While putting in the rebuilt engine, we discovered that the alternator was nasy and seized up. Needed pliers to spin it.

After dropping a few bucks for a new alternator, I wanted to make sure that this one stayed a little cleaner than the last one. Five-minute solution below:









Grabbed a piece of thin galvanized sheet metal from my scrap pile and went to work. The hole that secures the splash guard to the oil pan in oversized. I didn't want the vibrations of the engine to stress the metal. Perfect example of why I named this XJ build "Quick n Dirty".

 

I went ahead and bought this brace, should have done it in the first place. With all your skills you could fab one for it, but they really are not that expensive I got mine from M.O.R.E. 4X4

 

That plate is not a bad Idea, I wish there was a good way to move the alternator and still keep my ac

 

Found this brace as well.
https://www.mountainoffroad.com/stee...-87-01-xj.html

Price doesn't seem bad, but I think getting a set of adjustable control arms is the priority for my jeep at the moment. Making up a steering brace seems like a nice Sunday project.

When it comes to air conditioning, I've read about people converting their A/C condenser into an on-board-air system for filling up tires and running air tools. Seems pretty nifty: http://www.jeepforum.com/forum/f11/c...p-pics-471962/

 

Just realized that I never ended up posting the pics of the winch mount I made up!







Also welded a chain to the hitch piece...my redneck security system

Looking back, I can see that the mount seems a little flimsy in the front. If it were to see a lot of downward force, it might bend. I might stiffen it up once I test it. It's been lent to a co-worker, but should have it back shortly.

 

That should pull you out of some tuff spots.

 

Finally went and bought adjustable control arms and 4.5" coils for the front. Definitely evened out the height of the Jeep. I still get death wobbles around 50, but it seems to only happen on bumpy roads. I won't dig too much deeper into that issue until my caster, alignment, and sway bar bushings are all perfect (The bushings are pretty worn out right now).

Some pics of the coil springs and new control arms. Pup for reference. After the picture was taken, I did some adjusting to get the arms to the right length.







I don't normally pause while wheeling to take pics, but here's a couple photos of a recent trip. Blue truck blew a water pump, so the green jeep was pulling it out of the trails. It needed a little help getting up one of the hills though. I'm liking the 4.5" lift setup with 31" tires and cut fenders. Much more room for flex.

 

Great thread.

Thanks for sharing.

 

Bringing this back up from the depths for a quick appreciation post and update. This was the first vehicle I owned that really got me comfortable being my own mechanic / half-*** fabricator. It unlocked a real intrest in welding as well, which I'm grateful for. Money well spent, I'd say.

This XJ was a champ, but sadly didn't make it far past 240,XXX. Ultimately the skirt of piston #2 broke off when I was on my drive home from work - completely out of the blue. Pretty sure I mention this in the build journal somewhere. Engine was making an awful noise, but no loss of power or compression. Only indicator that there was a problem was the fact that my Jeep sounded like a tin can full of rocks being shaken around.

Ended up rebuilding the engine, building a DIY stinger front end after almost hitting a deer, and fighting some overheating issues. I've seen this Jeep for sale on Craigslist and FB Marketplace at least three times since selling it - it becomes a little more beat up each time I see it lol. Since this Jeep, I've owned a boring 2014 Highlander, and now an '06 E350 camper project which has been a blast. Been getting into bikes recently, too.

So that's it, I suppose. Between this XJ and fixing my friends Cherokees and YJs, I've had it with Mopar for a while haha. Godspeed, comrades!

 

That's a pretty cool project. Something that will get you to some great places. We have some incredible dispersed camping areas that your van can easily access here in Colorado.
especially if you're into mountain biking or trail riding. A lot of the trails out here are multi purpose. Just requires a yearly $25 OHV pass for off road vehicles.(motorized)
My wife and I want a brand new Highlander some day too. We want it for traveling in our retirement years. I love messing around with my Xj. But some day I'll have to part with it as well.
I just really want to complete it to the way I want it to be and enjoy it for a season or two before I let someone else gets to use it. This rig will probably out live me the way it's going.

Hope you have a great time with you hobbies. Be safe!