I am going to cut everything off of the rail before I stiffen it. If I am going to add a little length this would be a good time to do it.

The next few days I am off so I hope to make some progress on it.

 

Well this XJ has seen better days. I had to replace all of the passenger floorboard and most of the driver's side AND the rear was rusted as well. I found that the tunnel is wrinkled from a wreck and the passenger rail is not quite straight.



There is a crinkle on the passenger side closer to the firewall.


Here I am using a jack to squeeze the plate down tight.

 

I added holes for plug welding the channel reinforcement. I went with 3x3 as it was available locally. Shipping to our island is expensive.

I have a little more undercoating to remove on the rail and after both parts are prepped I think I am going to add weldable primer. I don't know if it will make a huge difference or not.

Here is my reinforcement for the passenger side.

 

subed

 

I've nearly finished prepping underneath the jeep on the passenger side. It rained so hard today that there was water in the garage. Rolling around underneath on the creeper I still managed to soak my pant legs up to my knees. Hopefully tomorrow will be calmer.

I also purchased a set of Rubicon Express 4.5 inch lift from coil springs. I hope I can lift it before the snow sets in. I really want to have a second jeep for winter and there is still so much to do before this one will be road worthy.

 

I spent the weekend cleaning gutters and working on drainage around the house. It really howled here with lots of wind and rain.

Tonight I got the frame rail fully prepped and primed it with zinc weldable primer. Tomorrow I will tack in the reinforcement and hopefully my son will weld it in for me since it is pretty critical.

I may lower the mounts for the rear like it is done here http://jeep-xj.info/HowtoRearLeafMounts.htm

Although, with winter coming this fast I may have to finish up the rails and get the interior put back together. We'll see.

 

My son asked that I slot the uniframe reinforcements. So, the drivers side is slotted. I've tacked them in place and he will weld in the slots and add some perimeter welds as well.

 

Friday I am ordering RE 3.5" lift springs. I understand that they start out higher than advertised. I have front 4.5 inch so if I am a little low in the *** end I can relocate the brackets or get longer shackles.

I am SO going to have the XJ ready for snow this season!!

 

I ordered the RE 4.5" coils and 3.5" leafs. I also got the RC 1.5-2" shackles to make up the difference in the rear. I'm in the middle of installing the lift now and should be finished by Thursday. (Air compressor died, so it's all by hand) If you have the stock suspension, be prepared for a HUGE difference.

 

Please post your picture - I'll be curious to see how much rake you have with the leafs and shackles combined.

 

Yesterday, I blocked up the XJ and took off the wheels and tires. I spent a little time stitch welding the floorboards. And talked with my son about welding up the reinforcement plates.

This morning I ordered RE 3.5 springs and ubolts. I still need to decide on shackles. I think I would like to order a pair of the boomerang style. I'd like the XJ fairly level or even a little raked but not dragging the back end. EDIT: I ordered JKS Boomerang Shackles too.

Still so much to do and so little time to work on it.

 

I removed the front coils, front sway bar links, front brake lines and front shocks so it is ready for some plate up front.

Rear shackle bolt is turning in the frame. I wish I would have known I was going to replace the shackles before I welded the new cargo metal in.

My son started welding in the reinforcements for me.





It's nice to have a certified welder in the family.

 

I am looking forward to working on the project.

I read a great thread about an XJ build over in Iceland. They run 38's and bigger out in the snow on stock drive train. Loved the look of the giant tires!

My 3" ubolts are not 3". I misread and that was the overall dimensions. I am taking it as a sign that I should go ahead and use the 14 bolt as originally planned. I still have the D60 too so I am NOT going to have it on the road for the snow this year. I did put a fresh tires on my wife's TJ so at least we won't have to walk to work.

This weekends list:
Remove front fenders
Template front for reinforcement
Cut metal

 

Keep up the good work.

You better speed it up so you're ready for winter! Lol

 

I am not going to make it. So much to do and so little time and money.