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Necromancer Jeep (slow build)
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Attachment 403460
1990 Jeep XJ 2-Door 4.0L/AW4/NP231 220K miles I few months ago I picked up this Jeep on a whim. The pictures on the add looked rough and it looked even rougher in person. This thing has a LOT of rust and has been sitting since around 2010... https://cimg4.ibsrv.net/gimg/www.che...3039671505.jpg https://cimg3.ibsrv.net/gimg/www.che...b00327648b.jpg Looking at it, I knew this would be a huge undertaking. I was able to talk the PO down to $300 so I figured what the hell! This Jeep came with both the OEM transfer case skid plate and gas tank skid plate. It also came with vinyl flooring instead of carpet, and a mini-console instead of a full center console. https://cimg6.ibsrv.net/gimg/www.che...e7ea722c26.jpg https://cimg7.ibsrv.net/gimg/www.che...12312805e9.jpg https://cimg3.ibsrv.net/gimg/www.che...d420348be4.jpg https://cimg1.ibsrv.net/gimg/www.che...301ce98cb6.jpg https://cimg2.ibsrv.net/gimg/www.che...7d03d2fbd6.jpg The floors are completed rotted out in the and so are the rockers. However, the unibody itself is in good shape. I've been wanting to learn how to weld for a while, so I figure this will be a good project to learn on. https://cimg2.ibsrv.net/gimg/www.che...3c06c32484.jpg I finally got it in the garage recently, and the first order of business was pulling the axles out from under it. It came with a two-piece D30 and a D35 rear, 3.55 gears. I'm not going to use them, and they are currently for sale in the Knoxville, TN area if anybody wants them... https://cimg0.ibsrv.net/gimg/www.che...6b9ff9bc63.jpg https://cimg4.ibsrv.net/gimg/www.che...1b1319d876.jpg https://cimg6.ibsrv.net/gimg/www.che...7b70087cbf.jpg Then I began pulling back the vinyl flooring to see the carnage... https://cimg0.ibsrv.net/gimg/www.che...9b1464580f.jpg https://cimg6.ibsrv.net/gimg/www.che...df9a23d839.jpg https://cimg2.ibsrv.net/gimg/www.che...530ff072f0.jpg https://cimg7.ibsrv.net/gimg/www.che...0fd4400587.jpg https://cimg8.ibsrv.net/gimg/www.che...23c8364980.jpg https://cimg5.ibsrv.net/gimg/www.che...170975a3a1.jpg Yikes! But it is what I expected. I picked up a set of floor pans from a guy here locally who sold his Jeep before he got around to installing them. They should fit perfect. https://cimg6.ibsrv.net/gimg/www.che...9c378913e4.jpg https://cimg7.ibsrv.net/gimg/www.che...f2d5897b3c.jpg Then I drew an outline and got to cutting... https://cimg6.ibsrv.net/gimg/www.che...5932834dba.jpg https://cimg8.ibsrv.net/gimg/www.che...adb757dba7.jpg https://cimg7.ibsrv.net/gimg/www.che...2249ac63f0.jpg And that's it for now. I read that it is best to cut out and weld one side at a time so I haven't cut out the driver's side yet. I bought some POR-15 and my plan is to clean up and paint the insides of the uniframe channels before I weld the new floor panels in. I have never welded before and I recently acquired a Century 140 welder that I am excited to use. I have some flux-core wire but am debating picking up a tank of Argon/CO2 for MIG welding. |
This Jeep has been "dead" for some time now. As the title of the thread implies, I intend to bring it back to life! :sorcerer:
Here are my plans as of the time of this post:
https://cimg8.ibsrv.net/gimg/www.che...7efd65fdfb.jpg It came with 4.10 gears, factory locker, and an aftermarket differential cover. Notice how it did not come with knuckles. I purchased WJ knuckles for it. :thumbup1: For the rear axle I am going to try to find a Ford 8.8 with 4.10 gears, disc brakes, and factory limited slip. However, if I come across a 4.10 geared Chrysler 8.25 out of a 2.5L XJ for the right price I'd definitely consider it. |
Here is the factory build sheet:
Equipment Listing Vehicle Description 1990 JEEP CHEROKEE Monotone Paint Power Front Disc/Rear Drum Brakes Rear Fold w/Removable Cushion Seat Passenger Assist Handles Mini Floor Console 4-Speed Automatic AW4 Transmission Command-Trac Part Time 4WD System Floor Mount Automatic Shift Lever Dana M30/181MM Front Axle 3.55 Rear Axle Ratio Tinted Windshield Glass Front Door Tinted Glass Tinted Rr Drs/Qtr/Liftgate Glass Fixed Door Vent Glass Rear View Day/Night Mirror 85 MPH Primary Speedometer Cigar Lighter Glove Box Lamp Halogen Headlamps Black Front Bumper Black Rear Bumper Black Grille STANDARD EQUIPMENT Bright Windshield Moldings Rear Qtr Solid Window Insert Belt Moldings Rear Fascia Skid Plate Applique Federal Emissions EVAP Control System 20 Gallon Fuel Tank Bright White Clear Coat AM/FM Radio Power Rack and Pinion Steering Perforated Steering Whl w/Red Stitch Inside Mounted Spare Tire 15X6.0 Styled Steel Wheels Build To U.S. Mkt. Specifications GVW/Payload Rating Federal Govt Bid - U.S. Zone 11-Chrysler Corporation-Consign Fleet Option Editor Skid Plate Group Heavy Duty Suspension Group SE Decor Group 105 Amp Alternator Low Back Bucket Seats OPTIONAL EQUIPMENT H.D. Vinyl Floor Covering Reversible Carpet/Vinyl Cargo Mat Spare Tire Cover All 4-Speed Automatic Transmissions Dana 35C/194MM Rear Axle Trac-Lok Differential Rear Axle Left Remote Mirror Right Remote Control Mirror Power Mirrors, Fold-Away Air Conditioning Digital Clock Front License Plate Bracket Auxiliary Transmission Oil Cooler Heavy Duty Engine Cooling Bright White Clear Coat All Radio Equipped Vehicles 4 Speakers Front Heavy Duty Shock Absorbers Rear Heavy Duty Shock Absorbers All Tires Full Size Spare Tire P205/75R15 BSW All Season Tires All Steel Wheels Warranty Registration Card-Govt Bid Tag Instructions Manuf Statement of Origin 9 Additional Gallons of Gas Rear Spring Group I Left Front Spring Group Ix Right Front Spring Group VIII Price Protection - Code B Road Ready Service/Courtesy Delivery Prepaid Holdback Sold Vehicle Special Bid-Ineligible For Incentive Domestic Government Bid Units |
4 Attachment(s)
I cleaned up the exposed unibody on the passenger side with a wire brush and flap disc. Then I gave it a quick coat of POR-15.
Attachment 403497 Attachment 403498 Attachment 403499 Attachment 403500 I couldn't find any weld through primer locally so I ordered some off Amazon. I'm going to coat the lip of the unibody with that which is why I left it bare. I should probably have mentioned that this is going to be a slow build lol... |
In the future you could pick up a can of Cold Galvanizing Compound from Home Depot. I used it all over when bad_idea off the forums welded in square tube in place of my rockers.
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Originally Posted by CantDrive55
(Post 3512340)
In the future you could pick up a can of Cold Galvanizing Compound from Home Depot. I used it all over when bad_idea off the forums welded in square tube in place of my rockers.
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Originally Posted by CantDrive55
(Post 3512340)
In the future you could pick up a can of Cold Galvanizing Compound from Home Depot. I used it all over when bad_idea off the forums welded in square tube in place of my rockers.
Originally Posted by unidentifiedbomb
(Post 3512349)
X2 that's what we use in our garage/shop when welding. Great stuff and cheap. For the future, C2C fab makes full length floor boards and most panels. Less pieces the better
I looked at C2C's stuff and almost ordered it but I was able to get the 4 floor pans (front and back on both sides) along with the outer rocker panels locally for $125. I haven't decided what to do with my rockers yet. If I restore them to stock then I will need to order the inner rocker panels from C2C. I'm also considering going the 2x6 tube route. Which do you think would be easier for a beginner welder? |
Stock panels will be easier to weld to, but 2x6s are cheap and much stronger. Depends on what you plan on doing with it too. 1/8" 2x6 would be much stronger than stock sheet metal rockers and easier to weld to the body. I went with 2x6 3/16" with DOM side tubing and tied them to my stiffeners.
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Originally Posted by unidentifiedbomb
(Post 3512892)
Stock panels will be easier to weld to, but 2x6s are cheap and much stronger. Depends on what you plan on doing with it too. 1/8" 2x6 would be much stronger than stock sheet metal rockers and easier to weld to the body. I went with 2x6 3/16" with DOM side tubing and tied them to my stiffeners.
My plan for this Jeep is to have it be capable off-road but also drivable on the street. I will be getting stiffeners eventually. I would prefer the 2x6 tubes but I'll just have to practice my welding a lot before I get to that point. |
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The day's work...
First I put another coat of POR-15 in the unibody channel, then I grinded the surfaces to be welded. Attachment 403519 Then I sprayed some weld thru primer. Attachment 403517 Attachment 403520 Attachment 403507 Attachment 403508 Attachment 403509 I also drilled some holes for spot welds into the floor pan and made some relief cuts Attachment 403515 Attachment 403516 Then I sprayed the bottom of the floor pan with weld thru primer. Attachment 403518 Attachment 403510 Once that was dry it was time to start welding! Attachment 403511 Attachment 403512 Attachment 403513 Attachment 403514 |
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Today I continued the process with the rear passenger panel.
Attachment 403534 Attachment 403535 Attachment 403536 Attachment 403537 Attachment 403533 I know my welds aren't the best but I'm learning as I go. I'll have to cut a piece to fill that gap in the middle. |
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I cut a piece for the gap between the floor pans.
Attachment 403539 Attachment 403541 Attachment 403540 Attachment 403543 |
Quite the project.
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Progress on this has stalled due to a combination of factors... Me being busy, being lazy on the days I'm not busy, and I had an accident with a cut off wheel that required six stitches in my right leg. I'm okay - there was no major damage done - but it has killed my motivation nonetheless. If those all sound like excuses... If I'm being perfectly honest... They are excuses!
BUT I did pick this up today for the Necromancer Jeep: Attachment 403786 A factory XJ Dana 44 axle out of an '88! Now with the front axle from the TJ, I will have bolt-in Dana 44s front and rear, which I am excited about. :rockon: Here it is compared to the D35 that came out of the Jeep: Attachment 403787 Now I have to decide how to build it. I think I will be taking inspiration from NickInTimeFilms' build on YouTube. |
Nick did a great job with his build, one thing I will suggest though is get some high clearance shock mounts, no reason to do all that work and have 8" long brackets hanging down on each end. Looking forward to the build
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