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2 door XJ - take 2

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Old 07-25-2016, 08:50 PM
  #46  
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I was productive today, but on the wrong tasks. I set to taking apart the engine that will become the stroke so can move it to my apartment easier. I should have been working on my lift or taking off my intake manifold on the engine in the Jeep. Whoops. I did get the passenger side of the engine converted to the 99s sensors and alternator and all that so the wiring harness didn't need chopping up. No pictures because it looks nearly identical. Added some of the plumbing as well. I ordered a new exhaust header since they come with the intake gasket I would need to replace anyway when I switch over the intakes so I don't have to mess with the vacuum system at all.

It was sludge free, still don't know why the PO said the engine failed.


Could not get the clutch fan off for the life of me and the internet did not yield fruitful results. Any suggestions?


Did the headliner tonight as well. Tip, us a lint roller to flatten it out and it'll clean while you work.




And because I'm not an internet phony I'll admit when I've been beat. I was so pissed at myself that I creased it that badly but at least it's in the back where I won't hardly see it.

Last edited by kylemason; 07-26-2016 at 08:07 AM.
Old 07-25-2016, 09:31 PM
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Every time you pass out in the back of your Jeep you have something to stare at-
I like your build- I'd like to drop a Stroker in my XJ someday....someday....someday
Old 07-26-2016, 08:07 PM
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Another productive day. Got the engine bay ready for the new exhaust headers and the 99's intake manifold - I had told myself a few purchases back I needed to stop buying new parts, whoops. At least it will fit on the other one too after it's built up.


Did the rear cut n fold with assistance from Bleepin' Jeep, his video is supper helpful, although misleading as he did it on the table in his shop and I was on the floor haha.


The leaf springs were another story.. after 30 minutes I had one of the 3 stuck bolts this far out..






Tomorrow I'm gonna try and see if paint lacquer with loosen up the tar in the floor pans so I can get those welded in and the undercoat that section. In the meantime I will rust convert and undercoat the rear half of the Jeep. Then I can put the gas tank and rear lift.

Last edited by kylemason; 07-26-2016 at 08:18 PM.
Old 07-27-2016, 01:39 PM
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I hate extracting bolts. 2 bits down and no closer to having them out.




But hat doesn't mean today was a waste. Let the rust converting commence.



Old 07-28-2016, 10:48 PM
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Just a mock up. Still hardly any closer to getting it running but it's nice to remind myself what fenders look like on it!


Here is a brief list of what needs done by the end of August:
  • fix floor pans
  • rust treat front 1/3
  • undercoat entire underside
  • install transmission and TC drop
  • install exhaust and intake manifold
  • extract rear shock bolts
  • finish installing lift
  • button up the plumbing in the engine bay
  • troubleshoot first start up
  • paint rims
  • tires, not sure if I want 265/70 or 275/75
  • paint prep
  • paint

Then down the line I'll do fender flares (need to find good ones for the ¼ panel cut and 2 door). Fab up a rear bumper, maybe a front one too.

And eventually I'll get to just enjoy it.
Old 07-30-2016, 10:21 AM
  #51  
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So I decided to use the rear sway bar mounts as bar pin eliminators and weld them on. Unless someone knows how to get those welded nuts off without an air hammer. I'll probably attempt to use a hammer and punch first as I'd rather not have to strip the undercoating I just applied to weld them on.

I am also going to run the original fender flares for a while so I need to fix those brackets before I can put them on.
Old 08-02-2016, 07:39 AM
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Doug at Napier has been great with his customer service. Might have figured out that their QF fenders will fit on 97-01 2 doors. I'll report when I know for sure.
http://www.napierprecisionproducts.c...V2-B-FF-QF.htm

The shop my place is at didn't have power yesterday so I couldn't do what I wanted. The exhaust I got doesn't have the clearance for the 99+ intake and I couldn't shave the intake because of the lack of power. And the eBay seller is being less than helpful. "I've sold 1000s of these without any problems." He offered a refund but it bothers me that he doesn't know the 99+ intake is different than the earlier models.
I did, however, manage to hammer out one of the 4 upper shock nuts so that is reassuring that I can use a hammer and old broken punch fix my problem.

Last edited by kylemason; 08-02-2016 at 08:08 AM.
Old 08-02-2016, 08:19 AM
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Progress...I'm glad your still kicking at it...
Some give up after the first month of such a build...
Old 08-02-2016, 10:57 AM
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Originally Posted by 88whitecomanche
Progress...I'm glad your still kicking at it...
Some give up after the first month of such a build...
Thanks, I'm glad someone is reading! I mean I technically gave up on the first one, but it was a rusty lost cause.

I feel like I am always rushing it, so once I have it back in my garage I'm going to go back and do a few things I am skipping now (sanding and painting the axles and knuckles, etc.) and while it's apart I can replace bushings and all that. Much like cspud721's Clean 2001 DD Build -props to him and the detail he is going through - can only hope to get mine that clean!
Old 08-02-2016, 04:13 PM
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I'm reading, just not commenting lol
Old 08-02-2016, 06:17 PM
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Originally Posted by unidentifiedbomb
I'm reading, just not commenting lol
Great thanks! The motorcycle forum I am on, CustomFighters.com has a like feature, so you can tell people are paying attention and there isn't the need to just say "like". It's nice to know people are looking though! Gives me motivation to give you more to see.

Can't wait for paint!
Old 08-02-2016, 08:32 PM
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Nice work on resurrecting an XJ!
Old 08-03-2016, 11:18 AM
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Originally Posted by NPx
Nice work on resurrecting an XJ!
Thanks Doug - looking forward to figuring out this QF fender business.
Old 08-03-2016, 12:54 PM
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I'm looking for some specifications on the OEM wiring harness - see here: https://www.cherokeeforum.com/f89/wi...7/#post3286856

I want to rebuild it to have it out of the engine bay and add another fuse box for the accessories. I want to mount the PCM and fuse box in the glove box if there is space after some cutting. This will be a project I do long term - not in the next month by any means - just hunting for information in the time being.

Last edited by kylemason; 08-03-2016 at 01:00 PM.
Old 08-03-2016, 10:07 PM
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Got out the last three of those stupid upper shock mounts bolts and welded nuts!! Finally! I'm gonna wait til my leaf spring settle before I do the BPEs.

Got the majority of the black undercoating painted. Will do touch ups tomorrow night. Having an inkling feeling the guy who's shop I'm at didn't pay for August and that's why we don't have power.. I need to get that sorted out because I as racing this sunset today. Nonetheless being under the Jeep holding a flashlight in one hand and a brush in the other.

Then I laid out the rear lift components so I can install that tomorrow night after the touch up painting of the black undercoat.
And lastly here are the pictures I have to send to the eBay seller showing the contact the intact makes then installing the intake.




Last edited by kylemason; 08-03-2016 at 10:59 PM.


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