Prius Volume II
I beat the **** out of my jeep learning how to wheel and had a great time. but I do have love for XJ's and this one deserves better. it's time for a rebuild
Blue Prius Volume I Index of links/write-ups: trimming my fenders cowl hood my cowl hood Dukie456 durango steering/ zj tie rod SYE install my D30 spicer 760 ujoint with full circle clip upgrade cage ideas #1 cut/fold rear quarter panels how to use seafoam bored throttle bodies WJ knuckle swap BotakBeng's SYE install write-up Inspirational Build Threads: X1994J goneboating06 96_xj Detour xclusivexj liftedjeepxj n_a_i_w |
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recap
got a jeep for $1000 Attachment 349787 took it all apart Attachment 349788 Attachment 349789 got a lot of parts and built it 1993 XJ 4.0/ Aw4/ np231/ 121,000 original miles Engine/Drivetrain: zj fan clutch, no thermostat, B&M trans cooler, power steering cooler JB conversions SYE, xj front shafts (front and rear) Suspension: 4.5" rubicon lift (USA), adj RE short arms, RE track bar, double shear track bar bracket welded on, RE leafs, LII shackle relocation, JKS boomerangs, bilstein shocks, parts mike SS brake lines Steering: durango steering box, zj tie rod, goferit knuckle insert, JCR spacer Axles: HP30, aussie locker, 4.56's, spicer 760's, full circle clips, ruffstuff cover ford 8.8, detroit full case locker, chromos, 4.56's, ruffstuff swap kit, ruffstuff cover Wheels & Tarz: 33x12.5 km1/ 15x8 soft 8's Attachment 349790 not long after, flopped it Attachment 349791 and kept wheeling Attachment 349792 Attachment 349793 Attachment 349794 Attachment 349795 |
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although still driveable, having a shattered windshield, ugly body damage, and permanently no doors was getting annoying
step one buy a parts jeep Attachment 349782 this one was sitting out front of Ruffstuff. I picked it up for $300 and sold maybe $150 in parts off of it Attachment 349783 Attachment 349784 took it to a friends frame shop and gave it a good pull Attachment 349785 commence project Attachment 349786 |
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so basically the idea here is to make a new section that will fit onto my jeep perfectly, rather than cut a number of small pieces and hope they all mesh toghether enough to fit a door
xj's are held together by a million million spot welds. I've been drilling them back and peeling back big layers of jeep. here is a small example Attachment 349772 and here is my new piece all ready to go on. it took about a week to get this all done Attachment 349773 and right here is a bolt. we removed that bolt and cut out the section around it. then literally bolted my new section into place Attachment 349774 and there it is Attachment 349775 Attachment 349776 |
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here are the final stages
Attachment 349581 Attachment 349582 cut up the driver side for the 2x6 rocker Attachment 349583 and immediately after test fitting I decided I didn't like it. these would look way better if I cut the doors and tucked them even higher. to bad the other side was already pre welded in place. nothing is set in stone. maybe I will keep cutting Attachment 349584 hung a door and test fitted a windshield. we're only off by a few centimeters in a few spots. I'm happy with it Attachment 349585 and then I came home to these waiting for me on my doorstep. the first thing I noticed is that the middle sections are about half the size and weight as the ruffstuff ones. I think I'll be much happier with these Attachment 349586 |
sweet looking good! when i saw the new jeep i just figured youd be swaping everything over to that one. you dont like the 2x6 rockers without the doors cut?
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Originally Posted by Power73
(Post 2314501)
sweet looking good! when i saw the new jeep i just figured youd be swaping everything over to that one. you dont like the 2x6 rockers without the doors cut?
stay tuned for a cage and paint in the next few weeks |
That's really cool that your committed too yours, many folks just say "these XJs are a dime a dozen, just pick up a new one and swap over axles".
I'll be keeping my XJ as long as i possibly can, thats for sure! :cheers: |
yep! I made the mess and now I'm cleaning it up. I've burned through enough cherokees (pun). this ones been nothing but good to me it's earned some TLC
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Originally Posted by Atmos
(Post 2314537)
yep! I made the mess and now I'm cleaning it up. I've burned through enough cherokees (pun). this ones been nothing but good to me it's earned some TLC
:laughing: |
CageCageCageCageCageCageCageCageCage!!!! This rigs gunna be epic
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I have a windshield. fitment isn't to bad the corner is a little off
Attachment 349040 it's done just needs doors. wheeled her the other night and it held up fine Attachment 349041 |
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here is the write up I used for welding to a unibody http://www.pirate4x4.com/forum/9750902-post14.html
it recommended cleaning the frame by hand with 80 grit (so you don't remove as much material from the already paper thin frame as you would with a grinder). but I found that using this orange clean and strip wheel at a low speed cleaned the frame bare and didn't even shoot sparks. awesome tool cleans damn near any material right off of metal Attachment 349036 layed down some galvanizing primer Attachment 349037 Attachment 349038 and since I bounced my frame off the rocks a good couple times, fitment was an issue. after some hammering around I got it close. there were still gaps. it wasn't particularly fun welding these to anyone considering rock crawling I highly recommend you install at leaset middle frame stiffeners before you anything else Attachment 349039 other than that I was much happier with these HDOffroad stiffeners over the ruffstuff ones. these weighed about 10lbs each and were easy to work with. I've still got a couple more welds to make, then clean, then lay down some paint |
What thickness are they?
Making great progress! |
thanks. they are 10 gauge
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