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Project Horcrux (Lots of PICS)

Old 10-22-2015, 09:30 AM
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Location: Douglasville,GA
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Year: 1990
Model: Cherokee(XJ)
Engine: Renix 4.0
Default 1990 XJ Solid Build Project (Lots of PICS)

Hey Everyone, Thought it was time to start a build blog on my 4-Door 1990 Renix XJ with 4.0, NP 231, AW4, 4WD, Dana35/Dana 30 I am calling Project Horcrux (unless someone can come up with a better name, my wife his a Harry potter fan, so she like that name) So here is how I got it. One of my Best friends was in collage and needed a little extra money. He owned an Early 90's Mazda Miata and a 1990 Jeep XJ. Being that the Miata was alot better on gas, he decided that the jeep needed to go. Unfortunately, was pretty rough. It had a major oil leak, It didn't run well, The paint was all but gone, It had Vacuum Leaks out the wazoo, all the electronics were problematic, Inside was extremely dirty, Massive hole in the muffler..... you get the point. The only thing that was good on this were the Tires. 31" BFG TA/KOs.

Anyways, 5 months goes by and he cant sell it, not even 1 offer. He calls me and explains the situation he is in and asks for help (he is a very proud person, so this was hard for him.). He was trying to sell for $2,000. He told me that If I wanted it, he would sell it to me for $1,500. I had been talking to my wife about buying a jeep to build into a trial rig for a while and she was fully on board. My father in law has a Fully Crazy Built 71 k5 Blazer Trail rig(Pic Below) and I had been wanting to join him on some trail rides. So I took this opportunity to ****** this up as a long term project.

So a month goes by and unfortunately I don't have any time to work on it. Then comes the sign from above. (*heavenly sounds start playing*) My wife's DD was a 2014 Mazda CX-5 that we bought brand new. In 2 years, it had been in the dealership for different problems for over 40 days all together. We talked about it and we decided to go ahead and file the paperwork the declare the vehicle a lemon. Instead of turning around and buying another vehicle right away for her, she said... and I quote "Why don't we take the money we were paying for my DD and put it into the Jeep and I will drive that until its ready for trail only mods".........

So, at this point, I asked if she was sure, then I asked if she was really really sure, then I took her out to dinner. So now we are here... She starts driving it next week and I have already ordered a bunch of parts. I have been working on it over the past 3 weeks in any spare time I have. This is where we stand...

Things I have done exterior:
-Restored the entire cooling system (Kept the closed cooling system with the Volvo cap mod and drilled the thermostat and burped the system.
-Big 3 Upgrade (Alternator, Battery, and Grounds)
-Front Axle disconnect vacuum eliminator Kit
-Fixed the oil leaks (CCV was gone, various gaskets, blah blah blah.)
-Complete tune up (dist. cap, Plugs, wires, seafoam treatment, belt, waterpump, timing...etc)
-Started Cleaning what I could of built up oil scum in engine bay.
-Built a wiring Harness for the Headlight Low beams and High Beams
-New Headlights
-Flushed the Transfer case with new fluid
-Fixed Power steering pump leak
-New Zone off road Shocks (Extremely Happy)
-Replaced fan clutch (Came with jeep from PO)
-Full Custom Magnaflow Exhaust (buddy owns a muffler shop and we trade off work for services)
-Ripped out everything Aftermarket (crappy fog lights with botched wiring job was the biggest thing)

Things I have done to the Interior:
-Deep Deep Scrub Cleaning
-Dynomat Extreme EVERYWHERE!!! (used to work in a custom car audio install bay and had 5 boxes from there)
-Replaced all the factory audio system wiring
-Kicker 1000.5 Amp with Kicker QS Coaxial Speakers and an Alpine Type R 8" woofer
-Replaced Driver seatbelt
-Replaced Gear selector Cover
-Replaced Front Cabin Light (was missing)
-Replaced headliner (Wife was a big help with this)
-Cleaned out all the Air Ducts
-Replaced rear hatch Shocks
-Custom Built Cubby Sub
-removed spare tire Interior Stuff

Few....
So here is everyone's favorite Part.... PICS..
New Exhaust


Magnaflow 22" (Quite until you romp on it)



ran High and Tight



New Headliner, I was going to replace it with factory grey headliner fabric, but my wife said that I need to be outgoing and creative... This made her happy


Stary night fabric


It actually turned out really good.

Power steering pump


Dynamat!!


Did all 5 Doors

Cubby Sub



Behind Sub




Spray foam to fill tiny gaps



Took a weekend off and Friend I bought the jeep from wrecked his miata, so he bought a 02 WRX from someone who lived near me. Friend lives 5 hours away so I decided to go visit him for a day and deliver his car for him. I had also done a little work on his motorcycle for him, so I brought that to him also. What a good friend I am lol.



Where we sit now. Has a 4" budget boost on it from PO.

Alright. So This is where we are now. I have recently ordered a New Moog Drag link, and Moog ZJ Tie Rod that should be here soon. I ordered a IRON Rock Offroad Double Shear Adjustable TrackBar, and bought some paint. The office I work at has a now junker car policy (hoowity toowity Business park) So I have to paint it before I can drive it to work if I want.... So I bought 2 Gallons of Some Industrial/Marine Single stage enamel and whole bunch of sanding equipment and am getting started on that next.


This is where I got the Color Idea From


Its a Bright Lime Green

Now this is where I am. I also Ordered Some LED Fog Lights to mount to the bumper because My wife has horrible Night Vision. I will keep you up to date on whats going on. I would love feed back and Ideas for upcoming items. My next things on my list after paint is Armor all the way around, Ford 8.8 Rear Axle Swap. Some type of Lunchbox Locker front and rear. New bumpers with winch in front, Long arm Upgrade, and Exo Cage.

Last edited by xsparta11x; 10-30-2015 at 02:42 PM. Reason: Title Update
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Old 10-22-2015, 09:43 AM
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I wish my wife liked my jeep
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Old 10-22-2015, 12:27 PM
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UPDATE:
New Moog V8 ZJ Tie Rod and new Moog Drag Link just came in, Will be installing those tonight, while I have everything off, Im going to paint the front axle. Might go crazy and paint the tie rod Green Also.

Last edited by xsparta11x; 10-22-2015 at 12:50 PM.
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Old 10-30-2015, 02:37 PM
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Update:
Alrighty, So the Iron Rock Offroad HD Adjustable Track Bar with double shear bracket finally came in. I also Ordered a JCR Off-road Steering Box Brace while I was at it. I currently have alot of slop in the steering box So I am going swap it out with a Re-Manufactured 1998 Dodge Durango V8 Steering Box from O'Rileys. After this Upgrade, Next Major Thing to do is Paint..... not very excited about this.... but has to be done.
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Old 10-31-2015, 01:21 AM
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Box is a direct swap. Easy peasy
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Old 11-03-2015, 06:26 PM
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Update 11/3/2015: Well Last week I took the Jeep to my Buddy's exhaust shop to get a Catalytic converter put on(wife was being fumigated), on the way there, I saw the temp gauge go threw the roof. I limped it there and started looking around. I saw the Water Pump puking Fluid...Great.... SO After The exhaust was finished, I started working on the Water Pump issue. My house was too far away so Limping home was not an option. Luckly my buddy said, lets go ahead and just replace it. SO he went and picked up a new water pump and Gasket for the thermostat while I started removing the old. Took about 3 hours to do and by the time I was wrapping up, it was about 9pm. Well as Jeep luck would have it. I was literately putting in the last bolt for the thermostat (the bottom bolt that holds the housing) when half the threads for the bolt hole, snapped off... (level of frustration.. about an 8.98/10) so after about and hour of screwing with it, we got a longer bolt to bite just enough to thread in. We then welded the bolt to the block and cut off the head of the bolt to now have a post. We used a nut to secure it. Worked great. Filled it up, burped it, then checked for leaks.... Yeah no leaks!!!! Its now about 12am and so I make the 30 mile trip home. Never gets above 200. It is now cooling better then ever. I guess if This had to happen, Happening at a buddy's garage is about the best possible place. Only sucky part, come to find out that the Catalytic converter I had put on, is hitting against the uni body, need to have it redone.

3 Days Later...

While my Wife was handing out Candy to Tick or Treater's I was swapping out the Steering Box...(yeah...) While I was at it... I installed a JCR offroad Steering box Spacer/Brace. The guys over at JCR know what they are doing... Perfectly designed, and very install friendly. The Box sucked to get it becuase I waas by myself, and it was quite heavy. Through, I only cut myself twice..... not to bad.Anyways, it helped TREMENDOUSLY!!!!! No more slop in the steering. I took it out for a test drive, tightened it up about an 1/8th of a turn on the adjuster, then called it good.


Last night, I went and installed the Iron Rock Offroad HD Adjustable Trac Bar w/ Double Shear Bracket.... Easy Peasy... came with all the necessary parts and instructions even gave me Torque Specs. Could not be happier with the purchase of this. Now the Axle is nice and centered.


Now, I think i'm going to go to the JY this weekend to pickup some new side mirrors. I'm going to try to get some Black ones from like a 97. Mine are quite literately falling off.



So Where are we right now.... Currently My Dodge Ram DD is in the shop getting a broke exhaust manifold bolt taken care of..(started to do it myself, but it was seized real good) Will be picking that up tomorrow and then taking the jeep back to get the Catalytic converter fixed. Once this is done... Paint!

Last edited by xsparta11x; 11-03-2015 at 06:44 PM.
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Old 11-03-2015, 08:24 PM
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My mirrors had the same problem except they fell off every time I closed the door. Got some news ones from 97 up jeep last week.
Attached Thumbnails Project Horcrux (Lots of PICS)-image-3810695048.jpg  
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Old 11-04-2015, 09:57 AM
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Originally Posted by 93XJeeper View Post
My mirrors had the same problem except they fell off every time I closed the door. Got some news ones from 97 up jeep last week.
Thats what im going to do, how annoying was the removal and install?
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Old 11-04-2015, 12:57 PM
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I love the Horcrux name haha
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Old 11-04-2015, 02:24 PM
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Originally Posted by xsparta11x View Post
Thats what im going to do, how annoying was the removal and install?
pretty easy only took a but 15 minutes to install. Only annoying part was taking off the door panel to get the little plastic triangle cover plate off. Other than that, simple.
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Old 11-05-2015, 01:09 PM
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Originally Posted by 93XJeeper View Post
pretty easy only took a but 15 minutes to install. Only annoying part was taking off the door panel to get the little plastic triangle cover plate off. Other than that, simple.
I worked in a Custom Car Audio/Video place for 5 years so I can take a door panel off in record time!
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Old 11-05-2015, 01:10 PM
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Originally Posted by charbur View Post
I love the Horcrux name haha
Yeah, the Wife is a Huge Harry Potter Nut so in order for me to throw all this money at this, she said I had to name it the Horcrux.
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Old 11-16-2015, 10:28 AM
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Update 11/16/2015:
Well Its Monday and I started the painting process Last Thursday, took 2 days to sand, and 1 Day to Tape. After I was done taping, I went and Picked up a gallon of Duplicolor Automotive Primer and There "Special additive reducer" pretty sure just lacquer thinner. Anyways, that laid down just Fantastic. Here are a few pictures before paint was laid down.














Alrighty, Now its paint time. This was the Annoying part. I was by no means looking for a show car finish. I mainly need something to cover the rust, and looks decent. I choose a single stage industrial enamel. Strong, rust resistant, all good stuff. Looking at the Paint spec sheet, it says to not reduce it if using a conventional sprayer. Well, that immediately clogged the gun, and unfortunately I was borrowing the spray gun (real nice Eastwood Gun) and didnt have any other Tips. So I had to reduce it about 30%. not exactly perfect, but what I have to work with. So now that the paint has been reduced so much, I am having to do alot of thin coats, or else the paint will run really quick. I did the 1st coat yesterday in the afternoon, then another one really really early this morning before I left for work (around 5am). The Spec sheet says the paint is good down to 40 Degrees, this morning was 47 so I was cutting it close. Pulled it out of the heated garage, spray took about 30 mins. Then pulled it back in. Right now Im at work, and with the 8 hour wait time between coats, as soon as I get home, I will do coat number 3, then probably coat number 4 late tonight. Im thinking probably 5 light coats should do the trick. Here are some pics of the paint.








The pictures don't do it justice, Its a dark Lime Green that My wife Picked out. For my First time Painting a vehicle, not to bad on my part. I will get some more pics when it is all done.
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Old 11-23-2015, 06:35 AM
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Well, Painting is Done"ish". I had more troubles then you could even imagine with this paint. Didn't want to be reduced, dry spray, then running, then flaking.... This was my first time doing anything like this so I am going to chalk this up to probably factors caused by my lack of knowledge of painting. Im going to take some compound and polish to it in a couple of days once its cured more. All in All, not to bad. I am going to probably go back over it come spring time when it warms up though. But for now, It still turns heads, all the time. Once the paint cures completely (about 2 weeks), I am going to paint the grill, luggage Racks, and Bumpers Black. I am also going to touch up the black skirt around the bottom and on the flares. Also installed some mirrors from 2000 XJ, Old ones were totally shot. litterly just cut the cable and sprayed over the mount. I already had the new ones.







OK whats next.... Next is going to be a Long Arm Upgrade. Currently the caster angle is all out of wack and makes it a pain to drive on the interstate. (Constant white knuckle from all the sway) Decided to go with Serious Offroad's Serious Longarm Upgrade.
http://www.seriousoffroadproducts.co...4-7.5-S-A-Lift

I have read nothing but High Praise about this kit. The guy also seems really cool. Im going to let the holidays pass until I venture on this though. Ill post a pic once I paint the remaining pieces black.

Last edited by xsparta11x; 11-23-2015 at 02:27 PM.
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Old 11-23-2015, 04:09 PM
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Wow !!! great works, congrats
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