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DBP Rubicon Trail Build

Old 09-26-2016, 07:04 PM
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Default DBP Rubicon Trail Build


Found this 99 XJ on Craigslist today and decided that it was time to build a second trail rig to be used by my buddies to accompany me on the Rubicon. I already have an 06 TJ on 35s with 114:1 crawl ratio so I figured this XJ would function well as a people hauler to get a few dudes into Rubicon Springs.

The rig is a 99 XJ with 140,000 miles on TH odometer. Head was rebuilt last month a head gasket replaced. Unfortunately, the PO did not install new lifters, which is why the rig was dirt cheap. Theoretically the lifters on the sixth cylinder are toast so my first task will be to remove the head and replace all 12 lifters.

Phase two of the build will be devoted to making this rig fully functional on 33s. I plan to regear the HP30 and 29 spline 8.25 to 4.56, install lockers, and chromoly axle shafts. Suspension will include metal cloak coils, RE springs, metal cloak track bar, JB conversions SS SYE, Zone hydro shocks, and metal cloak or Savvy off-road control arms.

I will update this thread once the build commences in order to document our progress.
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Old 10-04-2016, 11:35 AM
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Removed the cylinder head this weekend and discovered that one of the lifters was FUBAR. Determined that the camshaft was likely toast so any easy lifter replacement turned into a much bigger project. In addition to the cam and lifters I plan to replace the water pump, timing chain and sprockets, and radiator hoses.

Here is where we stand today:

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Old 10-04-2016, 12:05 PM
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sub'd for future progress!
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Old 10-04-2016, 07:28 PM
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You are building a trail rig for your friends to drive? Can I be your friend?
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Old 11-05-2016, 07:41 PM
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Originally Posted by Jalebate View Post
You are building a trail rig for your friends to drive? Can I be your friend?
Yes sir. Building this rig for my buddies. Finally reassembled the engine and fired her up. Runs well for a $1,500 vehicle. Placing an order this week with Ares Fab for OTK steering, front/rear bumpers, and rock sliders. Decided to go with clayton long arms in the front with 5.5" RE coils, Rancho RS 5000X shocks, HD off-road shackle relocation, RE 4.5" rear springs, and IRO double shear track bar. This should keep us busy until we regear and install lockers/chromoly shafts this spring.
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Old 11-05-2016, 10:22 PM
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Subbed. Gotta see where this goes
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Old 11-06-2016, 07:02 PM
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Spent a couple hours today on general maintenance items. Dumped the transmission fluid from the pan twice and added a couple gallons of fresh Dexron III. Front HP30 was leaking and low on gear oil. Pulled the cover and the oil looked foul. Oil in the 8.25 looked decent but decided to change anyways. Lube Locker gaskets for both axles are on the way.
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Old 11-07-2016, 04:05 PM
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Any shots of your TJ?
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Old 11-07-2016, 09:37 PM
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Originally Posted by Jeepology View Post
Any shots of your TJ?
Here is my Right-Hand drive TJ.


<br/>
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Old 11-07-2016, 09:42 PM
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Somewhere on the rubicon.
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Old 11-08-2016, 05:54 AM
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Sweet TJ!
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Old 11-17-2016, 04:39 PM
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Been ordering parts the past two weeks. So far we've purchased the following:

Bilstein 5100 shocks
5.5" RE coils
4.5" RE leaf springs
Ares Fab front and rear bumpers
Ares Fab rock sliders
Ares Fab one ton OTK steering

Planning to purchase the remaining items for our build during black Friday. Once all parts have been accumulated we will spend a solid weekend installing.
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Old 11-27-2016, 01:05 PM
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Still in the parts acquisition phase. Ordered the following over the weekend:

IRO double shear track bar
JKS revolver shackles
RuffStuff frame stiffeners

Put about 150 miles on the rig this week and the oil looks good. No sign of coolant in the oil and lifters are quiet.
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Old 12-12-2016, 12:56 PM
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Spent the weekend tearing apart the XJ so we can get the new parts installed. Removed all steering components, brakes, transfer case crossmember, frame side control arm brackets, and removed the frame undercoating.

Frame stiffeners will be welded on this week so we can install the Clayton long arms.
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Old 12-12-2016, 02:05 PM
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Looking forward to seeing the progress of this, very similar to the build im currently working on.
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