Juustncase

Well, I guess its time to make a thread for the build of my girlfriend's jeep.

Quick Summary:
It is a 1994 XJ Sport, with 230k+ miles on it and still going strong. I have mostly performed maintenance work to it with only slight modifications. I wanted to get the reliability and weak spots taken care of first before moving to modifications.

A little about myself:
I am an avid Nissan enthusiast specializing in Z31 300zx's(84-89). The Nugget is the only non-nissan we own and has been a very trusty rig. I was never really a Jeep guy, although all my friends are. All of them owning TJ's, and ZJ's. I have always been a Land Rover fan. One of my first vehicles was a 1990 Range Rover that I restored the frame on(rust) and drove until my parents traded it in. Once I started dating Sarah, she got me into them, so now I have the Jeep bug and the Nissan bug! Btw. we have a '03 Sentra SER Spec V, '88 300ZX, '93 Infiniti Q45 and the XJ. The 4.5L V8 in the Q45 is going in my Z this summer

My girlfriend is a state park ranger on a mountain and uses her Xj for work, so making sure the Jeep is safe a top priority.

Exterior:
Painted the wheels
Cut off the rusty rocker panels(welding in new ones this spring)

Engine & Accessories:
Replaced the alternator a month ago from ZJ
New battery
New 7.5mm wires
New Cap

Suspension:
new track bar
new tie rod ends
new sway bar links
new steering stabilizer
new shocks (Sensa Trac)
new rear shocks(sensa Trac) with helper springs

Brakes:
Just rebuilt the rear drums
Newer front rotors
Newer ceramic pads(hate them)

Interior:
Sony CD deck
RF 450.1 Amp(blown)
Assorted Alpine Subs(stolen)

Future Plans:
2" lift (shackles and front spacers)
31" tires
Replace seats and base carpets
New headliner
Front Calipers
Axxis Metal Matrix Pads
SS braided brake lines
Control arm bushings
Leaf spring bushings
Bigger Front and Rear Sway Bars
New rockers
Paint the Jeep
Tint the Windows

Pics:












Working Pics:

Juustncase

Well, this past weekend I ripped out the interior to take care of some rust issues in the floor. After a day and a half of prep work and fiberglassing, it came out pretty well. Next I need to fiberglass some rockers in.

I removed the carpet and this is what I found(pic shows post 1st round prep work):

Passenger Side Before:


Drivers Side Before:


Passenger Side After:


Drivers Side After:

tuxfan212

Nice. I just used an old computer case to fix my floor with. Although yours was quite a bit worse.

xjoffroad

looking good!

mud_digger

can you post up some clear photos of the rockers after you cut them out?

Juustncase

Yeah, I can take pics of the rockers. They are already partially cut out, I need to prep the area more before fiberglassing. I will take pics of the current state and post prep work.

Also, other things that I accomplished this weekend were:

Removed the moldings with the red stripe

Installed new wheels and tires off of a Wrangler(they are a little smaller) that i got of Craigslist for $140 for all 4.

Patched up a small leak on the muffler

Thoroughly cleaned the base carpet with a hose, greased lightning and a hard bristle brush. It came out great!

Now the the floors are whole again and the exhaust quieted, the ride is a lot quieter and solid. However, now I can hear the U-joints in the front that are starting to go.

Juustncase

A little update: Installed new U-joints, front wheel bearings, front pads(got rid of the ceramics-they suck), greased up all steering tie rods and ball joints. Replaced rear diff fluid. I cant believe how gross the old diff fliud was, it looked like muddy water! Well I guess the last time it was changed, they only used gasket maker.

Sanded and painted the diff cover, changed tranny fluid/filter. Still need to do the transfer case and front diff fluids.

I went to fiberglass the rockers in and found that the floor section underneath the rear seats and rearwards needed the as weak and needed the same work as the front needed. :X

Here are some pics:











Already prepped and put the first couple layers of fiberglass on the rear drivers side section, its curing right now. I'll have pics when its light out.. ugh am I tired!

Juustncase

Oh! Also! We started to strip and paint her:

X1994J

Her as in the Jeep, or her, as in HER?

Jeeps lookin good.

Silver60th

More girlfriend pics!

I mean...Jeep pics....AHEM

Good job, keep it up!

Juustncase

Haha, thanks for the support guys! Update!


passenger side rear section- first layer of fiberglass down

Another pic:



Drivers side rear, 4-6 layers of glass down, primered

Juustncase

Stole my DSLR from work and took better pics:

I have been working on getting the car to an inspectable state. She needs to pass this month. I have prepped everything and all that needs to be done is fiberglass laying:







Also! I got a new cat back exhaust from Rustys off road. 2.5" mandrel bent, with a cherry bomb pro muffler:



Going to be getting some General Grabber AT2's in 235-75-15 next month. They and hopefully get all of the body work done as well. Current Exterior:

chrisonline1991

I'm liking this jeep. You really know how to fix rust problems. I live in AZ so i don't have to worry about rust but my old car was filled with rust, i hated it. What color are you painting it?

cascadeclimbn

Looking forward to more of this build! Pics, pics pics!!!

Juustncase

I installed the exhaust last night! Now it really sounds like a jeep! It does drone a little bit, but remember, I still have holes in my floor! :P

It will be painted flat desert tan and all the trim is going to be blacked out. The reason it is primered on one side right now is because someone backed into her front qtr a couple months ago and I replaced the panel and headlight trim and started getting her ready for paint. Then I found all of the rust in the floor. :/

I am going to have the camera this weekend, so I will document all of the work that I am doing:

-fiberglass layup
-rocker panel forming

Also, other maintenance things that have been finished in the past month:
-New U-Joints
-New front wheel bearings
-New front brake pads
-rear diff oil+ gasket
-tranny filter and oil
-transfer case oil
-front diff oil + gasket
-Painted the rear diff cover