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2000 TDI (blacky)

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Old 01-30-2015, 12:19 AM   #1
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Default 2000 TDI (blacky)

I'm a bit of a diesel freak and have converted all our vehicles to either electric or diesel.
93 ZJ with a 2.8L Isuzu which has been our family DD for the last 12 years.
http://gastodiesel.tdconversions.com...isuzu-4jb1-tc/
Fantastic fuel mileage and lots of power.
Our 2008 Dakota quad cab got a Cummins ISB170 three years ago and has towed our 5th wheel from coast to coast and put on over 20,000km with minimal problems and good fuel economy.
http://gastodiesel.tdconversions.com...ummins-isb170/
My shop truck is a 1999 Dakota with basically Isuzu NKR running gear and a three ton dump deck.
http://gastodiesel.tdconversions.com/1999-dakota-isuzu-4hf1/

Now its time to pass the 93 Grand down to our daughter and I'm building us a new DD.
Starting with a pretty clean 2000 XJ with a 5 speed. It will get a 1.9L VW TDI with some aftermarket goodies. Small lift, wheels and tires. Probably a few other little things as well.

There are some amazing builds on this site and I hope to have input from some of those builders along the way.


Here is where its at today:

Last edited by evguy; 03-04-2017 at 09:10 AM. Reason: Update
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Old 01-30-2015, 12:21 AM   #2
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Now here is a build I'm gonna like.
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Old 01-30-2015, 10:39 AM   #3
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watching
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Old 01-30-2015, 10:59 AM   #4
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dope.
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Old 01-30-2015, 11:10 AM   #5
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#VDubLife lol
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Old 01-30-2015, 11:27 AM   #6
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This sounds awesome. Can't wait to see the updates down the road
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Old 01-30-2015, 10:45 PM   #7
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OK, so lets get caught up.
With all the time and $$$ that's going into this thing and I want it to last as long as there is fuel to put into the tank. I stripped it down. Way down.
Pulled everything out from under the body from engine, trans, rear axle, fuel tank and anything else that was bolted on.
Strung it up and sand blasted the underside anyplace there was a hint of rust starting.

Sand blasting and painting the underside. by evguy, on Flickr

It was pretty clean by the time I went through 2 bags of sand.

Jeep underside after sandblasting by evguy, on Flickr

I sprayed the whole thing in Rustmort and let it sit for the day to neutralize any remaining rust before rinsing the whole thing back off.

Freshly painted undercarriage by evguy, on Flickr

A good coat of self etching primer and then two coats of two part automotive paint.
Once the paint was setup for a day all the seams and voids where rust liks to start were sprayed with an industrial waxoil rust preventative.
Have you figured out that I hate rust!!
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Old 01-31-2015, 12:02 AM   #8
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Sick! Definitely following this.
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Old 01-31-2015, 04:40 AM   #9
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Holy crap, that thing wasn't that clean when it left the assembly line.
You do good work sir.

Will be watching this build.
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Old 02-01-2015, 07:05 PM   #10
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More sand blasting and painting.
Transmission and transfer case painted with medium silver wheel paint.
Sand blasted and painted with wheel paint by evguy, on Flickr

And the 8.25 rear axle which also got new seals, brakes, drums and lines.
Rebuilt 8.25" rear axle by evguy, on Flickr

I started to strip the front end this weekend and hope to get it sandblasted and maybe painted if we get a sunny day later in the week.
Got the pattern for the cast aluminum engine adapter designed and maybe have it cast this week.
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Old 02-01-2015, 07:19 PM   #11
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im gonna like this
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Old 02-01-2015, 09:27 PM   #12
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Good stuff! Nice to see builds with such detail like this.
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Old 02-01-2015, 10:34 PM   #13
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Since you got your axle off. Might as well convert those drums to discs with some ZJ backing plates. Better stopping power for the Diesel engine.
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Old 02-01-2015, 10:50 PM   #14
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Maybe next time. Its got all new drums, shoes and hardware kits so too late to turn back now.
Its just a little 1.9l diesel so not a monster and weighs quite a bit less then the 4L that came out.
The two sitting next to each other are pretty funny considering they are about the same power or a bit more for the little TDI with some help.
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Old 02-01-2015, 11:27 PM   #15
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Quote:
Originally Posted by evguy View Post
Maybe next time. Its got all new drums, shoes and hardware kits so too late to turn back now. Its just a little 1.9l diesel so not a monster and weighs quite a bit less then the 4L that came out. The two sitting next to each other are pretty funny considering they are about the same power or a bit more for the little TDI with some help.
Since it's all new hardware then yea not worth it. Drums aren't the worst when maintained. Good luck with your build.
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