EndlessMtnFab

Well, I'm finally ready to start posting some pictures & info about my Cherokee build.


I was having trouble coming up with a good name until I spoke with a fellow club member. He was chiding me for getting too wrapped up in technical details and wanting to discuss theories & concepts.


The S.O.B. told me ... " Man, you are a tech snob "



And so we have a name !!




That said .... Project Tech Snob is a 97 XJ that had 276,000 on the motor before the #6 piston cracked. Even with the rev limiter at 5K .... a motor that old doesn't like to aggressively approach it.


Setup wise .... it was an Up Country package with a 5 speed trans & 3.07 gears ( HP30 / 8.25 ). Ran 30 x 9.50 tires from Day One (we bought the Jeep back in 1997 with 5,000 miles on it ... while we were living in CO ).

As the motor got older, I swapped in some free 3.55 gears to ease the motor's strain. Gas mileage dropped by 1/2 mpg. Avg economy was between 21 and 22.5 with a corrected odometer. The Jeep had all the factory skidding at the time.


I have been working on this a while, mainly due to my balancing the company (parts sales/outfitting, gearing, & custom fab), house projects, and the Jeep all at on time.



Rather than give all the specs in one shot ... I'll just release things as I go. Should keep the anticipation high.

EndlessMtnFab

It's an old picture ... but it gives you an idea of what the truck looked like when I started.








Nothing to report about the Jeep until this happened.












Another friend from a different Jeep club was kind enough to work out a deal with me for his stroker motor. He destroyed his ZJ ... but only had 5,000 on the new motor. It is a 4.7 engine (4.2 crank, machined 4.0 rods and .060 overbore) that has been done by a trusted shop in his area. Ran 24 lb/hour injectors.








Cleaned it up. Used some POR 15. Swapped over some of the accessories. Painted with POR Engine Enamel. And we have a pretty motor !

EndlessMtnFab

While the motor was on the engine stand ... I called up Brown Dog Industries to inquire about their block mounts. At the time, I was running the MORE Bomb Proof mounts and was very satisfied with them. I inquired about the compatibilty and Tim said they would work. However, being that I was one of his dealers ... he made me an offer I couldn't refuse. Now the MORE offroad mounts sit in a box and I have new BD engine & block mounts.


I was aware that BD uses 7 bolts for the driver side block mount (receives more torsional stress) and 4 bolts for the pass side. I request Tim send me an "unfinished" pass side ... so that I could modify it more to my liking.






And this is what I ended up with.








Painted up !









The problem was ..... the engine bay looked like this





and I was just *thrilled* was this

EndlessMtnFab

For all my welding .... I cannot do body work for squat. But I gave it my best impersonation.
















While I had the sand blaster out .... I cleaned the outside frame rails in preparation for TMR frame plates and a set of "Famous Maker" Chassis Stiffeners. I coated both the frame rails and the insides of the stiffeners with Zinc Primer / Cold Galvanizing compound to keep rust at bay (between metal surfaces). *Warning* USE CAUTION WHEN WELDING WITH THIS STUFF !!! FUMES CAN LINGER AND CAUSE SICKNESS !!!









I drilled additional holes in the main chassis stiffener to allow me to rosette/plug weld to the frame rails. This will further stiffen everything up. Take your time and skip around while welding to prevent "over-heating" the sheetmetal frame rails.







And finally, an unmounted shot of the TMR frame stiffener.

BamaXJ

Nice start so far! What are your plans for this beast? 4.7L sounds niccceeeee.

EndlessMtnFab

Ahhhhh .... but you just have to follow along.


It's already known (here on CF) that I'm doing a custom long arm --- but I don't want to give away the info. Makes reading fun, doesn't it ?



Joe

ironhead64

More! More! Don't leave us too long, Joe!!!!

EndlessMtnFab

Hang on a few hours ... my goal was a morning & evening update for you guys.


I'm way ahead of this project than you think ..... I just wanted to make sure I was far enough along that I wouldn't "run out" before the truck was/is ready.



Joe

bmosso3

nice job! more pictures! now! haha jk

ironhead64

That's cool. I loves me a good build thread with pics!!!!

ltlgreenXJ

This is gonna be awesome! Good job, Joe! Can't wait to see the rest.

EndlessMtnFab

Remember ... I'm not a body man. I don't like welding sheetmetal.











I also wanted to reinforce the steering box area. Several companies make suitable reinforcements. But me, being the excessive compulsive neurotic that I am ..... wanted to make my own. Mainly because I wanted provisions for a YJ 4 bolt steering box.



Made some templates ....












Cut them out (inside & outside rails, of course) ....





Then added the proper spacers to mount the box and drilled lots of rosette weld holes.

EndlessMtnFab

Machined a spacer out for the 4th bolt (XJ steering box uses 3 bolts, YJ box uses 4 bolts). Cut out a piece of the frame rail ... and grafted the spacer in.









Coated the frame rails and insides of the plates with the zinch compound again (see warning above about welding ---- FUMES !! ). Then started welding all four plates, taking care not to concentrate the heat in any one area for too long.

Mr.JayDeeM

damn nice welds!

SpitFire

subbed!