My build

94xjstud · Apr 20, 2010

This is not so much a building thread as a built/improving thread but here we go . . . I started with a stock 94 xj, D30/older 8.25, np231 4.0L in 2005.
I added the rusty's 4.5 short arm with rubicon 31's (can't find any pics). Then I added warn bumpers front and rear, JCR sliders, black steelies and 33's. First pics I can find:

Bumpers started to wiegh down the xj so I upgraded the suspension a bit and went with rubicon express 5.5" springs and 1.5" boomerang shackles

Bent my upper control arms and tierod, so I upgraded to rough country arms and brackets and rustys tie rod

94xjstud · Apr 20, 2010

Added an 87 xj Dana 44. Put 4.56 and aussie lockers in the front and rear.

Broke a few front shafts so I upgraded to the new/stronger shafts.

Snapped the draglink and decided it was time to upgrade the steering with a ballistic fab kit

Had some heating problems with a messed-up radiator, so I upgradded to a 3-cor radiator and hood vents

Crappy/not hot enough welds broke on the trail

Grinded the bad welds out and layed some good ones in

94xjstud · Apr 20, 2010

Added some hood pins

Made all four doors removable

Routed the intake through the cowl

Cut the front fender pinch seam and I have more recently cut more of my fenders for more flex room (no pics).

Added the Aurora back-up lights

Now I the only left to do is weld up my new track bar and brackets from ballistic fab. The plan is to weld the bracket to a 9" piece on angle steel (already cut and ready to go) and carefully weld that to the frame.

94xjstud · Apr 20, 2010

Random whellin' and poser pics

94xjstud · Apr 20, 2010

I flipped the steering over the knuckle for a little better clearance, but I am worried about the stress on the one grade-8 bolt. What do you think?

Cut the fender for more room, gonna put some door sealer stuff on the edge to clean it up.

The new track bar mount that will hopefully get welded on tomorrow.

Let me know what you think.

DeftwillP · Apr 21, 2010

Yeah, that one bolt will get a lot of stress. I've seen here on Naxja where guys have made it double sheer by fabbing a bracket that it welded to the knuckle and covers it from the top of the heims.

Edit: cool build though

94xjstud · Apr 21, 2010

Do you a thread link? I am thinking about doing one out of a couple pieces angle iron welded together so it lines up right.

94xjstud · May 7, 2010

So my welder (neighbor) has been slacking on welding my stuff up, I know what an a**hole ha ha ha, so no progress on the trackbar.

I did get some new stuff though. I bought new steel shims, becuase my Rusty's ones exploded, and some differential guards so here are some pics

But as always there was a problem, the one of the ubolts sheared in half cause the nut was stuck, so I just gut off the other one. I'll be ordering some new ones soon to finish the job though. I also picked up some lights that I will be making into rock lights (making is the key word becuase the supplied wiring is ridiculously stupid). I'll post pics when I finish hopefully tomorrow.

Opinions and advice or always welcome

billyjp2 · May 7, 2010

what kind of seats are those?

xjsport96 · May 7, 2010

Nice build.

94xjstud · May 7, 2010

billyjp2 said:
what kind of seats are those?

Not sure the brand, but I bought them for SUPER cheap from quadratec and I can't seem to locate them now sorry

94xjstud · May 8, 2010

I mounted and wired up the rock lights. Took awhile cause I had to re-make all the wiring. There are two jammed up into the front fenders out of the way from tires and two drilled in the body next to frame but protected by the rock sliders. Problem is as soon as I got it all wired and running for a bit I blew a fuse, so I am going to replace and upgrade tomorrow. Pics:

Comments, questions and advice always welcome

soopergoober · May 8, 2010

Just a question of curiosity - Were the Rusty's springs softer than the RE springs? Looking at the pic the 4.5" Rusty's springs have 15 coils and the RE springs are an inch longer and have 13 coils.

Looking good btw.

94xjstud · May 8, 2010

yeah they were softer, but too soft for me. With the bumper and winch I probably lost 1.5" to 2" on the rustys

soopergoober · May 8, 2010

94xjstud said:
yeah they were softer, but too soft for me. With the bumper and winch I probably lost 1.5" to 2" on the rustys

Gotcha, I had never really paid attention to the coil count on rusty's springs. They almost look like they're just longer stock springs! :sure:

94xjstud · May 12, 2010

Got bored as I was changing the oil on my honda so I mounted a fire extinguisher, my rock light switches and "built" a storage thing (cut an old clothes basket and screwed it to the opening in the back) to hold a first aid kit. Pics

94xjstud · May 12, 2010

I also need some new u-bolts, where do you guys/gals get yours? my local stores don't really have them for a D44 rear

NJblackdeath4x4 · May 12, 2010

ballistic fab has em for $10 each with washers n nuts

http://www.ballisticfabrication.com/U-bolt-with-nuts-and-washers_p_1698.html

94xjstud · May 12, 2010

Thanks. I love that company

94xjstud · May 19, 2010

Not much progress, but it I got the axle shims in and the new u-bolts put. All of the wheel are back on and hopefully on Sunday I am getting the track bar and mounts welded on (I have to move it like 30 ft. down the road to the welder)

Questions, comments and advice welcome

My build

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