kmk523

Hey guys! First time Jeep owner here and I've got to say, I love my little Cherokee. I wanted to start a build thread so I can see how far the Jeep has come and maybe others will get some enjoyment out of it.

I've built a few GMC Jimmy's and one Blazer but they were always so big and heavy. I sold my last Jimmy because I couldn't get the motor running right after it sat in the previous owners yard with no axles for a year. I ended up bringing this '96 XJ home the same day for half of what I sold the Jimmy for.

The day I brought it home


It was pretty nasty on the inside but it ran great and had a bunch of new parts (tires, battery, full exhaust, crank position sensor, shocks, and brakes). I built a bumper for it and ordered a winch pretty quick.


Next was the 3" Rough Country lift and I crammed some bald 34" MTR's on it.






I took it four wheelin' a few times at a local place which has now officially opened as an offroad park.




It became clear pretty quick that I bought a rust bucket. I didn't think to look at the floor pans the day I bought it since there was no signs of rust in the rockers or anywhere else.


The rust runs along both sides of the unibody from front to back. It also ate through part of the frame right above the rear axle. This is when I decided to start cutting.






I chopped the bottom part of the frame and slid in some 3x3 tube and started reworking the rear end.














This pretty much brings me to up today. I just got my rear leaf spring bushings in the mail today so hopefully I can get the axle back in it tonight.

kmk523

I'd really like to keep this thing light and compact. Most of the trails we run are 4 wheeler trails so they are pretty tight. So the plan now is to finish up the rear end with original axle and s-10 leaf springs for now. I do have a 14 bolt rear axle waiting but I haven't come across the right front axle that I can afford. It's also going to get 2x6 rockers tied into the old and new sections of frame. Chop the top, finish the floor pans, put a fuel cell in the bed then find someone with a bender to do a roll cage. I hope between the roll cage and 2x6 rockers, that will stiffen everything up and not put too much stress on the section of frame that's been welded in.

Here is the Jimmy that I sold to get the Jeep. It was pretty much stock except a dana 44 front and 9" rear axle.



And the Blazer that I wish I could get back. It had a dana 60 and 14 bolt rear with 35" TSL's.

cleenrob

super jealous of that blazer! i had one for a while and wsh i stil had it, and my jeep of course

kmk523

That's one that I really regret selling. I always wanted to get 37"-40" tires for it.

kmk523

This weekend I got the rear spring bushings mounted then started working on chopping the top. I was going to use the original d pillar but didn't like the angle of the rear so I switched it up and was able to use part of the c pillar and the original windows. I've also started framing in my bed rails. It's starting to look like the extended cab Cherokee I've been wanting to build.

kmk523

I was also able to cut down the original roof rails for the roof rack and use them. Not sure if I want to keep them or not.

AirborneDeth

Looking good.

I have the cajones to cut, but lack the fabbing skills to complete it. (I was set on doing it to my last xj before I got rid of it.) The one I have now is too nice to cut.

kcdt58

Looks pretty neat! Looking forward to see the "finished" product if there is such a thing.

kmk523

Thanks guys! I generally just get an eye roll from my wife so it's nice to know that other people like it too.

This may be my first and only project with sheet metal fab, it's kicking my butt...

cleenrob

Very nice! Ive always wanted to do something g like this with my xj

GreenXJ98

It turned into a Cheromanche build! Looks rad man.

kmk523

Cheromanche... haha I like that.

kmk523

Didn't get any pictures last night but I've decided to reuse the stock fuel tank and mount it in front of the rear axle, recessed down into the bed floor. I've also started closing in the back of the cab which I knew was going to be hardest part.

kmk523

Progress is slow but it's coming along.

kmk523

The roof is cut and braced but I ran out of gas while welding up my relief cuts. Also got the gas tank filler neck ran up to the bed rail for mounting.
Since I can't weld anything right now, I'm going to start cutting out all of my sheet metal for the back of the cab and bed tonight. I also need to decide on a rear window. I saved the factory hatch window but it's not going to work due to the curve and size.