembers, etc, etc, we will paint and undercoat all the bare steel.


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post #15 of 24 Old 04-22-2015, 01:12 PM Thread Starter
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On Day 3 we decided to take a break so we drank beer and played hop scotch all day..........


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