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-   -   Project Vulcan, '94 XJ (https://www.cherokeeforum.com/f46/project-vulcan-94-xj-239924/)

SirCyber 11-15-2017 03:33 AM

Looking really good!

Thompson128 11-17-2017 10:36 AM

Nothing picture worthy last night. I got my new axle bearing and seal pressed on. Reinstalled. So far no leaks. She's back on 4 wheels again. Then went about welding a small patch on a rust patch near the driver side drain hole. It's ugly so I'll take pictures after I get it ground down and dialed in. Carpet is on it's way. Should be here Tuesday. Hopefully I can start putting the interior back together. I just need to weld the holes shut on the new pans. It seems to have more holes than the factory pan, not sure what they are all for so rather than rubber plugs I'm going to seal them up. I'll leave one in front and one in back just incase I ever need to drain some water. I don't play in the water too much so I don't see that happening. But, never know. Next up will be getting all the ZJ seats mounted up. Then I plan on redoing all the wiring for the aftermarket accessories. I'll do I nice write up on making a fuse and relay box that should look pretty clean. I also plan on making a custom center console. Anyone got some pics for inspiration?

Thompson128 11-19-2017 10:59 AM

Got the finishing touches on the floor. Got to work on the passenger seat. Which was easier than the driver side. Then just mocked it up.
https://cimg8.ibsrv.net/gimg/www.che...49426c8920.jpg
https://cimg0.ibsrv.net/gimg/www.che...39fb81fc07.jpg

Thompson128 11-19-2017 12:10 PM

Got the brackets painted. I used the POR-15 Top Coat. Hopefully this will prevent future rust.
https://cimg3.ibsrv.net/gimg/www.che...f2a04d86aa.jpg

Thompson128 11-22-2017 08:48 PM

Driver side frame support is installed. Time for passenger side, clean up the welds and undercoat.https://cimg6.ibsrv.net/gimg/www.che...f268df9ca8.jpg

Thompson128 11-22-2017 11:32 PM

Passenger side done. Plus UPS came right as I was finishing. Still needs more trimming, but I like the carpet. Fits good and color is good.https://cimg3.ibsrv.net/gimg/www.che...de9a921cc0.jpg
https://cimg4.ibsrv.net/gimg/www.che...aaaece4794.jpg

XJIrish4x4 11-23-2017 01:44 PM

Looking good and some quick progress on your work! What is with the tube setup in the rear cargo area you got shocks towers braced back there?

Thompson128 11-23-2017 06:49 PM


Originally Posted by XJIrish4x4 (Post 3442331)
Looking good and some quick progress on your work! What is with the tube setup in the rear cargo area you got shocks towers braced back there?

Thanks! I get to it when I can. The rear shocks are relocated the top of the leaf perch and ran through the body to the tube braces. It allows for a longer shock, more travel, and keeps the shock mounts high up for clearance. I'll take some better pics when it's cleaned up. Right now all the interior trim is sitting in the cargo area.

Biggsly 11-23-2017 08:23 PM

Looking good.

Thompson128 11-28-2017 08:11 PM

Finally! Some progress. I got the carpet done and cut to fit. Then got the interior mocked together. Started on the backseat. The bottom cushions needed some trimming. I got the cover in the wash so no more progress until that's done. Looking good so far though.
https://cimg8.ibsrv.net/gimg/www.che...af41003e15.jpgThere will be a lot more leg room once I get the cushions cut.
https://cimg9.ibsrv.net/gimg/www.che...c90d4c0b76.jpg
https://cimg0.ibsrv.net/gimg/www.che...10aa90db74.jpg
https://cimg1.ibsrv.net/gimg/www.che...ef3daba2e8.jpg

XJIrish4x4 11-29-2017 12:21 AM

Very nice!

Thompson128 12-03-2017 07:35 PM

Did some small stuff today. Got the new e-brake handle installed. This is from a 99. I got everything swapped over to support the newer center console. I used a small piece of metal as strapping for the front so that I could use the existing holes.
https://cimg6.ibsrv.net/gimg/www.che...0e182cd66f.jpg
I also did the shifter and the vent duct. I will take pictures when I get it cleaned up.
My switches came today so I got to work getting them installed. I'm still waiting for some other things so I just mocked up the switches so I can start wiring them sometime this week. I used a piece of trim from another Cherokee as the backing plate. I want it to match and didn't want to use metal. I think it should work well. I like the color and texture match. The bonus is if I don't like it there it's very easy to undo because I didn't make any new holes (yet). We will see how it turns out.
https://cimg6.ibsrv.net/gimg/www.che...76a5618657.jpg
Then I needed to do something about the broken battery box. All 3 Cherokees at the local yard were broke in the same spot as mine. So until I get a new one or find a better solution, this is it. I used a bushing and a hose clamp and made some small slits for the clamp. It works for now but it's not a permanent solution.https://cimg8.ibsrv.net/gimg/www.che...458fcea236.jpg

Thompson128 12-04-2017 11:16 PM

Woo. Lots of stuff done today. I got the headliner in. I took it out of a 99 and it doesn't have the same mounting for the rear sound bad. Also my Jeep has the full console and this one does not. If the previous owner hadn't hacked the overhead up I would have tried to make it fit. But it looks like crap so I used the little dome light. I needed to make a small bracket to adapt it because the bracket for the full overhead sits about 6 inches back. I used a strip of 12 ga steel and drilled it to match then recessed for the harness and ran some screws through the inside of the housing into the metal. The lenses cover the screws and looks factory.
https://cimg2.ibsrv.net/gimg/www.che...815d697b28.jpg
https://cimg3.ibsrv.net/gimg/www.che...257f51822c.jpg
The color also lightens it up inside so that's a nice bonus.
Then my stuff came and I got to work wiring the fuse and relay box. Here is how far I got so far. I will get it finished up tomorrow but it's a start. I still need to plan out the ground and 12+. Need to math out my wire size. I will be running 14awg to all the accessories. And I'm using 20awg 9 conductor wire for getting to the switches in one nice package. I also ordered some 9 pin connectors for the back of the switches rather than having to unplug all of them and figure out how it goes back together whenever I need to pull panels.
https://cimg7.ibsrv.net/gimg/www.che...1070d93777.jpgAll crimped and soldered connections.
https://cimg9.ibsrv.net/gimg/www.che...a5dd4ae2e0.jpgThe start to the spaghetti.
As promised here is a picture of the console mostly finished. I need to order one of those metal brackets that go under the armrest section because the plastic one I got is broke.
https://cimg3.ibsrv.net/gimg/www.che...d4d921927b.jpg

Also got the rear seats covered and installed.
https://cimg8.ibsrv.net/gimg/www.che...fe4ae869d5.jpg

Thompson128 12-13-2017 11:02 PM

So, after combating a nasty sickness and spending a lot of time at work, I finally got a day to make some progress. I got the rest of the wiring done inside the relay box. It barely shuts, but it fits.
https://cimg3.ibsrv.net/gimg/www.che...6ff2d8139a.jpg
Then I found a nice spot to mount it. I was actually surprised how nicely it fit. All I needed was a small strip of metal to extend the mounting post on one side and it bolted right in. No new holes required. Plus it leaves it quite accessible for hooking things up.
https://cimg6.ibsrv.net/gimg/www.che...24f30c868b.jpg
Then I started wiring it in. For the power I'm using a solenoid that is triggered from a relay, from an ignition powered source. I used a relay for the trigger just to ensure there was enough amperage to support the load. The wiring is a bit messy in the photo. I've cleaned it up some since.
https://cimg1.ibsrv.net/gimg/www.che...6b6e9ade80.jpg
This should be more than enough to support the loads coming out of the box. Next I got to work on the switch panel. I ditched the idea I had of putting it under the glove box. I didn't like how far away it was. So I decided to use the ashtray instead. I'll take pictures once it's in, but here is the wiring. I used a plug-in connector so I don't have to deal with a million spade connectors any time I need to move stuff around. There are still two pins available for future add-ons as well.
https://cimg0.ibsrv.net/gimg/www.che...8c70725055.jpg
https://cimg1.ibsrv.net/gimg/www.che...964fed3561.jpg
And just to show why I'm doing this, here is just some of what I've pulled out so far. It was an absolute nightmare of wiring. There would have been no effective way to troubleshoot anything if there was an issue with one of the accessories.
https://cimg1.ibsrv.net/gimg/www.che...4dca3acdb2.jpg

vulcan96 12-14-2017 09:34 AM

Your doing a stellar job.
I like to see when peeps take the time to wire correctly, anyone can hack and splice. But it takes serious time to do it right.


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