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post #1 of 15 Old 10-30-2019, 08:02 PM Thread Starter
hodgexj1996
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My Franken****boXJ

Sup guys. Finally registered after being a forever lurker. Figured I'd share my stuff with the world.

About 10 years ago I built my 96 xj up pretty good.

6.5", 35s, 4.56s, homebuilt bumpers etc. Not long after I finished I sold it to fund my diesel bug. Well, fast forward to this September I managed to scoop it back up. My intentions were to restore it. After a little bit of digging into it and alot of inner debate I decided that rust had overtake alot of its structural integrity and even though I'm capable of ressurecting it, I went in search of a cleaner chassis.

I stumbled upon a 2000, bad motor but pretty much mint. Scooped it up for $600 and my project began.

I've dropped my 96 motor and 231 with an sye in. Converted the motor to the coil packs, plumbed in the 4 o2 sensors on my header and swapped all the necessary sensors. Built a full exhaust using both vehicles exhausts, fully welded.

Gutted the interior, fixed a few spots in the floor pans, shampooed rug, cleaned seats, sealed firewall leaks at hvac box, painted the headliner board with graphite Rustoleum Peel Coat, and got it all back to 100%

Swapped my D30 with 4.56s and a lock rite as well as the 8.25 with a power trax. Used my 4.5" coils, made a bastard pack out of the lower leafs of my old lift packs but kept the OEM main leaf. 1.5" shackles. OME extended travel Shocks. I made my own short arms using Currie Johnny joints on both ends, as well as the upper mounts on the axle.

Today I mostly completed my brake lines, stainless pre bent kit from SS Tubes. Need to rework the passenger front line a bit through the engine bay and rebend the wheel side but it's all in. Deleted ABS as well so I'm tracking down the stupid fitting for the rear of the Prop valve.

Currently waiting on R.C control arm drops, shackle Relocators, flag nuts for the shocks and braided lines. Have a head unit on the way to finish the interior as well.

Need to sort a few silly things like modify my rack mounts and swing out on my tire carrier.

Plan is to run some 33-34s and just have a reliable second vehicle to load up when I decode to take the GF and dog on adventures. It's been alot of work, and there's still a ton to do. I'm slowly refurbishing a majority of the parts as I swap them over. It's saved me a ton of money, but takes a lot longer than anticipated. 20190914_133358.jpg20190915_140525.jpg20190929_175650.jpg20191010_101727.jpg20191010_144028.jpg20191017_183919.jpg20191018_111336_001.jpg20191020_161828.jpg20191021_120024.jpg20191021_120044.jpg

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post #2 of 15 Old 10-30-2019, 08:05 PM Thread Starter
hodgexj1996
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Some more....20191023_130627.jpg20191023_133344.jpg20191024_164748.jpg20191025_095813.jpg20191025_154101.jpg20191025_154118.jpg20191025_154026.jpg20191025_154600.jpg20191027_162946.jpg20191027_163006.jpg20191027_163014.jpg

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post #3 of 15 Old 10-30-2019, 08:06 PM Thread Starter
hodgexj1996
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We all love pics! Some more....20191028_123010.jpg20191028_123025.jpg20191028_144832.jpg20191028_144843.jpg20191028_172041.jpg20191028_172108.jpg20191028_171941.jpg20191028_172137.jpg

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post #4 of 15 Old 10-30-2019, 08:08 PM Thread Starter
hodgexj1996
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Factory Fresh Interior....lol20191029_163632.jpg20191029_163639.jpg20191029_163651.jpg20191029_163704.jpg20191029_163730.jpg20191029_163759.jpg20191029_163810.jpg20191029_163858.jpg

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post #5 of 15 Old 10-30-2019, 08:15 PM Thread Starter
hodgexj1996
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Random Pics from.today before it rained

This was the abbreviated version of about a months worth of work. I can honestly say there isn't one bolt I haven't touched on this vehicle. Nothing earth shattering per se but as I go in cleaning, painting and refreshing each area. Kind a treating it as a resto/mod as I go.

My 96 was built more for trails here on the east coast, and I beat it up pretty good. This time around I'm leaning towards....dare I say....an overland mindset, minus the tents and stuff. If I get to that point I'll have a trailer to set up for camp duties. Overall I'm trying to overbuild it so I don't have to worry much. Keeping it turn key and not over the top.

If anyone has any questions on anything feel free to shoot. Especially for an H.O motor swap into a newer model.

I'll update as I go. Still waiting on a bunch of parts and sorting some miscellaneous stuff out. 20191030_120405.jpg20191030_134133.jpg

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post #6 of 15 Old 10-31-2019, 10:44 AM
chris87xj
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Welcome to the forum.
This jeep knows what love feels like. That interior looks spectacular.
I have a 2dr 96 the same color

***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 #7 of 15 Old 10-31-2019, 06:56 PM Thread Starter
hodgexj1996
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Quote:
Originally Posted by chris87xj View Post
Welcome to the forum.

This jeep knows what love feels like. That interior looks spectacular.

I have a 2dr 96 the same color
Thanks!

I'm currently laid off so I have plenty of free time. I have turned ever single bolt on this truck, legitimately.

The interior was in great shape, just musty. I am in NJ so for me to find this rig as clean as it was was like finding a unicorn.

Currently getting my butt kicked doin the brake job. I ordered a pre bent stainless kit, it fit well but small alterations are tough by hand. That and I csnt find the fitting for the back of the Prop Valve (circled)

Once I get the brakes sorted it will be close to ready for the shake down drive. screenshot_20191031-144444.jpg

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post #8 of 15 Old 10-31-2019, 07:45 PM Thread Starter
hodgexj1996
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So I got my head unit installed, brake lines installed, rear shock upper flag nut kit and shackle Relocators in. Head unit was a basic plug and play from quadratec. Forgot to snap a pic. It's simple, nothing fancy. Need to re wire the front door speakers but that's non essential.

Brake lines have been fighting me, these pre bent units were close fit, but the tweaks to make them to my liking are difficult as the stainless line doesn't like to bend by hand. Ordered a New Old stock Prop valve so hopefully I can have them buttoned up early next week. Need to cut and flare the front wheel well connections but aside from that it should be good. Fingers crossed nothing leaks.

Rough Country products all showed up. Brake lines are nice looking, flag nuts are nothing fancy. Shackle Relocators were a nice setup for my mild uses. I had the original hd offroad ones, do compared to those these were a breeze to install. Minor prying since my drives shackle box is a bit wonky from the factory but nothing to complain about. I dropped my shackle a hole and only gained about 1/2" height. Should level out nicely.

Tomorrow I'll be installing the CADs and running over all the stuff I've installed and revising my to do list.

Getting down to the wire weather wise, I'd really like to get this thing driveable by next week.

Tires are gonna be my biggest hold up as I don't have any sourced yet. Might just buy brand new if I can't find any decent used. 20191031_171352.jpg20191031_171339.jpg20191031_172901.jpg20191031_172810.jpg

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post #9 of 15 Old 11-01-2019, 11:25 AM
chris87xj
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Quote:
Originally Posted by hodgexj1996 View Post
Currently getting my butt kicked doin the brake job. I ordered a pre bent stainless kit, it fit well but small alterations are tough by hand. That and I csnt find the fitting for the back of the Prop Valve (circled)
I had the same problem so I borrowed a tube bender and double-flare crimp tool from the auto parts store and re-used the factory fitting.

***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 #10 of 15 Old 11-01-2019, 02:21 PM Thread Starter
hodgexj1996
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Quote:
Originally Posted by chris87xj View Post
I had the same problem so I borrowed a tube bender and double-flare crimp tool from the auto parts store and re-used the factory fitting.
Yea, I have the lines all good except I need to cut and flare the connections to the front wheels. That's this weekend. Have a new proportioning valve coming for a non abs cherokee, got tired of running around trying to make it work. Once that's here I'll be ready to bleed the brakes and get it out on the road.

Control arm drops were installed today and I threw drive shafts in to check pinion angles. Everything looks peachy. Super excited. I had it fully dropped and I have no binding, axle sits nice and level through its full travel and I have minimal drift to the drivers side. Hope I mitigated the bump steer I was having at the 6.5 lift I was running.

Have a few odds and ends to check like a sloppy output yoke on t case and freshen the rear brakes up, but the list is infinitely smaller than it has been. Fingers crossed it's on the road next week!

Picking up some jk wheels and spacers tomorrow. Need some tires as rollers until I get my yard cleaned up than I'll get my 315s tossed onto the wheels and bump stop as needed.

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post #11 of 15 Old 11-01-2019, 02:25 PM Thread Starter
hodgexj1996
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Pinion angles look pretty happy, so I'll run them as is and adjust if necessary.

Last 2 pics are the wheels I'm grabbing tomorrow and how these doughnuts are gonna look on my rig until I can swap my 315s over.

20191101_134342.jpg20191101_134439.jpg20191101_134454.jpg20191101_134407.jpgscreenshot_20191101-142554.jpgscreenshot_20191101-142537.jpg

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post #12 of 15 Old 11-02-2019, 05:52 PM Thread Starter
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So today I picked up those jk wheels and spacers. For 300$ i couldn't say no.

Tightened the output shaft yoke on t case, got front brake lines buttoned up and tore the rear drums off to get ready to freshen up the rear brakes tomorrow. Still waiting on the proportioning valve I ordered, so far that's my biggest hang up.

Need to center the axle, do an alignment, and button up the brakes. Gonna trim a little, remount stock flares and get ready for cut and reweld on the rear quarters. Than it's just modify my swing out arm, redo the rack mounts and give the ol girl a once over. Fresh fluids, bolt check etc. We're getting close.

I have 315 70 17s sitting in my garage I'm hoping to mount on the rims. Just need a baseline of how much bump stop and trimming work I'll need so I'm gonna run these stock jk rubbers for now. First things first I need to get it on the road before j can worry about any of that. 20191102_181503.jpg

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post #13 of 15 Old 11-06-2019, 06:01 PM Thread Starter
hodgexj1996
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So I finally got the brake lines to stop leaking. At some point I'll take it to a shop and have them redone. Of all things I can do, a double flare properly is not one of them.

So I went about trimming the sheet metal since the stock flares won't be goin back on. Only cut up to right below the factory flare holes. The stock flares murdered the paint under them, so a quick repair was in order. I plan on properly cutting and rewelding the lower quarters and rear wheel wells to match the front this spring but I needed to get a little clearance for my 315s. If needed I'll trim more once I get them on. Quick trick I learned to patch non structural rust holes, aluminum hvac tape. It sticks like an angry gorilla when properly prepped. Rhino Linering shops use it to cover holes when factory plastic is removed. It'll keep the holes sealed and rust at bay for the winter. I'm using herculiner since I got a kit with the jeep and it's free. The winter will chew it up pretty bad, but it'll get me by. Tomorrow I'll get the rest of the painting done, both bumpers included, and a couple extra heavy coats of herc on this pig.

Fixed my tire swing out as well. I totally spaced out and started the body work with the jeep facing the wrong way. So a 50' extension cord, 110v flux core welder and a ground lead that's on its last leg equates to gorilla welds....but the grinder and bedliner will hide the embarrassment. Stoked with how it turned out. It's solid. Should hold the 35 just fine.

As of now I just need to get the axle centered, do an alignment, bleed brakes and finish the rack mounts. Oh and plastidip the wheels once the tires are changed.

IT'S SO CLOSE I CAN TASTE IT

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post #14 of 15 Old 11-19-2019, 06:26 PM Thread Starter
hodgexj1996
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Update since it's been a bit. Have almost everything sorted. Took it out for a shakedown run today. Need to trim a touch more and throw 3 hockey pucks in the bottom for bump extensions. Will stop about where it's stuffed in the pic.

Front axle is getting torn down. Adding IRO almost alloy kit, adjusting pinion preload and new pinion seal. Adding a frame side drop tack bar bracket for my abomination of a track bar setup and my angles will be good enough to suffice until I get an OTA setup.

Jeep drives damn near perfect aside from needing a true alignment, runs 65-70 with no issues. It feels very balanced offroad as well set up like this. Not very impressive with the flex, but it makes up for it with the 35s and lockers. Weekend after Thanksgiving I'll be taking it out to AOAA in PA for its first official trail run.

https://www.ironrockoffroad.com/Merc...uct_Code=10114

This is the kit I'll be adding to my axle shafts. My ears are getting loose on the joints, I already have 760s so instead of spitting a cap I'll just add this to it and freshen up a set of spare shafts with this kit as well. 20191115_134825.jpgName:  42696.jpg
Views: 16
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post #15 of 15 Old 11-23-2019, 05:39 PM Thread Starter
hodgexj1996
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Tossed on the Clayton drop bracket for 6-8" lift and my angles are much better. Mitigated all but the slightest bump steer, which I can't do much about with the track bar being quite short. Mind you im @ 4.5" lift. Was worried about track bar vs diff clearance but everything works good.

Waiting on my almost alloy kit to come in. Gonna do that, pinion seal,pinion preload and tweak alignment a bit more before my trail ride next weekend. Either hitting Aoaa or Rausch with a few buddies. screenshot_20191123-182813.jpgscreenshot_20191123-182821.jpg

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