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The "XJ to Buggy" Build

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Old 12-02-2014, 01:20 PM
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Got the passenger side boatsides a little more finished:



Started narrowing the front header panel...yeah its in a pile right now



Hope to at least have the boatsides wrapped up tomorrow and the front header panel further along.
Old 12-02-2014, 01:20 PM
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Got some front tube work done, as well as got the new front clip narrowed for mock up. As well got the A-pillar sweep tube finished (theres 6+ bends in the damn thing), as i've had it sitting around for a bit, and the window supports:





With the front clip "in place":



Coming along, just waiting for the ORI's to get it a roller
Old 12-02-2014, 01:21 PM
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Little update:

Got some more tube work done on the front:





Re-did the upper panhard mount somewhat. Moved the hole down some, and added some weld washers to help prevent any wallowing:



Did some rear tube work to incorporate the back bed some more and give it and the upper link mounts some more support:





Thats it for now...but the end of this weekend should produce a big one
Old 12-02-2014, 01:22 PM
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So these boxes show up today for me when I get home...



Ladies and Gentlemen, I present you with....







































































B-B-B-B-BLIIIING!!!







After looking some things over and flexing the suspension...looks like I want to change some "small" things.

*move rear suspension and front suspension forward 1-2"
*Inboard the axle side of the LCA mounts on the front suspension some

Gonna be a long productive weekend!!!
Old 12-02-2014, 01:23 PM
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So....I came home and then see this...




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ITS...A...ROLLER!!!

Been damn near TWO years since this thing has been on its own weight! :hail:

Lots of pics













And since I know there will be questions on some things...

*This is basically full bump it is sitting at in the picture, sits ~68" tall to the top of the tube...forgot to measure the belly

*The semi-cirlce tube in the back near the strut was tacked in since I thought I was going to need to notch the bed frame...moved some things around and didn't need it

*The mounts are NOT done...I just needed them to be done enough for it to hold its weight since I'm moving later this week to a new place...(luckily next door ) There will be boxing and gusseting of the mounts in time to come...
Old 12-02-2014, 01:23 PM
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Ok so I guess it about time for an update with pictures

Getting things in the rear planned out :



Been working on my fuel cell cradle on and off for the last couple of days...its finally done minus the over the cell straps. For this being hand cut with an angle grinder and some drill press work, i'm pretty happy with how it came out...though it did cause me to have to go get metal drilled out of my eye...



Tube work out of 1.25" in the back...its been actually flipped from this to move the fuel cell behind the passenger to offset weight in the buggy.



It all "in place"...







And finally getting the rear strut mounts braced...



Thats where i'm at right now...next it getting the Action Packer bin mounted as well as my radiator.
Old 12-02-2014, 01:24 PM
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So got a little more work done this weekend...

Got the ORI mounts in the rear finished up:







As well got the Action packer mount knocked out...pictures and lighting make it look a little worse...



In place...



With the bin all clamped in...



Now to get the radiator done...
Old 12-02-2014, 01:25 PM
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Picked up a set of G-Force 5-point restraints from a freind for $80:



Picked up a D300 from another friend for $100.
It has a broken rear output (which happened near 4 years ago now and I was partially responsible for it breaking by persuading someone to a certain line )



Gonna use this in a Box4Rocks Doubler setup with 32 spline outputs replacing the stock ones

Started the radiator cradle for the Griffin Radiator I got from Loobz



Got ONE tube done for the rear (really was not in the mood to notch yesterday)



And I've been working on stripping the harness with help from a freind...this stuff is what nightmares are made of:



Stuff that has been gone through or still needs to:



What has been removed:

Old 12-02-2014, 01:26 PM
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Aaaaand....an update...with pics!

So far i've:

-Nearly finished up the boatside tubes

-About gotten the radiator mounted as shown in the pics. Still has some work needed done to finish things up (more mounting tabs, make it removable, etc.)

-Cut out the floor (though there is a little more to cut out)

-Got the cowl cut down and welded/blended to the tube


This weekend I'll crank on it for a bit since I don't have any school next week since its Thanksgiving Break. Hopefully i'll have my fuel stuff sometime that week so that I can get the fuel plumbing all mounted and try my damnedest to rig up power with a battery and fire the motor!

Pics:

Radiator Cradle and mounts:







Cowl:





Floor, or lack thereof







Old 12-02-2014, 01:27 PM
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Got my fuel stuff in, thanks to Tim at LII!

All the fuel stuff layed out...$$$


Getting the Trick Flow Fuel Filter mocked and tacked in place:



The Walboro Fuel Pump mounted:



Got the Aeromotive Fuel Pressure Regulator mounted (can kind of see it in the previous picture as well).



Some other stuff thats going on alongside...

Doubler stuff getting dealt with somewhat...



Goodie box, in said box: AA 32 spline rear D300 output, Toyota flange, JB 32 spline D300 front output and JB rebuild kit for the D300

Old 12-02-2014, 01:28 PM
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Got a little done on the rear, some more bracing and making the radiator removable:




Worked on the exhaust some as well. Cut and reworked the exhaust headers to point the exit straight down instead of down and back:


A little engine enamel to pretty them up some:


Hacked up the old exhaust and got it started, it wraps down and around the front of the oil pan. Just need to order a muffler and a new CAT:


Also go started on the interior dash and console:




Got a mock doubler setup in to see clearance of things as well, now just need to get the real one in!
Old 12-02-2014, 01:29 PM
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Got my exhaust done and routed. Still need to pull it back out and get it fully welded:




Got my fuel cell straps made so the cell is now finally secure (in case your wondering I drilled out all those holes in the straps):



As well got some more done with the dash/interior. Got some bracing done and mounted the stock tranny shifter...work perfectly:





Last but not least, got my battery box made up. Wanted to go with an odyessy battery instead of an optima but for $22, the Optima was in the budget.



Battery in box:



Mounted in buggy:

Old 12-02-2014, 01:30 PM
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Got this little beauty done FINALLY...been slowly working at it forever now.




Sandblasted and painted the case and got it re-fitted with AA HD Rear Output, JB HD Front output, new 1310 front CV yoke, rear HAD Toyota Flange, a complete rebuild kit, all new bolts, and ground out the shift rail.

Got this sucker in the other night...and yes it HAS to be clocked like that for my setup. I won't BEGIN to tell you the nightmare that kinda caused me redrilling the Tranny adapter thingy.



Next up is getting the D300 all bolted up in there, then measuring for my rear DS so Jess at HAD can get me one made up as well as ordering and getting the cable shifters setup.
Old 12-02-2014, 01:30 PM
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Got my cable shifters in...went a little long and a little too thick I think...these things are BEEFY!



As well...got my cutting brakes and brake pedal assembly/diaphragms in :grinpimp:


I'll let the pictures speak from here, but got:

-Top of the rails skinned
-Steering wheel column mounted
-Passenger side floor skeleton done
-Started cleaning up the wiring and running it through the fire wall
-Got Computer and Fusebox mounted
-Supply & Return coolant tubes bent up, run & mounted
-Other small stuff



Old 12-02-2014, 01:31 PM
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