Here's a little info about me and my future build. I'm deployed to Afghanistan right now but am buying the parts over the course of the year to assemble my own doomsday jeep.
Right now it sits in my stepdad's shed covered in dust and pigeon poop. It's a 4X4 1986 XJ, 2.8v6. Auto tranny, and an unknown T-case. Stock height with stock rollers. The interior is decent. I'm going to re-dye the carpets after i pressure wash them and get new covers for the seats.
I'll probably install a cheapo dvd system in the back for the kiddo during long rides.

When I get back, my brother and I plan on gutting the interior, drivetrain, and anything else that will unbolt from the rig. From there, I'll take care of all of the bodywork re-painting it Mopar Sublime Lime or Hemi Pearl Orange. After that, I have an AL's Liner kit so I am going to undercoat the jeep and the lower 6-8 inches of the doors and rockers. It will receive custom built front and rear bumpers and a safari rack on the top to mount my lights and carry any essential extra gear. I'm going to strengthen the body by cutting out the stock rockers and welding in 2x3 box tubing that has been notched to fit. It will be cross braced into the stock subframe and the roll cage I'm installing in the interior.

The drivetrain will be replaced with a 4bt cummins turbo diesel, NV4500, and probably a NP241 w/SYE. I'm probably going to deal with Thoroughbred diesel on my performance needs for the 4bt. I'll be calling the local junk yards in ky looking for the tranny w/t-case from a wrecked truck. I also need to find the pedals and console from a manual Cherokee.

I'm going to run a rusty's 6.5inch long arm suspension lift.
I already have a 8.8 rear from an explorer. I have to get a dana 44 for the front.
I'm looking at running 3.55 gears w/33 inch tires. It may sound offly low, but the diesel motor loves to run in that 1500-2200 rpm range. That puts my cruise speed at 1700 rpm for mileage purposes. I'm not entirely sure of the lockers I am going to run in them yet.

The 4bt is basically a 5.9 12 valve cummins minus 2 cylinders. I got mine from a bread truck with less than 100k on the odometer. Fuel wise, I have a Bluegrass fuel systems bio-diesel system. It allows me to process used oil and make my own blended fuel out of it. Due to the lack of electronics in the 4bt, I'll be able to run a 75% Oil, 25% road diesel mix. To add some more power in the engine dept, I'm going to step up the turbo one size, make a few injection pump modifications, and add an air to water intercooler because this is a non-intercooled engine. This should net me 30-35 mpg on the highway. Running mixed fuel, I'll basically be paying for 2.5 gallons of diesel for every 10 gallons.

So it's gonna be cheap on fuel, have a great amount of torque, and be relitavely easy to work on. It still gives me a lot of room for upgrades in the future ex: Water/Methanol injection, beefier axles, transfer case upgrades.

Feel free to chime in on your thoughts. I'll catch up on here to let you guys know how I'm coming on getting parts and will include full teardown and restoration pics once I get back to the states.

 

sounds like an awesome build coming up. i've always wanted to put a diesel in my xj so im definitely looking forward to seeing the progress and build up

 

SOUNDS LIKE IT GOING TO BE INTERESTING
but......... you need some pics

 

x2

 

Sounds interesting looking forward to seeing it all happen. GTFO of Afghanistan ASAP and get this going!

 

Don't worry, when I get home, I'll be taking lots of pictures of the teardown and rebuild. I'm going to do it as budget minded as possible and do the vast majority work myself. A couple of Marines I work with are diesel mechanics and they are going to help me with the fueling and operations of the engine. Other stuff ex cage, wiring, paint, suspension. That's all me.

 

 

I got the picture guys. Worthless without pictures... I've still got some time left in good ol afghanistan. As soon as the build begins, this thread will get lots of pictures and step by step how to on a 4bt cherokee swap.
I've done v8 s-10's and rangers before. This will be no more difficult.

 

how much longer you got in that hot boX?

 

been here for 5 months. I get a few weeks of leave in 3 more. Then back here till feb of 2012.

 

so you go for 8 months, get a few weeks off than go back for more? so quickly after an 8 month deploy, thats some

 

Yea, My unit is doing 12-13 months in country. I'm gonna be here the whole time minus my leave for R&R aka Rest and Relaxiation. Even with a wife, kid, mortgage, and bills, I'm saving money to build my toy. I sold my busa before I left. I told my wife that I'm gonna build my jeep or get another high end crotch rocket. She agreed with this. Plus it's fun for the family vs just me. After splitting lanes on my 1000rr on I-5 in San Diego at 100+ the wife won't ride with me anymore.

 

dang, after that do you have to go back again or what? and what exactly are you doing.. over there

 

Training team Officer in charge/ Weapons instructor. Myself and my Marines train the Afghan Army.

 

ahh, you see alot of action?