ABCs One ton XJ build - JeepForum.com
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post #1 of 12 Old 10-07-2019, 12:30 AM Thread Starter
abc_was_here
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ABCs One ton XJ build

I was in the middle of building my YJ when finding out my wife was pregnant, so I decided the YJ build was over. I want to build something a little more street friendly and easier to load gear, our dog, and something for the newest addition to our family.

All thats really left of the old YJ


still in the middle of parting the YJ out however ive also started the tear down of the cheap XJ I already owned as a future mud drag jeep. Now its going to get a 04 SD Dana 60 with spartan locker, and 78 GM 10.5 with Torq locker both with 5.38 gears.

Started working on in this week
1992 Cherokee 4.0L HO
Ax15 5 Speed (Swapped external slave from my YJ)
NP231J w/AA SYE and Teraflex 2 Low (also taken from my YJ)

Day I picked it up just as a one day some day project paid $250 bucks, not perfect cosmetically but rust free and a solid unibody.



lucky to have access to a lift got the transmission and transfer case swapped



moved it out of the shop to begin tear down





Got the axles and bumpers out over the weekend





Tires I got from a buddy 37/12.5r17s will last me long enough to decide to go large or buy new 37s



mounted on my beadlocks



Dana 60 and 14 bolt (need to get some paint on those new parts)





Some of the parts I need to install plus waiting on my Truss and 3 link Crossmember from a local company








1992 Jeep XJ one ton build
1995 Jeep YJ 4.0L wheeler PARTED
1992 Jeep XJ 4.0L Supercharged PARTED
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post #2 of 12 Old 10-09-2019, 12:18 AM Thread Starter
abc_was_here
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Got more parts, these hiems from ruffstuff are beefy



got my new exhaust, 3 link crossmember, truss and stiffeners





some of my welds that seem to be improving


1992 Jeep XJ one ton build
1995 Jeep YJ 4.0L wheeler PARTED
1992 Jeep XJ 4.0L Supercharged PARTED
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post #3 of 12 Old 10-09-2019, 08:07 AM
chris87xj
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Looks like this will be worth watching.

***Chris***

"You can set my jeep on fire and roll it down a hill,
But I still wouldn't trade it for a Coupe DeVille."


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post #4 of 12 Old 10-11-2019, 12:01 AM Thread Starter
abc_was_here
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Ran out of welding wire so I fired up the plasma cutter and cut off the perches I recently welded on for the YJ

Not the greatest with the plasma cutter and managed to blow through a tip pretty quick (helps if you remember to turn on the air compressor) lol still way better then using cut off wheels!












1992 Jeep XJ one ton build
1995 Jeep YJ 4.0L wheeler PARTED
1992 Jeep XJ 4.0L Supercharged PARTED
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post #5 of 12 Old 10-11-2019, 12:04 AM Thread Starter
abc_was_here
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Quote:
Originally Posted by chris87xj View Post
Looks like this will be worth watching.
Hopefully I can keep some updates coming! I've got some unrealistic aspirations when I want this thing wheelable.

1992 Jeep XJ one ton build
1995 Jeep YJ 4.0L wheeler PARTED
1992 Jeep XJ 4.0L Supercharged PARTED
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post #6 of 12 Old 10-16-2019, 12:05 AM Thread Starter
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Getting started on the frame stiffeners, I need to go buy a couple more C-clamps and replace the ends on my extension cord for my welder so I can reach the jeep outside the garage.

This thing was completely in the way. Read several things saying to modify the stiffener to fit around it, instead Im going to weld it back onto the stiffener.









getting the rail all cleaned up



all mocked up

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post #7 of 12 Old 10-16-2019, 10:58 AM
lovett86
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Pretty nice build your doing

its a rusty one

https://www.jeepforum.com/forum/f22/90-yj-frame-swap-build-up-1434246/
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post #8 of 12 Old 10-17-2019, 11:57 PM Thread Starter
abc_was_here
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Quote:
Originally Posted by lovett86 View Post
Pretty nice build your doing
Thanks! hopefully it stops raining so I can get more stuff done.

1992 Jeep XJ one ton build
1995 Jeep YJ 4.0L wheeler PARTED
1992 Jeep XJ 4.0L Supercharged PARTED
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post #9 of 12 Old 10-24-2019, 11:43 PM Thread Starter
abc_was_here
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Finally got got the rear frame stiffeners finished. Once the new fuel filler lines in I can reinstall the fuel tank and get started on the rear suspension. I also got made the rear bastard pack.







also my welder broke and a friend let me borrow this bad boy


1992 Jeep XJ one ton build
1995 Jeep YJ 4.0L wheeler PARTED
1992 Jeep XJ 4.0L Supercharged PARTED
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post #10 of 12 Old 11-09-2019, 01:25 AM Thread Starter
abc_was_here
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Finally got to do a little more work on the Jeep. Got the gas tank reinstalled, new filler hoses, gas tank skid, hitch, shackle relocation boxes, lift shackles, and my bastard pack.











part of the reason I havent been working on the XJ, been a long time project and used rubbing compound and wax. Really impressed how it turned out. wish I took a good before and after shot.


1992 Jeep XJ one ton build
1995 Jeep YJ 4.0L wheeler PARTED
1992 Jeep XJ 4.0L Supercharged PARTED
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post #11 of 12 Old 11-09-2019, 11:27 PM Thread Starter
abc_was_here
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Got the rear end mocked up

Shackle angle to much?








Really not as much lift as I was expecting, I still think after trimming a 37 will fit just fine


1992 Jeep XJ one ton build
1995 Jeep YJ 4.0L wheeler PARTED
1992 Jeep XJ 4.0L Supercharged PARTED
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post #12 of 12 Old 11-10-2019, 10:42 PM Thread Starter
abc_was_here
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Finished burning in the new leaf spring perches, and got the rear end bolted in so I can remove the rear jack stands to install the mid unibody stiffeners.







now that all the holes are marked just need to clean up the rail and start welding
underscore and hodgexj1996 like this.

1992 Jeep XJ one ton build
1995 Jeep YJ 4.0L wheeler PARTED
1992 Jeep XJ 4.0L Supercharged PARTED
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