Starting work on '90 XJ
01-31-2010, 05:51 PM
#1
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Year: 1990
Model: Cherokee
Engine: 4.0
Starting work on '90 XJ
This is my stock 1990 XJ that I finally started working on today...
So I started working on my rack today and it's been one problem after another. Managed to make 2 1/2 whole cuts before the circular saw went out. Now have to wait until I can change the brushes in the motor before I can continue the work. Well since I couldn't start fabrication on the rack I decided to remove the factory roof rack and side rails. I managed to get some of them out, some of them were stripped out, some I couldn't break free, and some just turned and wouldn't back out. Once I got it all off this is what I found...not pretty!!!
This is one of the few that I found that were still okay...
Well it looks like I have ALOT of body work to do that I wasn't planning on having to worry about!!! Besides having to cut out sheet metal anyone have any other ideas???
So I started working on my rack today and it's been one problem after another. Managed to make 2 1/2 whole cuts before the circular saw went out. Now have to wait until I can change the brushes in the motor before I can continue the work. Well since I couldn't start fabrication on the rack I decided to remove the factory roof rack and side rails. I managed to get some of them out, some of them were stripped out, some I couldn't break free, and some just turned and wouldn't back out. Once I got it all off this is what I found...not pretty!!!
This is one of the few that I found that were still okay...
Well it looks like I have ALOT of body work to do that I wasn't planning on having to worry about!!! Besides having to cut out sheet metal anyone have any other ideas???
Last edited by tactical40cal; 01-31-2010 at 05:54 PM.
01-31-2010, 06:04 PM
#2
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Year: 1990
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Also...how did ya'll run the rack lights into the cab? I really don't wanna drill any holes in the roof...not that I'd have to since I already have holes in my roof 
...but just looking for some ideas...
...but just looking for some ideas...
01-31-2010, 06:21 PM
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Year: 1994
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yea that rust def aint good. as for the wires. i pulled back the rain gutter and put the wires under there. from there, i ran the wires into the top of the door and under the a pillar panel all the way down under the hood latch handle and to the fire wall
01-31-2010, 07:11 PM
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Year: 1989
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hey man when you say south louisiana ....where u at i am from south la also .....patterson
01-31-2010, 07:17 PM
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cool deal! as far as the holes in my roof i think i'm gonna hit up the body shop at the tech school in abbeville or lafayette and see what they can do for me. i know at one time they would do labor for free and all you had to do was pay for supplies. i'll let you know more when i know more. i think i'm gonna have them leave a hole for me to run my wires through in the back and i'll just use silicone to seal it. that's how they do it on our police units for the light bar. i do plan on adding an inline quick disconnect with a trailer plug or something.
01-31-2010, 08:08 PM
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01-31-2010, 08:51 PM
#9
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Year: 1994
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hey im im in new iberia. but we have a trip planned to sicily island the weekend of the 20th yall should head up i have a couple friends goin in their jeeps and also some people from louisianajeepers will be there
01-31-2010, 10:17 PM
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01-31-2010, 11:12 PM
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02-05-2010, 09:37 PM
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Year: 1990
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Roof Rack
Started roof rack fabrication today...only had 3 hours to work on it so I got a lot of the cutting done. Gonna start the welding tomorrow. 
02-05-2010, 10:44 PM
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Year: 1990
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Hoping to get alot more done on it tomorrow. Even crossing my fingers to finish it. Let me just say that I've never seen one designed like this so it should be interesting. It'll be 4'X6'X6" tall. BIG rack! I've seen the ones that only cover about 1/2 the roof and I just don't see a point to those