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1990 expo/hunting build

Old 03-09-2016, 09:41 PM
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Default 1990 expo/hunting build

Picked up a 86 xj last year to start a build but after I got it tore apart realized there was way too much rust to put any money into. Also have an 85 GMC that I have been driving but wanted a better daily driver plus I like the jeep platform. This week bought a 90 xj from a friend for $500. He said fuel pump or relay was out cause it wouldn't start. Pulled it home on trailer and as I was unloading it off the trailer saw the plug to the fuel pump hanging. Plugged it in and it cranked right up.
This weekend I did all the usual tune up, plugs, wires, and oil. Also changed water pump and thermostat.

Plans are:
Flex fan
Radiator
3" lift
31x10.50 bfg km2
Build bumpers and roof rack
Paint
Cargo area drawer

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Installed gauges to replace dummy light gauges
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Installed cold air intake
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Old 03-09-2016, 09:46 PM
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Cleaned up the interior and decided to build a cargo box from the plans in the fab forum.
First built a jig for the box

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Here it is tacked and test fit

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All welded up

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Ready for paint
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Old 03-10-2016, 07:53 AM
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Congrats on the score and the easy fix. I like the box, nice work. But the "cold" air intake...you do realize that the air it will be using is just hot air from the engine bay, right?
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Old 03-10-2016, 04:16 PM
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Originally Posted by jay_sco View Post
Congrats on the score and the easy fix. I like the box, nice work. But the "cold" air intake...you do realize that the air it will be using is just hot air from the engine bay, right?
Yeah I realize that. I did this because it was a cheap and easy fix to replace my air box that was broken.

Today made a basket that fits on the driver side of he cargo area where the factory spare goes. This will be used to hold tow straps and other recovery gear.

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Last edited by Brock2013; 03-10-2016 at 04:19 PM.
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Old 03-12-2016, 12:11 PM
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Worked on the cargo area this morning. Got box and basket mounted and built a platform for storage underneath.

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Built a tray that slides underneath for tools but still haven't put the dividers in it yet. Still have to built the tray for the other side

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Also ordered my lift from Rustys Offroad. Went with the 3" AAL kit. Can't wait for it to show up.
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Old 03-15-2016, 05:27 PM
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Lift showed up today. Will probably put it on this weekend. Also got a new fan clutch to replace the worn out factory one.

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Am also in the process of building a roof rack do should have it done in the next couple days.
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Old 03-19-2016, 09:06 PM
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So put the lit on today. Took a few hours but everything went pretty smooth. It was a chore getting the rear tires off. They had been on there so long that wheel had rusted to the hub so had to pry the wheel away from the hub.

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Here is the finished project. I put some 30x9.50 tires that I had from my other xj that I am going to use until I get some new wheels and tires.

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Old 03-21-2016, 11:01 PM
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Installed roof rack today.

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Old 03-23-2016, 05:36 PM
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I like that roof rack design a lot - never thought about using the existing captive nuts, now where is my welder...
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Old 03-23-2016, 09:37 PM
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Originally Posted by Brock2013 View Post
Worked on the cargo area this morning. Got box and basket mounted and built a platform for storage underneath.



Built a tray that slides underneath for tools but still haven't put the dividers in it yet. Still have to built the tray for the other side



Also ordered my lift from Rustys Offroad. Went with the 3" AAL kit. Can't wait for it to show up.
Why aal and not new leafs?
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Old 03-30-2016, 09:54 AM
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Originally Posted by Martlor13 View Post
Why aal and not new leafs?
Mainly because of price right now. I may upgrade in the future though.

This past weekend I had a few problems. I broke my fan shroud while putting a new fan clutch on and just zip tied it up to be able to use it but while on my way home from work, the shroud hit the fan and broke and poked a hole in the radiator. So I got a new radiator and hoses and got them out in. I also changed out the thermostat while I was there so I could get the cheap Murray stay out and put in the Stant superstat that I had ordered. After I got that sorted out it was back to the fun stuff. I got some LED light strips from Amazon and put in for interior lights. I also mounted a couple quick fist clamps to hold my axe in the cargo area. Today I plan on mounting a couple led 18w flood lights on the back of the roof rack and tracking number says adjustable track bar and new steering stabilizer is supposed to show up today.

Here is some pics of the lights

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