My xjuggy build open to all comments

dave92cherokee

NAXJA Forum User
Location
Lynchburg, TN
After some advice from starboardm I decided to start up a build thread for my rig to show some of the minor progress so far and plans for the future. I welcome all ideas as I'd rather do it right then needlessly spend money on something that's a bad idea or not of any use.

Current specs:
1992 xj sport 4.0 4x4 30 front 8.25 LSD rear
4.5" mixed lift rusty's coils up front and bastard pack rear
no swaybar's front or rear

Now onto the pics.
Don't have any pics of it stock but this is pretty close
4.5" lift on 31" buckshots
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Next was a rusty's offroad stinger and atlas 10K pound winch up front
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Next step was to go doorless and got some aj's superrails

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And of course with being doorless came the good herculiner interior.
What i found under the carpet when pulled.
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But looks alot better after putting the herculiner in
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Wheeled it like that for a while and ran good but still got hung up on a few things. So next came the 34" LTB's that I put on last fall.
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Plenty of room in the front but space in the back was pretty limited.
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Wheeled it like that a couple of times and got my new 93 DD. So with having a new DD decided to park this one and start doing the work on it I'd been wanting to for a while. First thing first decided I was going to chop the top of it off quite a while ago so off it came.
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Also knew I was going to want more clearance in the back so moved the gas tank up and recessed into the floor. Then after following along with starboard's boatside thread thought to myself "why not can always use a little more clearance on the sides". So I pulled off the doors and front fenders and started cutting. Little did I know that this was the end of the xj. While following along with starboards thread I was also following along with a few other cage build threads getting ideas for the design and layout for the cage. So I guess I must have started day dreaming with the sawzall in my hands (which we all know never ends well) and this is what happened.
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HOLY S**T! :shocked:You are Brave I thought I was crazy when I cut the hell out of my front fenders on a perfectly good jeep with a sawzall. Well good luck will like to see how it turns out.
 
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Add alot of 1 1/2-1 3/4" .120 DOM or something similar, 1 tons, doubler and wheel. Looked like a nice Jeep to begin with..
 
That's how it's sitting for right now while I try to sell the bumper and the new tires to build up a little cash for the next stage. This will be a slow build thread but I will update as I get things done but as it's getting colder won't be alot getting done on the weekends. Right now I've got the dash cut in half and everything on the pass. side gutted and gone. I've got the TCU mounted on the firewall where the glovebox used to be and I'm working on moving the ECU and fuse box inside to the firewall as well. While I'm doing that I'm also eliminating some of the no longer used wiring that's under the hood to clean up the jeep rat nest we all have. Now onto the build plans and looking for some input from those that have done it as to anything I'm overlooking or things I should pay attention to during the process.

Floor will be completely cut off in front of the front leaf mounts and cage will be built up from there up kind of like jumpthis's cage.
Plan on getting brianho's frame stiffeners from front back to where everything is cut off, fully welded and smoothed over for a clean finished look.
Boatsides will come up about as high as starboards are with 2"x6" .120 wall box tube and 2"x2" .120 wall box for the support/tie in's. It will then be plated with 10 guage steel and covered in 1/2" UHMW with counter sunk bolts to give smooth sliding surface.
Front end will be narrowed about 6" on each side and have tubes from cage running along and tying into new front bumper.
For suspension I'm planning on 16" sway a way air shocks 2.5's in the front and 2.0's in the back with mounts built in front and removable engine crossmember tied in.
For axles I'm planning on kingpin D60 up front with 35 spline inner's and outers, 538 gears and ox locker.
In the rear is going to be a shaved 14B with spool and 538's, will probably try to get a 14B from a 2000+ gm to get stock disk's (unless they're weaker than the older one's).
Transfer case will be either a 231/300 doubler or if I can swing the cash an atlas 10.34:1.
Engine will get fully rebuilt and made into a 4.7 stroker, ported and polished.
Tires will be 40" pitbull rockers or another 40" tire of highly aggresive tread at the time, mounted on 17" stazwork's double beadlocks.
Not sure on seats as I want something that's highly water resistant but not the high dollar wet okole seats with 5 point harnesses tied into the cage.

There will be other little odd's and ends here and there but that's the big items and plans for the next year or two. Like I said it's going to be a slow build as I don't have alot of cash on hand and have to take care of the family but it will get there. So if anyone has some input on the plans or what to be aware of please post up and let me know.
 
wow:eek:. Looks like you'll get great in-town mileage :eyes:

Any idea what it weighs now?

No idea what it weighs right now but with everything that was cut off it removed probably close to 200 lbs.
 
just be carfeul with that. add a cage or it will fold like an envelope right down the middle. Looks great though talk about custom. I chopped one of mine a few years back right behind the back door. basically a 4dr comanche. looks great
 
Yah it's going to have a full cage from front bumper all the way back with 1.75 or 2 .120 wall DOM.
 
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