Just Another XJ on tons, coilovers, 42's, etc. Build

[freerider15]

Truck update

As I got it:

Front before:

After:

Rear before:

 

[freerider15]

Rear After: (2008 Tail Lights and a Recon Smoked LED 3rd brake light)

HID's (low):

HID's (high):

Overall...I'm more than happy with how it all came out :smokin:

As you can see I also added smoked cab lights and different wheels. As you can see the passenger side mirror is broken. I'm going to be replacing the mirrors with ones off a 2007, since they're heated and have integrated blinkers :grinpimp:

The HID's are nice...the only thing I might complain about is the its not a "diffuse" pattern but has some jagged "lining" in it...hard to describe. But for $50 i'm happy!

I'm going to remove/tape off all the plastic (bed caps, rear bumper top, handles) and get them all painted as well since they've faded a bit.

The only other plans I have for it really are a 7" flip-up in dash DVD/MP3/etc. player for the long trips, and doing a DP Tuner (Guages, Exhaust, etc.)

 

[freerider15]

Update:

Picked up a spare for a song...it's a 42x17R16.5 on a TR beadlock.

Thing is...its BIGGER than my 42's by a good amount! (both are aired up to the same PSI)

Oh well!

Got this beauty from Jess at High Angle Driveline :grinpimp:

Installed:

Got my old rear driveshaft lengthened, cv ball replaced and all new joints put in:

 

[freerider15]

You can see how close it is at full bump...but it clears!

Got the triple stick setup done. The handles aren't remotely done, and a little more finish work to do on it but it shifts!

Got the alternator and orbital mounted, used the alternator mount of a WJ 4.0:

Getting much closer to getting the thing moving under it's own power!

 

[freerider15]

So I know i'm a bit overdue for an update, between moving at the beginning of january as well as the last couple month being really busy...its hard to have been productive :shaking:

Needless to say:

What's been done:

- Tranny Cooler mounting done.
- PSC pulley mounted on pump
- Pump mounting finished up
- New tubing and seat mounts done for the front of my driver's seat
- Finished driver's side floor bracing
- Finished triple stick setup

I'll let pics speak for themselves

And a sneak preview...actually looks a lot better in person (and for some reason this picture makes the buggy look "portly" :laughing

 

[freerider15]

Alright...so I've been rather busy lately. :grinpimp:

Working from home has its perks...

Bought this from a buddy locally, Tyler (tmorgan4) here on the boards.

Nice big Weatherpack kit:

Which helped me to do a bit of this:

Which in turn with a bunch of loom I found in the trash at a client site allowed me to get this stuff done:

Now for a bit of interior stuff:

Got the passenger side floor about knocked out. These two floor panels have actually been about 80% done for a long time now, but finally got them finished up and bolted in:

As you can see from this pic, interior panel tabs are getting done:

I do have the main cross dash actually 90% done (bolts in just need to open up the gauge cluster hole a little more) which I'll post up later. The center console dash piece is going to get cut out tonight most likely.

Now...that leads us to something that took a while to think through and actually get done. This took a little busting out of the enginerd in me to get knocked out, and i'm pretty damn happy with it.

It would be...my tranny shifter :laughing:

So you can see how it sits here in relation to the seat:

It *might* look like it would get in the way or be obstructive somewhat...but it actually damn near perfect in its location. Very easy to reach and shift.

An overall shot:

 

[freerider15]

I basically used what is known as a revolute joint, a joint that only has rotation in one direction which in this case is to the left and right (driver / passenger). Ultimately what I wanted was a shifter that was easily reachable, and could be slammed into reverse if need be and not go into park without extra movement. Essentially what I wanted was a gate shifter...but I didn't have the room to mount one.

This did take some lathe/end mill work since things like the female part of the revolute joint aren't easy to find, but I'm really happy with how it sits/works.

I still need to do some lathe work to make the final linkages since the one that connects to my transmission from the shifter is a mockup (its actually the same one from my NP231 shifter).

I'll try and let pictures speak for themselves but I can clarify/explain more if anyone would like.

So by some of those pictures I think most people should be able to understand how it works. Essentially the spring puts pressure against the handle, so to shift it in park you have to push over, then up as you do with certain gate shifters.

Last but not least...the gigantic piece of aluminum I got this last weekend. Its a 4 x 10 piece of 5052. This will be used to make my center console, door panels, floors, and possibly my roof if need be :grinpimp:

 

[freerider15]

So didn't quite get as much done as I wanted this weekend (always seems to be the case) :laughing:

Most of the dash is done. Still a bit of finish work to be done on these but they're about 90%. The horizontal dash's opening for the gauge cluster I need to get some end mill work done on. As well there will probably be speakers mounted on the ends of it eventually. The center console peice needs a bit more work (open up holes for cutting brakes, switch mounting holes, tranny temp gauge hole, flap discing, etc.).

I got started on my full hydro hose running/mounting.

Lets just say it was much easier said than done :laughing:

I found out at full bump there was a bit less room than I thought and hose routing is going to be fun. As well the routing that I had intended between components in the engine bay didn't exactly work out as planned. But, needless to say I think I got them pretty figured out. I just need to get my suction hose made, and the two hoses going to the ram.

I will say field servicable fittings are the shit. Didn't think it was going to be so fricken easy to make hoses!

 

[freerider15]

So I now have all my hydro hoses except for the suction line done.

I'll let the pics speak for themselves...but after looking it over and thinking for several hours this is about as good as the routing is going to get. Everything will be sleeved with FireSleeve, not I'm not too worred about abrasion/heat.

And no...the zipties are not final "mounting"...other things will be used for final mounting. :laughing:

You will notice things are very...close...at full bump. Unfortunately there isn't much I can do to fix this other than possibly running a hard 90* right at the ram then a straight fitting from there.

Since i'm rarely if ever going to be anywhere near FULL bump on both sides I'm not toooo worried. Only time and wheeling will really be able to tell.

 

[freerider15]

 

[freerider15]

So, it's been a bit of little sh*t lately.

Got the blinkers and hazards figured out, just need to get the switched and wire them up. That just leaves the headlights to figure out.

So far my switches will be:

- Blinkers
- Headlights (low / high)
- Hazards
- Fan bypass (to turn taurus fan on high)
- Interior lights (will probably wait until later after it is all done to do these)

Got the front fairlead mount done:

Now...for the part i've been bugged about for while.

I was going to wait until near completion to let the "cat out of the bag" per se...but meh. That cat...would be my body panels and what I had up my sleeve. So I'll bring out the pictures

Got the passenger side fender mounted:

A look from the front :smokin:

And the big one...my rear quarters and lights:

I did say it would be body paneled like an XJ!

 

[freerider15]

With that out...I move onto this little piece of bling that showed up today courtesy of Chris (hitman_1b).

Yes...it is only one for the moment. I'll be ordering the rest of them when I'm in the painting stage so they aren't sitting around taking up more room.

Well...with the front end nearly done, that left one thing. The hood.

First: take a fukkload of measurements, scratch head, and then do a lot of wtf

Second: Get hood and remove underbracing.

Third: Mask for your cuts.

Fourth: Spend an insane amount of time working on it...and the SCRAP it!

:shaking: :laughing:

Yeah...sorry if anyone wanted to see that go somewhere. I was hoping that would work out since it was the original hood of the XJ before buggification. After working on it for near 10 hours it just wasn't going to be up to par with what I wanted...too warped and didn't want to play nice with the engine cage.

I have another plan, which involves starting with a flat sheet of 16 or 18Ga and making my own.

To give everyone an idea of what it was like outside the garage this past weekend and how things have been

:laughing:

 

[freerider15]

Well...that brings it to about current-ish

 

[Vanimal]

looks friggin awesome dude, nice work.

 

[garrett83]

I'm diggin the use of the front fenders as rears. Very nice.

Do you have another rig you use while this one has been getting worked on?

 

[Boostwerks.com]

I love the fact you decided to skin it. Looks so badass! Fantastic work.

 

[POSJ]

The craftmanship is amazing dude...wish I had those skills. I love the front end, definately my favorite buggy front.

 

[MoparManiac]

The craftmanship is amazing dude...wish I had those skills. I love the front end, definately my favorite buggy front.

x2.

Gonna look sick when it's fully skinned.

 

[kastein]

Looks pretty damn awesome! I like the skins, got any plans for putting doors back on? It'll fold in half otherwise :eyes:

I'm curious to see how you intend to do drivetrain work with the engine cage on there... hope you never have to do a valve cover gasket.

 

[POSJ]

I'm curious to see how you intend to do drivetrain work with the engine cage on there... hope you never have to do a valve cover gasket.

I'd throw some I.D. tube clamps on it....