XJ Project

[87B2XLT]

Lookin' good! Nice integrated "bumpers" in progress. That thing should be fairly indestructible when it's done... or at least I'd hope so. Dare I even ask how much all that DOM is costing? That is one thing that'll probably have to be shopped up and budgeted for me... when I decide to buy it. Definitely going to be shopping around and hopefully find a lull in the prices and maybe get a steal deal on some. Anyhow, can't wait to see the finished product!

[Chuck]

Lookin' good! I like how you guys are starting off the front end, too.

godadone said:

...The money shot. (wasn't easy.)

...

Ever heard of the army cluster? I couldn't find a pic online, I'll have to see if I can find a chance to bring one of my books from home and scan a pic and the procedure. It was one of the welding qualification tests for WWII aircraft welders -- it's essentially three tubes, partially fishmouthed, slotted down the center, and joining at a common point in the middle of a 1/4" gusset plate. Welder had to start with plain tube and the plate, cut the slots, form the tube, and complete the welds, then they were band-sawed down the middle across the 12 welds for inspection. You had to have complete penetration on all welds with zero drop-through on the inside, including the welds between the 0.065" tube and the 1/4" plate. Oh, and all done with an acetylene torch. ;D

[KarlVP]

Wow, I don't think I ever need to get that certification.

Too much of a PITA for me.

Anywho, here's more progress.

A look at Tom's precision sawzalling skills. Just when you thought there wasn't anything left to cut.



This piece is all sunk down in there now. THe glovebox doesn't open anymore, but we think we can take care of that with more sawzall work.



Drivers View



These pieces are going to need minor adjustments but you get the idea.

[KarlVP]

With most of the 2 inch tube work done, it's time to start on the "dinky" 1.5 inch stuff.



The windshield cross brace. This will have holes drilled in it to work as the defrost. (redneck engineering at it's finest)



We are going to have fun sawalling the glove box so we can close it.



Angled b pillars to aid with ingress and egress (navy words)




6 inch lip as required by washington law. (Yes it will be "street legal" when we are done.



Mike is crazy and wants an 8274-50 (best winch ever made) in there so we are going to cram it in. We are going to use some headlights from an s-10 blazer in the grill and "try" to make it look like an XJ when we are done.



the rear end. We will have a MJ taligate back there along with some super bling LED tail lights.



With all that done, we went on a night run. Wheeled until about 2am when I snapped a contol arm off my TJ. So we packed it up and went home for some sleep.

[Jim63]

Looking good! Looks like its going to be a real fun xj! ;D

[KarlVP]

It was a nice day so we decided not to go wheeling and get some work done.


Shiny New goodies delivered by the UPS man.



If any of you wondered why the Jeep has a giant "fishmouth" now you know why. This winch is huge.


students.washington.edu/mdj2/Pictures/Cherokee/March%2018/March%2018%20002.JPG

We started ripping the AC system out to use as on board air. And we are going to move the power steering cooler over some to accomidate the winch.



Thar she be.



We are going to make a plate so if the cable stacks up on itself, it won't damage the radiator.


Finally, we started making a frame for the beast. These plates are what the "indestructable" (read: already bent) Skidplate will bolt to. We had to weld some bolts to them so the skid plate will bolt back up. The big holes are for welding it to the frame.





Just when you thought we were done cutting..... when you can't sawzall any more, time to bust out the torch.


We are getting closer. Another couple months and she'll be ready to rock.

[KarlVP]

Hey LOOK!!!! A frame!!!!



Fun with the torch.



B to B tie in piece. We are going to work on this a bit more for the trangulation, but now we can mount the harnesses and the rear seat passengers will have something to grab on to.



Also added these fancy standoffs for the 6" lip.



Lastly, work on straightening the skid plate.

[87B2XLT]

Fun, fun. I guess that's my only drawback on looking for a cheap XJ to 'build', although, one of my shipmates totalled hers... and all that was ate was the passenger's rear quarter. I dunno if she was b-s'ing me, but she said the insurance company totalled it. I think it was a newer one (1998 or so), same color as Dave P's, close to the same year as well. Going back to the start of this post, my only drawback meaning the unibody framework, etc. Not discrediting an XJ, because I have seen them do some pretty awesome feats, and they are generally an all-around good performer, even in stock form.

[KarlVP]

With the skid plate all straight, it was time to add some reinforcing strips.



And finally, with all the tube how we liked it, time to burn it all in. This is the point of no return.


Remember those frame rails we made? Here are the tie in pieces to the cage.



Yup, it has a frame now.



We made these plates to get a start at boxing the now very weak rear spring mounts.



And the bottom part to the rear bumper. This will have a reciever mount dead center for a recovery point.



Just a test fit to see how far a 12.5 wide tire sticks out.

[KarlVP]

A Pillar Triangulation Complete


Mike had his wife sit in the Jeep and asked her where she wanted handles. So we buzzed them out real quick.



What's this!!!?!!?! Prepping for paint work? You mean it might be ready for the Memorial day run!!!??!?!



Claire and her mad fat painting skills. She picked the colors, we kept teasing mike that he was going to have a Jeep done in all pastels, but Claire wanted to keep the white/black scheme.



All primed and ready to go



Now all we have left to do is herculine the tub, build some doors, make the fold down windshield, make fender flares, finish painting, install some winch controls, wire up a dual battery system, replace the motor mounts, install the 5 point harnesses, Fluid changes all around, and get this thing ready to kick some trail!!!

[KarlVP]

Can you say progress?

We got all the welding done from the firewall back. Got what's left of the original sheet metal welded to the new frame and cage tie in points.



Close up of the grab handles.



We sawzalled the glove box, bolted the top part back on the dash, and it works like a champ. Good as new.





Freshly re-inforced leaf spring perches.



We put the seats back in, measured for harnesses and welded tabs to connect them to the cage.





Front frame rail and steering box stiffeners welded in. These were a pita to do, but turned out real nice.



After getting all the welding done, we had some beers and started slinging primer like it was nobody's business.



One week left to the big run, and too much work left to do. Hopefully we can get the herculine done this afternoon.

Oh, 36 IROK's anyone?

[JeepinGoose]

To say "impressive" does not do justice. That thing is sweet, and is gonna be a beast when its done. When are you guys looking at being done?

[KarlVP]

"Done" Is a relative term.

We will have it ready to wheel the big memorial day run on the Naches trail this weekend. It won't have doors, flares, lights, or a tailgate, but it will be wheelable.

After this weekends shakedown run, we will do all the little things to it. Tube doors, add the tailgate, build a roof, build some flares.... little things like that.

More progress pics....

herculiner in. And we didn't get any on our Hootuses.




Front end finish welded. We made gussets to tie the front bumper into the frame we made.






Getting closer. Paint tonight. Tires tomorrow. Tow to the trail friday, wheel all weekend!!!!!!!!!!

Oh, it has a nickname now. Tubeasarus Flex.

[KarlVP]

It's ALIVE!!!!! IT'S ALIVE!!!!!!!!!!!!!!!




However, Mike broke his front axle ring gear this weekend. So, back in the shop it goes.

[XJames]

godadone said:

With the skid plate all straight, it was time to add some reinforcing strips.

Thats the t&t y-link right? I just got mine in. getting painted right now. How do you like it and does the skid have some problems? You straighted it and reinforced it.