Alright, so I guess this is due for a long overdue update
So, since last time there's been a bit done.
Cooling Issue:
So overall, I'm decently happy with my cooling system. It's "issues" have not been so much due to it, but user error or part malfunctions (mentioned below).
The DC Controls fan controller, when set to it's lowest kick on setting, was still having the rig hover just above 210. Well, I realized I had the temp probe coming in from the wrong end, so I flipped it around. Due to the temp probe being within the fan shroud, that was also causing a little bit of an issue, with the probe seeing lower temps than it should. So, I grabbed some clear plastic I have around, and blocked off the opposite side using some tranny cooler zip tie pieces, to prevent air flow of that small area.
Result? That kept them temp hovering under 210, all day, no problem...well...kinda.
My biggest issue is cheap 80A relays. Even though the fan is 0 to 100%, it smoked one 80A relay (Import junk, enough said). Well, I rewired the fan so that the bypass was on the low side of the fan. This way, if the controller failed, I could just run the fan on low full time (this keeps it right about 210 all day).
Well, ran Carnage the other weekend, and just as I'm getting out the exit...bam...I can hear my coolant overflow tank boiling.
I haven't had a chance to pull the dash off yet, but I'm preeeeetty sure the sh*tty 80A relay died...again.
So...**** those relays...
If it is indeed the issue, I'm just going to do what I should have in the beginning, and get an 85A continuous duty solenoid and never have to worry about it again!
Otherwise, the only thing I would probably change, would be to eliminate the soft hose that connects the two hard tubes under the belly. I'd either figure out a way to get one long piece in there, or have fittings welded on to be able to run braided hose. I used some RTV on the connections down there, as well as switched everything over to T-bolt clamps and got rid of the crappy worm clamps. So far, leak free.
Trans Cooling:
So after swapping out the defective trans gauge, I've been good on trans temp...until this last weekend. If mobbing around on trails, it can get warmer than it should (~250). I just don't think the little cooler and fan I have are up to the task when not going crawling, but not driving at higher speed.
My solution to this, a bigger, more efficient cooler mounted in the rear. The current setup is a tube/fin, I'll move to something larger that is stacked plate/fin with an accessory fan. Luckily the biggest PITA of that, will be taking the seat out, and panels to get hoses made and in for the rear. That brings me to:
Steering Cooling:
This is something I've honestly never had an issue with, until this last weekend (gunning around, and the run on Carnage). I could hear some whining coming from my pump, and I started leaking some fluid out between the orbital and left rear fitting (if looking at the orbital from the top, with the steering shaft towards you, it would be the left rear output, which goes to the ram).
The weird thing was, with me in low-low, and the pump whining...my rig kept wanting to die. If letting off the throttle, it would die. It would start right up and work fine, but then die if not giving it a little gas. I'm thinking that possible in low low, and the pump causing a little more tension, that it just wasn't enough to want to easily stay running. Otherwise, it's never been an issue. Once we got to the top of the exit and let it sit...no issues all the way through Chinamans back to camp.
I'm running Amsoil Hydro fluid. I might see about doing a flush of it depending on how it looks.
Once we were off the trail, and it cooled down...no issues or whining at all.
Luckily, I do have another cooler in a convenient spot that work for Hydro
I'm going to use the current tranny cooler, as an additional in line cooler for the hydro. I figure that should be enough to quell any issues going forward.
Other Things:
I got the front 300M RCV's in. That was a NIGHTMARE...well at least the first side was. Turn out I needed to clearance the inner side of my SOLID knuckles to prevent them from hitting the boots. But, they're in an running now!
The rear got some Yukon 4340 shafts, hard to pass up a BOGO sale! I thought I was going to be able to cut these on my bandsaw...NOPE! It got through about 1 tooth...then nothing. It will cut through thick mild steel no problem. So...out came the chop saw. ****, even that I had to go bits at a time, letting both cool off. But finally, got them cut, leveled, beveled, and it.
BODY PANELS!
Got all the body panels finished up
The doors are AL, with bends to match the body line. A thanks to Scott at Addicted Offroad for saving me a bit of time and getting those body line bends taken care of for me!
The hood came out better than I had thought. It's not perfect, but I'll take it!
Painting is still an art I've yet to fully master (I mean, I've only done it twice now :laugh

. The base coat is easy...it's that damned clear coat that is an art!
As a note, the paint I used...is $120...a QUART. I wanted the rig to look good for a least a little while
Hell, I ever used my professional quality buffer to give her a once over before going wheeling!
I worked until 2:30 in the morning (having started at 3pm the day before) to get them done in time for the activities that following weekend (see next post

)
Overall, I'm really happy with how it all came together.
I'm pretty well done working on it now other than those simple things listed, and adding some additional lighting.
It feels...weird...being done after ~7 years of building, and nearly 10 years of acquiring parts.
Luckily I have another XJ (mild) that I am building to keep me going (along with the shop interior finish, the truck, trailer, and so on :laugh
