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Project Vulcan, '94 XJ

Old 10-28-2017, 08:14 PM
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Location: Port Orchard, WA
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Year: 1994
Model: Cherokee(XJ)
Engine: 4.0
Default Project Vulcan, '94 XJ

So, backstory. I am 24 and an enlisted E-5 in the US NAVY stationed in Bremerton, WA on a submarine. My job mostly entails working with computers and fixing all the BS that breaks on a 33 year old sub. I grew up wheeling. My dad still has the '74 Bronco we would take out every weekend in Dresser, WI. I grew up around this stuff. That being said, I never paid much mind to what happened when we got home. Unfortunately the lessons I could have leaned were lost. And seeing as there is now 1500 miles between us, the most help I can get is a phone call. So, here we are. This will be my second Jeep project. Prior to this XJ I had a '98 ZJ that I raised from a perfectly well all original 90k mile rust free body. I don't have any regrets with the ZJ but there were things I decided I would do different if I were to start again. Then I got an offer I couldn't refuse and sold the old girl. With some cash in my pocket I decided I wanted an XJ. I'd never owned one but they seemed to be a bit easier to build up to what I wanted. Priorities are 4 doors, 4.0, and this time around I wanted to get a head start. I knew if I found the right deal I could save a lot of money on parts. About 3 weeks on every "for sale" site you could think of I stumbled upon this XJ on FaceBook Marketplace. I know, not where I would expect either. However, the guy was unfortunately fresh out of work and had a well built rig for a price I was sure was a mistake. A few texts back and forth and I thought it was a good enough rig based on his description to hook my trailer and drive 3 hours to go take a look. Well, she needs some love but I thought the price was still right. So without further adieu, here is my 1994 Jeep Cherokee. I have listed the known modifications below. I hope everyone can enjoy my build and maybe learn something from it. I know I will. And, with any luck she will be ready to go come spring. Because I'm already dying to take it on the trail. I've named this beast Vulcan based on the Roman god, because I'm a nerd.

Here she is the day I picked it up. 24 October 2017. This is the build sheet I received from the P/O.

Engine: 24lb injectors, Baja Beast cam, fuelpro fpr, walbro pump, braided lines with Earl's connects, highmassflow TB, rc TB space, port matched intake and exhaust, hi flow exhaust, electronic fans.

Axles: Currie d44 front fully race prepped chromoly shafts Dynatrac ball joints, gussets, 5:13 gears Currie 35 spline race 9 inch rear, nodular 3rd, strange gear set, 5:13 gears, Yukon Grizzly 35 spline locker.

Interior: Switch board, aftermarket steering wheel, pedals, shift select, main roll cage hoop installed, ttf rear shock towers and x brace, Red top battery.

Suspension:Qr limit straps, bumps around, Fox remote reservoir front , Bilstien rear shocks, deaver 11 leaf race pack, rc coils, LONG ARM FRNT, SYE KIT RE, JKS DISCOS, c3or coil adjusters.

Misc: Cb, 50" Light Bar, Vision X pods, Tube Bumpers, Rock Sliders, ARES Rear qtr armor, 9k winch, Dyneema syn line 100ft. , Rock lights, 35 in Hercules like new on ProComp Wheels.







So. We have a decent base to a potentially excellent Jeep. Plans as they are now
1. Get the interior back into decent shape. (More on that a little later)
2. Rework all electrical as necessary.
3. Full fluid maintenance on everything.
4. Plugs and Wires?
Until I can get this thing on the trail to see where it may be lacking this is the plan. I'm sure things will come up, Ive got the rest of winter to figure it out. So here we go.

Project #1 - Interior
Here is where the fun starts. Imminently upon purchase I parked the rig in the garage and started a strip of the interior, the front seats are completely shot (no foam left) and the rear seat is gone. The carpet is disgusting and so are all the plastics and door panels. My plan was to just strip the interior and replace seats, however, I was met with a surprise.





As you can see there is a little rust (which I've read is common in this location). That being said, It has been rusting from the inside out thanks to a leaky windshield, so the floors are truly the only thing in need of repair. I jumped on the interwebs and have replacement floors on the way, hopefully mid week so I can continue with the rest of the interior. Also, just as a note, silicone is not a solution to a rusty floor covered in holes. If you're going to fix something , fix it right.

Last edited by Thompson128; 11-13-2017 at 09:34 PM.
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Old 10-28-2017, 08:15 PM
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Year: 1994
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Also, how would I make my picture a little smaller so they can be seen in one frame.

Anyway, I have some other tidying up to do.

Sway bar link mount at the axle.
Hmm...
Starter wire, that could have been fun.

Last edited by Thompson128; 10-28-2017 at 09:32 PM.
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Old 10-29-2017, 08:23 PM
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Made a lot of progress today, went and picked up a 95 that was in a collision for $200. Should be a good rig to have around for the little trinket stuff. Got my transmission inspection plate removed and installed. Then got both gas tanks removed and sending units swapped over, now the tank sits on the floor waiting to be installed. Unfortunately the interior is a little further gone than I had hoped so I won't be using it. I did manage to get a decent interior rear hatch panel. More to come this week. Floor pans should be here Wednesday.
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Old 10-29-2017, 10:59 PM
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Took a break from working on the XJ.
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Old 10-30-2017, 10:31 AM
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Keep up the pics and progress!! Your in Port Orchard and I'm over in Everett, waiting paitently to get home and tear into my 1989. I fear that mine will look just like yours on the interior, with rusty floors and due to a leaky windshield. I thought about replacing the floors with the pre-cut floorboard replacement parts but then thought about just cutting out what is bad and weld in patch panels. Time will tell depending on how bad it is. I look forward to seeing photos of your repair process to give me hope that mine will either but just as good (bad) lol as yours and that it will be fixable.
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Old 10-30-2017, 10:39 AM
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I know one thing... I'm happy to see another 9 inch install...
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Old 10-31-2017, 08:08 PM
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Made some decent progress today. Unfortunately I can't get this thing done as quick as I want until my darn floors get here.
First thing tackled was the tank.
Out with the old.
In with the new to me.
Must have done something right. LOL!

Then I took care of the starter wire so I could run the damn thing.
Still looks factory. Heatshrinked for protection. Rerouted the wire up and around the oil filter, hopefully this will help make less of a mess when removing the poorly placed thing.Then I took the seats out of the '96 I got in the back. I plan to make these work. They're nasty, nasty, nasty. However, if I can get the brackets to work I will find some ZJ seats. I LOVED the seats in my '98 ZJ so hopefully I can find a decent set.
This is what they look like after I hit them with some Super Clean and a 4500psi pressure washer.

Compared to what's in it now.



That's it for today. I currently smell strongly of gasoline and the old lady says I need to shower before the kiddos come around begging for free candy. So I'm going to draw a tall glass of whiskey and take a night.
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Old 11-01-2017, 08:41 PM
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Today I decided to work on getting the 96+ seats installed. Due to the fact I'm still waiting on floor pans for the passenger side. I only worked on the driver seat.
This is the bracket I made to adapt the front of the seats to the factory mounting positions.
The inboard side needs to be about 5/8" shorter than the outboard side due to a height difference on the seat brackets.
This gives an idea of what it looks like tacked together.
Take it out and weld it up. I'm still learning to weld so don't bash too hard.

Seat has full range of motion. I even placed the center console just to test.
Still need to take care of the outboard side in the rear. The inboard lined right up though.

That's it for tonight gents.
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Old 11-02-2017, 06:44 AM
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Looks like you got some leaking still going on? See that puddle on the floor?
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Old 11-02-2017, 07:04 AM
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Originally Posted by XJIrish4x4 View Post
Looks like you got some leaking still going on? See that puddle on the floor?
Its from the seats. I washed it, still has some water in it.
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Old 11-02-2017, 08:29 AM
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Oh okay lol I was about to say man it leaks a lot!
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Old 11-02-2017, 08:29 AM
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Oh okay lol I was about to say man it leaks a lot! wait di
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Old 11-02-2017, 03:26 PM
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I'm sure it does leak somewhere. Thankfully I can keep it in the garage until I get the rig fully sorted.
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Old 11-03-2017, 10:35 PM
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Brown Santa came today. Also hit up the Pick-N-Pull and found some decent seats. The driver seat is good to go. After the floor will be the passenger and rear seat. Hopefully I can make it work.
Driver seat looks good. Loved these in my ZJ. Can't wait to drive.
The rest.
Needed to remove the roll bar then I fit and traced the new pan.
Started making cuts. Had to call it a night for dinner. Should get it cleaned up tomorrow.
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Old 11-04-2017, 04:39 PM
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Made it as far as I wanted to without the front pan in yet. Rear is fitting nicely. Can't wait to get it burned in. Then I moved onto the rear axle, the passenger seal seems to be leaking all over my floor. Removed the shaft so I could get the part. Anyone know off hand what to order for a 35 spline Currie 9"???
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