2001 silver bullet build
 

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Just finished my 22'D x 32'W detached garage and my "turning 15" son has wanted to "Build a jeep".




Somehow I ended up with a rust free 2000 XJ (green) 500.00 , a 2001XJ (silver), and 2) 94 5speed parts XJ's.
Anyhow the silver 2001 is his, paid around 400.00, has a head gasket issue or cracked head. Underside is pretty rust free EXCEPT the back half of both rockers, and the last 6-8" of each frame rail (rear).
We plan to pull and rebuild the Engine, trans/transfer, axles.
Pull the doors, fenders, hatch and interior. Then roll it on it's side and tackle the underside and rust issues.
The garage has a full walk in attic for parts storage, and yes I plan to keep the garage this clean :)

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One thing on the 2001 Silver XJ I can not figure out.
The drivers side REAR door gap greatly increases as you go down (the rear edge of the rear door). Also the rear hatch gap is considerably wider on the drivers side than on the passenger side. I can not find any collision damage, nor can I find any possible scenario to widen these gaps on the drivers side rear area?


Drivers side rear door

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and here is the drivers side of the hatch

Quite the project it sounds. No idea on your gaps. Garage looks awesome! Doesnt sound like you should be shprt on spare parts either. Enjoy!

Thanks, the garage has been a 2 year labor of love. got in high gear to get it done so I could work with my son on the XJ project before he gets to that total "To Cool for Dad" age.
Funny, I started looking for a project XJ, found a 94 5spd that ran great but a tree caved the roof. Then The silver one and green one fell in my lap. Then a 2nd 94 5spd was basically given to me. I kept putting the word out and they started showing up.


We are going to do a 5spd conversion on the Silver one.

XJ have a way of doing that. Haha. Just picked up my 5th on friday. Only have my silver 01 and this silver 00 but i had 2 other 01s when I got my current one and last year bought a 99 for some parts and then sold it. Good luck with your son. Just make sure he checks out some of the guys build threads on here, should help keep him motivated. Might also cost you more $ though

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Stripping it down for a full restore

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front pans look good, the rockers are shot though

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rear pans are good

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First things first, getting the heated slab up and running.

Been a while,, My 15 year old and I were busy kayak fishing all summer, then chasing deer in the fall.
Time to get the heated slab operational and get this build going.
I "hope" to have the heat done this week, then back on the Jeep.
This XJ rusted in "isolated" areas, the floor pans are clean but the rockers are shot, rusted thru. also the rear 6-8" of each frame rail is rusted. I believe the rear frame rusted do to the installation of the after market hitch receiver.
Next out is the engine/trans/transfer,, gas tank and hitch.
Plan is to then cut out the rockers (and possibly the last 8" of frame rails), Then roll it out and sand blast the under side as needed. Roll it back in and remove the front/rear axles.
We plan on then "rolling" it on the side and repairing/detailing the underside.
New fuel/brake lines,
rebuild axles (re-gear/lockers/mall rated trusses)
Rebuild engine
convert to 5spd (presently auto)
Paint exterior
3-4" lift
31-32" tires
Make front and rear bumpers (If Tech Shop re-opens)


Realistically looking at 9-12 months

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Well, deer season is over, back to work on the jeep (14 in the freezer BTW :) )
Pulled engine and trans, got a small air compressor while I rebuild the big one (free)
Put together the mig cart, picked up a HF sand blaster.


Side note: I built and moved into this house 12 years ago, the old house had a detached heated slab shop. I sold my hot rods, tools, etc when I moved.
Just finished this shop build last year and my 15 year old wanted to build a jeep,, so "setting up shop" is taking 3/4 of our spare time.

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Package arrived from Amazon: Genisis 4.75" metal saw, and a compact reciprocating saw. The Genisis was an Amazon warehouse 1/2price used item,, it ended up being a new saw complete with all accessories minus the factory cardboard :Box"

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Cutting out the "know" bad metal so we can asses the mess, and write down a game plan.
The know rusted areas are: The rockers, the lower 1/4s and the last 20" of the rear frame rails. The rest of the uni-frames appear solid, but I think I will open then up from the top side, clean/treat/coat, then weld new "floor" strips back over.
Anyhow still taking out the bad areas.

So far the plan is:
Rockers: drill spot welds and finish removing inner and outer rockers. Sand blast, etch and prime remaining metal. Weld in new inner rockers, 2x6 tube for outers.


The rear 20" of each frame is gone from a "cave man" install of an hitch receiver,, cut out and splice in new rear frames (looking for donors)


I am Soo glad to be working in a heated shop that does not get shared with house hold and lawn items :)


Slack

following

Looks like quite the project! Excited to see where you guys go with this. I love seeing father son builds!

Yeah, I have to move alot of stuff around in my garage to get my Jeep in. Actually have to plan my weekends accordingly. My next house will have a full dedicated shop.