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MAD MAX 91 XJ Build

Old 09-30-2010, 02:12 PM
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Default MAD MAX 91 XJ Build

Just picked up this cherokee 3 weeks ago for $1500 with another set of tires. Immediately after I bought it I had the windsheild replaced. Looked under the carpet to see that the whole floor was rusted out, so I checked this forum and found out how to replace floor pans. After removing all the bad parts I was basically left with no floor at all. I am using street signs to replace the floor.* DISCLAIMER- It is illegal to take steet signs, I obtained mine legally.* I also discovered a tiny part of the frame was rotted out. I know how I am gonna handle the frame and make it stronger than factory. I am also gonna have to have 2 panels fabricated for me to connect the leafsprings from the frame to the body. I am in the middle of this and will post pictures as I go along. After I get the floor in I plan to Herculine it. I am debating on whether I want to Raptor line the outside.

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Old 09-30-2010, 02:36 PM
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looks good man! i like the black on black look
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Old 09-30-2010, 03:12 PM
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Cool looking project, love the homemade snorkle.(I need to make me one like yours) Another two door XJ on CF love it...............
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Old 09-30-2010, 04:02 PM
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oooo i like that
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Old 12-14-2010, 11:15 AM
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OK, I WILL TRY TO MAKE A LONG STORY AS SHORT AS POSSIBLE.I BOUGHT THE XJ, WANTED TO HERCULINE THE INSIDE. SO I TAKE OUT THE CARPET TO FIND THAT THE FLOOR IS REALLY RUSTED AND FULL OF HOLES, BARELY THERE. SO I START CUTTING AWAY THE BAD AND ENDED UP WITH NO FLOOR. I ALSO RAN ACROSS A FRAME PROBLEM, THE LEAF SPRING BRACKETS WERE BENT INWORD FROM NO SUPPORT( FLOOR) AND THERE WAS A HOLE IN THE FRAME RIGHT UNDER ONE BRACKET. SO I WENT ABOUT TRYING TO FIND WAYS TO FIX IT. I LIVE IN AN APARTMENT AND I SHARE THE PARKING LOT WITH A SPORTS BAR NEXT DOOR, SO EVERY TIME I WAS OUT THERE WORKING ON IT A BUNCH A DUDES WOULD GATHER AROUND TO WATCH AND ASK QUESTIONS. I HAD SOME PEOPLE TELL ME THAT THEY WOULD BE HAPPY TO HELP ME , GET MATERIAL AND WELD IT UP FOR ME. I HAD 3 PEOPLE SAY THAT THEY HAD THE MATERIALS AND WOULD DO IT FOR FUN. OF COURSE NO ONE CAME THROUGH. I HAD TO ORDER THE METAL OFF LINE AND OTHER PARTS, AND WAIT. I CAME ACROSS POLY-PERFORMANCE XJ REAR LEAF SPRING BRACKETS THAT SOLVED THE LEAF SPRING BRACKET AND FRAME PROBLEM AS THE BRACKETS COVER THE FRAME, SO I PICKED THOSE UP. PUT THEM ON AND WORKED PERFECTLY. I ALSO DECIDED TO PUT 3'' SQ STEEL TUBING INSIDE THE FRAME RAILS AND BOLT THEM TO IT TO ADD FRAME STRENGTH. I WAS PUTTING IN SIGNS FOR FLOORS BUT SINCE I WAS DOIN EVERYTHING ELSE, I DECIDED TO JUST GET THE REAR FLOOR PAN. I FOUND IT AT MILE HIGH JEEP REBUILDERS FOR LIKE $220 SHIPPED. THATS A GREAT PRICE SINCE EVERYWHERE ELSE WAS LIKE $300-$400. THE FRONT FLOOR I JUST USED SHEET METAL. I ATTACHED THE LEAF SPRING BRACKET TO THE BODY USING ANGLE STEEL AND PLATES.WHILE THE LEAF SPRINGS WERE OFF I REPLACED THE BUSHINGS WITH POLYUERATHANE BUSHINGS. AFTER ALL WAS DONE I FINALLY HERCULINED THE INSIDE. IT TOOK OVER 3 MONTHS BECAUSE OF WAITING FOR PEOPLE WHO SAID THEY WOULD HELP. WHILE I WAS WAITING FOR PARTS I DECIDED TO DO GREEN RACING STRIPES ON THE HOOD. THIS IS MY FIRST JEEP AND I HAVE NEVER DONE ANYTHING LIKE THIS BEFORE. I THINK IT TURNED OUT PRETTY GOOD.I GUESS IT ENDED UP BEING A MINI RESTORATION. FLOOR REPIR, FRAME REPAIR , RUST REPAIR, LEAF SPRING BRACKET REPAIR. THANK GOD IT RUNS GREAT. I GOT IT DONE JUST IN TIME FOR WINTER. IT RIDES 200 TIMES BETTER. I LEARNED TO ALWAYS CHECK UNDER THE CARPET WHEN BUYIN A JEEP.
HERE ARE THE PICS OF THE PROGRESS....















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Old 12-14-2010, 11:35 AM
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Those floors look like my old XJ, good job fixing it.
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Old 12-14-2010, 11:45 AM
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Wow.......never seen floors 'THAT bad..........
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Old 12-14-2010, 11:48 AM
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Originally Posted by Detour View Post
Wow.......never seen floors 'THAT bad..........
Take a trip to Canada. lol.

Jeep looks great man.
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Old 12-14-2010, 11:52 AM
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nice work, my floors looked like that too. and i don't think i did quite as good of a job as you did fixing it, should hold up good
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