Project: Geriatric Dinosaur

Andy in Pa.

NAXJA Member #180
Location
Downingtown, Pa.
I figured I would put up a post of the work I am doing to the XJ right now. As many of you know, my XJ is fondly referred to as "Barnabus Wrex", thanks to a little kid who was walking by the XJ with his mom, looked up at it and said "Look mommy, its Barney Purple..." (I hate that kid...). Unfortunately, my fiance (wife now) was within ear-shot, and she was kind enough to give the Jeep its name-sake. That was 8 years ago.

Oh, by the way, YES, THIS IS THE ORIGINAL COLOR!!! What was DC thinking when they picked this color?? Oh well, it was CHEAP when I bought it...

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The Jeep has been through many changes over the past 8 years, but soon after I built it, I installed Big Offroad 6" leaf packs with the military wrap. I have done so many things to make these springs flex (removed a leaf, cleaned/greased between each leaf a few times, tried running LOTS of weight to get the springs to settle...), but they have NEVER given me less than 8" of lift. Recently, I was able to pick up a brand new set of Rustys 4.5" leaf springs for CHEAP, so I am in the process of rebuilding the leaf packs using the Big Offroad main leaf, military wrap, and the long spring, then using 3 leafs from the Rustys leaf pack. My goal is to lower the Jeep a little (approx 1" to 1.5") and flatten out the leaf springs a bit more. I am using the Big Offroad main leafs because they are longer than the Rustys main leafs. I drilled out the leafs to use a 7/16" center pin (just a socket head bolt), and got new u-bolts (9/16") and plan on running leaf spring liners between the leafs. Check out www.stengelbros.com for a local source for U-bolts and spring liners.
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I am also planning on re-locating the shocks through the floor, so pulled the carpet in the rear of the interior, and found that there was no floor left around the plate that the roll cage welds to at the rear. I didn't get any pics of the lack of floor, but here are a few of me starting to fix it.
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So thats how it sits right now, I need to get more welding gas and get the floor fixed, then drill holes in it for the shocks... I am still waiting on the leaf spring liners too, so I can't put the springs back in yet.

More to come soon...
 
Sounds like a good plan, good luck!! Didnt you buy some of the Edelbrock shocks during the sale? If you're not going to use em PM me specs and a price, I might grab em at NACfest if they'll work for me :)
 
Looks sweet man!

Love the color, I get crap for mine all the time (affectionately nicknamed Tinky Winky :D).

Can't wait to wheel with ya at NAC-Fest!
 
i had looked into doing a teflon liner the whole length of the leaf but decided it would be too expensive. i'm interested to see what you're going to use.
 
Lookin good!

Did you get the material figured out for the spring liners? I saw this and remembered I never got back to you on that.

Yes, I ended up getting basically what Eaton Spring sells, without the ridge on the sides. I got it through Stengel Bros up in Allentown though, they sell it for $1/Ft. I need approx. 30 feet to do each spring.

Anthony... Teflon is WAY overkill for this type of application. I found that most spring liners sold are actually HDPE (High Density Polyethylene). I was going to get a sheet of 1/16" HDPE, but it priced out almost the same as buying it per foot. I got it 2-3/8" wide, we'll see how it looks when I receive it.

Just got some more welding gas, I know what I am doing tonight...
 
Sounds like a good plan, good luck!! Didnt you buy some of the Edelbrock shocks during the sale? If you're not going to use em PM me specs and a price, I might grab em at NACfest if they'll work for me :)

Yes I did, I'll probably end up using them. Once I get everything back together I'll know for sure.

Billyjp.... The whole cage was done inside the Jeep. Fully welding was done by drilling holes and dropping the cage through the floor, then plating up the floor and welding it all down. The cage is actually tied in at 12 pts.
 
Anthony... Teflon is WAY overkill for this type of application. I found that most spring liners sold are actually HDPE (High Density Polyethylene). I was going to get a sheet of 1/16" HDPE, but it priced out almost the same as buying it per foot. I got it 2-3/8" wide, we'll see how it looks when I receive it.

cool. i'm interested. that's been something that's been on my list but too far down (currently) to have funds diverted to it from other things.

a friend of mine made an electric car out of a triumph, i think it is, and that has rear leafs which he shoved 12 car batteries into. he made teflon plugs and put those in the ends of each leaf to regain height. i'm not so much interested in height as i am leaf spring longevity and smoothness of operation...
 
damn. haha alright, just wondering because I saw that you posted on the 98 2dr part out thread asking about those rears... :) good luck with the mods, see ya in june
 
damn. haha alright, just wondering because I saw that you posted on the 98 2dr part out thread asking about those rears... :) good luck with the mods, see ya in june

Ah... LOL, I may need those for the MJ... I have a set of old RS 9000 with the dampening adjustment, and I think I broke off BOTH of the little adjustment knobs this past weekend at RC.
 
Yes I did, I'll probably end up using them. Once I get everything back together I'll know for sure.

Billyjp.... The whole cage was done inside the Jeep. Fully welding was done by drilling holes and dropping the cage through the floor, then plating up the floor and welding it all down. The cage is actually tied in at 12 pts.

Hmm, i never thought of that.
 
purplicious. Good stuff andy. So whats your welder? I see its lincoln but whats some specs. I'm actually looking into getting something for small jobs/jeep mods here soon.
 
got scared there for a second, the title made it sound like you were going to change the name of Barnubus...
lookin good tho...

Just get it ready for NAC-Fest
on a side note I just recieved my new PSC steering kit and WOW is all I can say, good lookin stuff....
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I'll be busy saturday thats for sure.

ok hijack over.


STROKER
 
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quick question, andy. are you using the teraflex rotors in the rear, or did you drill a set of zj/crown vic/explorer discs for the 5 on 5.5??? If so, what did you do to ensure the accuracy of the holes?
 
Looks good Andy..Let me know if you need any help or want someone to bust your chops while you are working:repair:..I'm right down the street...
 
I love the color Andy!

Are you planning on sealing around the shocks when they go through the floor?
 
quick question, andy. are you using the teraflex rotors in the rear, or did you drill a set of zj/crown vic/explorer discs for the 5 on 5.5??? If so, what did you do to ensure the accuracy of the holes?

I had an offroad shop re-drill ZJ rotors to 5 on 5.5. Its not hard to mark and drill though. Once you get the 5 on 5.5 shafts, don't punch the studs into them (or punch the studs out if they are already in) lay the rotor across two 2x4's and place the shaft inside the rotor (with the shaft sticking straight up) and mark the 5 holes. The interference fit on the "hub" of the shaft and the rotor is tight enough that it is simple doing it this way. Using a set of micrometers, just measure the hole size in the other hole pattern on the rotor, and drill the 5 new holes that same size using a drill press.
 
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