Project RED ALERT: First Jeep First Build 97 XJ Sport 2-Door
 

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97 XJ 2-Door Sport ; been lurking around here awhile. Had picked up a 96 just like it a few weeks ago but floors where gone. Right as I was getting ready to order pans I found the 97. 97 Is much cleaner underneath since it was undercoated by dealership when it was ordered by previous owner. Already sold the 96.

Ordering parts and thinking about mods.

4.5" Rough Country Lift (Recieved)
RC Adjustable Track Bar (Recieved)
Rough Country N2.0 Stabilizer (Recieved)
C-ROK Steering box brace (Recieved)
Summit Racing® 85 Black 8 Series wheels 15x8 3.75 BS (Recieved)
BFGoodrich All-Terrain T/A KO 32x11.5
Billet Oil Catch Can Kit (Recieved)
Magnaflow Cat 2.5 (Recieved)
Cherry Bomb Glass Pack 2.5" 12" Overall Length (Recieved)
1 Gallon of Chassis Saver (Recieved)
Durango Steering Box Upgrade (Recieved)
OBX Racing Header (Recieved)

Fabricating as time permits:
Cold Air Intake
Front & Rear Bumpers
Reinforcing unibody frame rails in rear shackle areas with 3/16 steel plate and tying together with round bar between rails.
Rock Sliders
Safari Rack

Interior:
Removing Carpet and coating floor
Heavy Black Rubber Mats front, rear and cargo area
Dual Guage A Pillar Pod with Trans and Oil Temp
Interior is in good shape expect of course headliner.

Exterior:
Already Removed Side Moldings (where comming off anyways)\
Lebaron Hood Vents

Engine:
Plan to utilize most Mods from Dino's Jeep Tricks http://www.angelfire.com/my/fan/ & from this article in Jeep Magazine http://www.jpmagazine.com/techarticles/engine/154_1107_20hp_20lbft_for_your_jeep_4l_engine/viewall.html

progress
 

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These are just a few pics, have taken many before and after shots.

Only issues we have run into with build has been rusted bolts (broke a few) which was expected and the RC 4.5" kit came with 9/16" x 4" bolts for leaf to frame mounts and the factory welded in bolts are 14mm x 110. Picked up correct grade 8 bolts at local hardware store. Jason from RC sent me a hat for the trouble. RC customer service gets my vote 4 sure!

My 2 cents regarding RC 4.5" lift; add the RC adjustable track bar to the kit instead of drilling holes in lower track bar bracket. Just not that much meat on that bracket IMO and its an upgrade from the factory track bar.

Chassis Saver paint seams to be going on well after some degreasing and wire wheeling but just like POR-15 you cant get the stuff off skin! Started with wearing gloves, wished I had left them on.

Next on punch list is installing all new components for drum brakes and having drums turned.

Daughter has choir concert tonight so no working on jeep today as stated by my wife.

Over and out

OBX SS Header Arrived
 

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Mmmmm Pretty.

Going to hit it hard this weekend and hopefully be on the road.

She is on all 4s now with all new drum brake components (just had drums turned didnt need to replace those). Will post some new pics soon.

While tearing down for header and steering box upgrade found I needed a new pwr steering pump and rad. Lucked out and found a guy in Gas City via Craigslist that had a brand new rad and hoses he purchased for a build that he ended up scraping. Got it all for $50.:thumbup1:

Have throttle body all cleaned up (Seafoam and Elbow Grease) and now working on cleaning intake and polishing outside of it. Took my time and carefully cleaned out head intake ports without pushing crud inside. Will do the exhaust ports this weekend same way. Just kept my data vac I use at my computer shop at port opening at all times while pulling the crud/carbon towards the outside. (It has alot of suction and disposable filter bags so worked well) Once fuel/intake system is back together will fill up tank and pour in a can of Seafoam. Did this on my wifes 170,000 mile grand and fuel mileage jumped up by 4mpg within 15 to 20 miles of driving.

Going to hit Pull A Part this weekend in Indy for some 703 injectors steering pump and small trans cooler in order to fashion a steering pump cooler.

Thats it for now. Over and Out

703 Injectors Located
 

Hit the JY yesterday and scored 8 703 injectors and Power Steering pump.
Cut injector electrical connector off one of the donor 96 neons and made an injector cleaner with momentary switch, 12V wall wart and 1/2" ID clear tubing. Plan to use the blow side of my data vac to apply needed line pressure as it has an adapter that fits snuggly in 1/2" ID tubing.
Will use seafoam as my cleaner to pump through injectors both directions.
Picked UP new FelPro Injector O-Rings this morning on the way to work for 12 bucks.:thumbup:

Come on 5 o-clock!!:whistling2:
Should have some more pics up this weekend.

Pics
 

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OBX Header
 

The header from OBX had the flange welded on in the wrong position causing one of the flange mounting points to rest against the block. This prevented the header from comming down and seating on head. Going to get refund!

Welded up cracks in factory header and added some gussets for more strength. Wired wheeled it all down verifying there no more cracks then painted with flat black 2000 degree ceramic header paint.

Installed the catch can next to brake booster and got it plumbed in.

Should be able to get pwr steering pump back in this evening and go back through suspension checking all bolts cotter keys etc and begin running new 2.5" exhaust.

Fired it up lastnight with open header. :head:
Throttle response crisp with 703 (Neon) injectors.