CORE4WD XJ Build up

[CORE 4WD]

Figured I might as well post my heep!

1999 XJ Sport Auto, 8.25 Power Trax/HP D30





C.B./hand throttle-


Rock/work lights-


Red=spot lights, Green=rock lights, Blue=air compressor, Flood lights are wired into stock fog lamp switch-




E brake skid-


Winch bumper/front rock plate/Big Daddy tie rod-


Rock rail-



The angle piece is the rock rail mount-


Rock plate, also pinch seam mount for slider is underneath-


1/4 bob and gas tank skid (I'm building new bumper which will incorporate side protection)-


OBA Viair 460C/5 gal tank-

I'll be mounting an external hook up-


Fabbing 8.25 skid-

Trial fit, it'll get a gusset on the sides to strengthen leading edge-


Skid fitted and diff shaved-




The rocks at Crozet "shaved" the bottom a little more, it was dragged through Boulder Highway!
If it's smooth it's sliding not hanging-



3/16" worked good for weight of XJ, definitely 1/4" for anything heavier.


Added 6/05/06-
I am now building the bumper I wanted from the start, which will incorporate side protection for bobbed rear quarters. Here goes-









Pics added 24 May 06-
Finally taking shape-

Area under taillight will be boxed (what body damage?!)-

Uni-body tie-in-

Other side tacked-

Center tie-in to receiver-


Pics added 6/6/06 ;D-
Primered-



Installing-



End caps, need to countersink hardware new tires would probably rub bolt heads-





Pics added Aug 02...
Remote winch control install-
Dash piece out, control box bolted on-

Had to take dash apart a little to route wires, etc-

Mounted, antennae is in loom running up side of dash, wiring goes through firewall grommet-

Orange and yellow wires get hooked to solenoids to actuate in/out modes. Are two vice four solenoids (like Warn) better? Less to go bad and easier to troubleshoot if one does go bad?




Comments/questions always welcome...

[XJames]

Awesome ;D, I like the front bumper. I hope one day I will be able to fab my own stuff.

[Chele]

Nice rear skid...is that new???!!!! ;D

[Jim63]

hey I love that rear skid to!!

[CORE 4WD]

chele said:

Nice rear skid...is that new???!!!! ;D

Prototype 8.25, same concept as Nth, need to beat on it at Crozet to see if I like the 3/16" vice 1/4" thick plating. It'll be done tomorrow, tacked the gussets in today, finish-weld tomorrow and paint.

[Chuck]

Hey Dave, looks good. What are you using to bend your plate?

[CORE 4WD]

chuck said:

Hey Dave, looks good. What are you using to bend your plate?

Here's how I do it-
Score marks


Scored using a 4 1/2" angle grinder with 1/16" wheel. After cutting plate out it leaves enough on wheel to score areas without going all the way through-


Poor man's brake-


Ok, finish weld Wednesday? You have to go back and weld score areas for strength-

[What It Was]

Good fab Job!

[Chuck]

Good deal, it makes a nice clean bend too. I've used the heat-it-and-beat-on-it method where I needed a bigger radius, but it doesn't work well for long bends (can't get enough heat into the plate, even with a #4 tip on the torch). That could come in really handy later when I start on the front bumper, save me a lot of cleanup ...

[RuffRider]

I like the new skid. How do I get 1 of those?

[CORE 4WD]

Pick a number! Seriously, I'll build one for you, I'll add you to the list. Let me beat on this one next weekend to make sure I like 3/16" plate!!

[What It Was]

Hey man... I noticed you didn't weld the seems... Are you going to weld them for added strength or are you going to leave them as is?

[4WDnRocksNmud]

core4wd said:

You have to go back and weld score areas for strength-

[CORE 4WD]

Here's how you do it, Fife! Heeello!

core4wd said:

chuck said:

Hey Dave, looks good. What are you using to bend your plate?

Here's how I do it-
Score marks




Scored using a 4 1/2" angle grinder with 1/16" wheel. After cutting plate out it leaves enough on wheel to score areas without going all the way through-


Poor man's brake-


Ok, finish weld Wednesday? You have to add gussets to front lip, go back and weld score areas for strength-


Might as well keep going-






Can't wait to test it on some rocks! Jason (93RAMn01TJ), you're no Vanna White but thanks for "presenting". ;D

[Jim63]

looks good dave!