96XJ build in Pennsylvania

[Stukboy]

Ok, I've had this XJ for a few months and haven't done much but thought i'd start my build thread..

I used to have a pretty cool YJ on 36's but as my family grows my rig must grow.
I have a garage full of parts and plans for a family rock crawler.
From my YJ I have a pair of Waggy 44 axles, spooled, 4.88s, alloys and some other stuff with 36" Super Swampers. I also have 3 winches(yes, 3) A Warn 8274, Smittybuilt XRC8, And a Superwinch 3000#. I have Creeper Joints for up front and a 4link setup from the YJ for the rear. And, I have an internal cage(that needs a little modding) with 4 racing seats and 5 point harnesses for our safety. I know I have left out a few odds and ends but......

Here are the plans:

Obviously, I will put the axles under it using a 4link rear with Fox Airshocks and 3link with a panhard bar and coils up front, internal cage only in the passanger to hold the seats and harnesses, I have HD Offroad frame stiffeners and front end stiffeners before anything goes on to sure things up. In addition to the internal cage I will be doing an exocage to TRY and keep the body decent. I haven't decided which winch I want to use but am leaning towards the 2 big ones for both extraction and to pull the suspension down when I get tippy. I will be putting pins in the doors so I can remove them in good weather and putting my onboard air from the YJ.

I have a full plate with this project and feel slightly overwhelmed with it. I guess the reason is because I have alll the parts ready to go and want it done yesterday.

So far........

I have gutted the interior, taken off body and suspension parts, pulled the motor to make room for a "new to me" motor, rebuilt the tcase and installed a SYE from my old tcase. I hope to get it back into my garage by Thursday so I can pull the rest of the suspension and start installing parts instead of removing them.
Here are some pics of my progress: I will try to update this as I have seen others on here do. I sometimes forget to snap pics while I work but i'll try.

I would like to thank ALL the current and previous builders for the ideas so I can make my budget build XJ a reality. I like stealing ideas and it is the best form of compliment.

The last one is a teaser! Just a tasty treat.
Stukboy






(xj1.jpg)





(on trailer.jpg)





(empty1.jpg)





(empty.jpg)





(one open.jpg)





(opem2.jpg)





(done1.jpg)





(IMG00209-20091114-2055.jpg)




Attachments
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xj1.jpg (128KB - 0 downloads)
on trailer.jpg (83KB - 0 downloads)
empty1.jpg (108KB - 0 downloads)
empty.jpg (99KB - 0 downloads)
one open.jpg (124KB - 0 downloads)
opem2.jpg (98KB - 0 downloads)
done1.jpg (125KB - 0 downloads)
IMG00209-20091114-2055.jpg (79KB - 0 downloads)

[Stukboy]

So this is a problem!!! Why can't I post a pic?????

[The Griz]

you need to use photo bucket and than just cut and past the pick url from there to the post

[Stukboy]

I'm not that smart!!! The rules thing says "I MAY NOT post attachments"
Don't rub it in!!
Stukboy

[Ba-Riedo]

Upload your pics to photobucket.com (make an acct) then paste the img code that shows up below each picture in your album.

-Alex

[Stukboy]

OK, Maybe this will work. My thing still says i'm not allowed to post attachments though.
Stukboy

http://i870.photobucket.com/albums/ab268/stukboy/done1.jpg

http://i870.photobucket.com/albums/ab268/stukboy/opem2.jpg

http://i870.photobucket.com/albums/ab268/stukboy/xj1.jpg

http://i870.photobucket.com/albums/ab268/stukboy/ontrailer00000.jpg

http://i870.photobucket.com/albums/ab268/stukboy/empty1.jpg

http://i870.photobucket.com/albums/ab268/stukboy/empty.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00209-20091114-2055.jpg

Crossing my fingers and it worked!!
Thanx Ba-Riedo!!!

[POLAR_JEEP_04]

http://i870.photobucket.com/albums/ab268/stukboy/IMG00209-20091114-2055.jpg



this looks good!

[Stukboy]

It is.

Howl Winter Seasonal Black Lager by Magic Hat Brewery.

[Shorty]

too much Howl???? where's the updates??

[Stukboy]

There hasn't been any progress since my last post. You may ask why?
My Jeep has been Jeepnapped by my bro in law. Has was to do the engine
But has been tied up with his new house. So it has been sitting. I am however
Getting it back today. I thought it would be cool if he could knock out one of the
Things needing done so I could focus on other parts. (note to self: STUPID idea.)
One I get it back I will just do it myself. So that's the status. Once I have something
I will let it be known.
Stukboy

[Begster]

OK, Maybe this will work. My thing still says i'm not allowed to post attachments though.
Stukboy

No one is allowed to post attachments, it takes up too much space on the forum. That is why everyone uses photobucket or other line photo accounts.

[Stukboy]

Test update. Trying to post pics.

http://i870.photobucket.com/albums/ab268/stukboy/XJ10.jpg

http://i870.photobucket.com/albums/ab268/stukboy/XJ9.jpg

Well, it seems to have worked!!

It has been a long time since I updated this thread. Mostly because I forgot how and was just to lazy to figure it out.
With the help of RCman I started to play around tonight.
The 96XJ was trashed so I sold it. I picked up a running 92 Laredo and went to town.
I have lots of pics some good some not but the thing looks bad ass but still needs a lot of work. The endless work in progress.
Here are some older pics I had around:
http://i870.photobucket.com/albums/ab268/stukboy/XJ8.jpg

http://i870.photobucket.com/albums/ab268/stukboy/XJ7.jpg

http://i870.photobucket.com/albums/ab268/stukboy/XJ6.jpg

http://i870.photobucket.com/albums/ab268/stukboy/XJ5.jpg

http://i870.photobucket.com/albums/ab268/stukboy/XJ4.jpg

http://i870.photobucket.com/albums/ab268/stukboy/XJ2.jpg

http://i870.photobucket.com/albums/ab268/stukboy/XJ1.jpg

[goblazers_6]

Looks like a pretty small fuel cell. Rear link setup looks awesome though. What springs are those?

[Stukboy]

Just getting started with pics.
The cell is a 5 gallon. I ran from 12-5:30 at Rausch and had no issues but can see them if I have a longer day. Carried an extra 5 gallons in a can just in case.

The springs are stock front XJ. I have a set of 3-1/2" i'm thinking about putting in. Not sure though.

Here is one from last Saturday,

http://i870.photobucket.com/albums/ab268/stukboy/trailride5-14.jpg

[eflores]

Are those hd off road front stiffies?

[Stukboy]

Yes they are. They were VERY easy to install.

[Stukboy]

Took the stock crossmember and a piece of steel and went to work.

http://i870.photobucket.com/albums/ab268/stukboy/frontbumper1.jpg

The end result.

http://i870.photobucket.com/albums/ab268/stukboy/crossmember3.jpg

HillBilly Driveshaft.
http://i870.photobucket.com/albums/ab268/stukboy/driveshaft.jpg

Start of the rear bumper. I made the straps that go into the uniboby, plates that bolt to the rear on both sides and welded it all together.
http://i870.photobucket.com/albums/ab268/stukboy/bumper2.jpg

http://i870.photobucket.com/albums/ab268/stukboy/bumper1.jpg

http://i870.photobucket.com/albums/ab268/stukboy/bumper4.jpg

http://i870.photobucket.com/albums/ab268/stukboy/bumper5.jpg

http://i870.photobucket.com/albums/ab268/stukboy/bumper.jpg

Stukboy

[Stukboy]

Some rust repair.

http://i870.photobucket.com/albums/ab268/stukboy/IMG00107-20100421-2147.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00108-20100421-2148.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00109-20100421-2227.jpg

Some rear axle stuff.
http://i870.photobucket.com/albums/ab268/stukboy/IMG00120-20100423-2005.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00125-20100425-1917.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00126-20100425-1917.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00141-20100502-1842.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00149-20100503-2222.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00150-20100503-2223.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00154-20100503-2327.jpg
Fender trimming required.
http://i870.photobucket.com/albums/ab268/stukboy/IMG00166-20100507-2129.jpg

Front axle out and ready for stiffners.

http://i870.photobucket.com/albums/ab268/stukboy/IMG00190-20100512-1240.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00192-20100512-1354.jpg
OOPS! That'll leave a mark.
http://i870.photobucket.com/albums/ab268/stukboy/IMG00198-20100513-2248.jpg

Time for lunch
Stukboy

[Stukboy]

Tcase is in.
http://i870.photobucket.com/albums/ab268/stukboy/IMG00203-20100516-1818.jpg
Front axle parts.
http://i870.photobucket.com/albums/ab268/stukboy/IMG00221-20100519-1629.jpg
http://i870.photobucket.com/albums/ab268/stukboy/IMG00217-20100519-1537.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00291-20100609-1937.jpg


http://i870.photobucket.com/albums/ab268/stukboy/IMG00292-20100609-1938.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00300-20100610-2017.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00328-20100613-1545.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00339-20100613-2308.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00337-20100613-2216.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00336-20100613-2216.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00343-20100613-2345.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00345-20100614-1422.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00346-20100614-1431.jpg

[Stukboy]

Back to the crossmember.
http://i870.photobucket.com/albums/ab268/stukboy/crossmember1.jpg

http://i870.photobucket.com/albums/ab268/stukboy/crossmember2.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00302-20100610-2116.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00303-20100610-2238.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00305-20100610-2240.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00306-20100610-2240.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00304-20100610-2239.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00309-20100610-2333.jpg

Links.
http://i870.photobucket.com/albums/ab268/stukboy/IMG00319-20100613-0021.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00318-20100613-0021.jpg

http://i870.photobucket.com/albums/ab268/stukboy/links2.jpg

http://i870.photobucket.com/albums/ab268/stukboy/links-1.jpg
Trying to install it.
http://i870.photobucket.com/albums/ab268/stukboy/IMG00314-20100611-2257.jpg
It's in.
http://i870.photobucket.com/albums/ab268/stukboy/links3.jpg

[Stukboy]

Starting the front bumper and winch mount.
http://i870.photobucket.com/albums/ab268/stukboy/IMG00281-20100608-1304.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00282-20100608-1304.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00283-20100608-1400.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00284-20100608-1401.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00285-20100608-1401.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00286-20100608-1401.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00287-20100608-1402.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00288-20100608-1405.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00290-20100608-1411.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00358-20100618-2333.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00361-20100619-0017.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00364-20100619-1122.jpg

The bumper isn't done yet but should be getting back to it soon.

[Stukboy]

Starting the inside cage. I bought a cage from someone and it was for a 2Dr so the front was pretty much done. I cut the bars to the "B" pillar to shorten the cage up.
http://i870.photobucket.com/albums/ab268/stukboy/XJ6-1.jpg

http://i870.photobucket.com/albums/ab268/stukboy/XJ2-1.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00243-20100530-0024.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00244-20100530-0025.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00242-20100530-0023.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00233-20100528-1351.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00234-20100528-1351.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00237-20100528-1629.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00239-20100528-1630.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00241-20100529-2030.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00280-20100607-2226.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00279-20100607-2225.jpg

http://i870.photobucket.com/albums/ab268/stukboy/IMG00278-20100607-2224.jpg

http://i870.photobucket.com/albums/ab268/stukboy/rearshockstemporary.jpg

[RoyalXJ]

A lil word of advice....make sure to bolt that track bar bracket on as well

[cracker]

Make sure the drag ling and panhard bar are the same angle.

[xj9140]

Got to hand to you, looks like you work really fast and get a lot done, pretty nice. You may want to add some extra bracing to your frame side upper control arm mount. That and your going to want and double shear your stacked hiem drag link mount on the steering knuckle..

[Stukboy]

The work actually took about 3 months. Then I broke it and it has sat for almost a year. I finally got it fixed and decided to put up pics I had taken during the build.
I still have a ton of parts and a ton of work to do. I was happy to get it running and thought I would show it's current condition.
More pics will follow as I get back to working on it.
The knuckles are temporary as I have flat tops.
By track bar do you mean panhard bar? Or are they basiclly the same thing? Anyway it is bolted and welded. Thanx for the advice.
I think the drag link and panhard are pretty close to the same angle. Since it isn't street legal and will be run mostly at low speeds close to perfect is good for me. Until I have issues of course.
Thanx for the comments,
Stukboy

[twodoorXJ]

Nice build man! As you know, mine is very similar.

How have the waggy 44s held up to 36s? Stock shafts?