Project 3K XJ

[gimike812]

This is my XJ build.
Its a 1990 2door, 4x4, Renix 4.0L, AW4, NP231, HPD30 CAD front, D35 Rear 3.55 gears. I purchased it back in October 2009 for a sum of $750 not running. The plan is to build a capable trail rig to handle anything the AZ desert can throw at it. This will all be done on a extremely low budget of $3 grand or less. It will be Very tight. That 3 grand includes purchase price and fixing everything that was wrong with it including:
Broken harmonic balancer
New Timing cover seal
New rear main seal
New Coolant Pressure bottle
Radiator hoses
New oil pan gasket
Repair the previous owners crappy ignition wire mess.


Build plans are on the semi extreme side as well
axle swap with gears and lockers
32's-35's
Custom long arms
5-6" lift
Beefed up steering
Sye
Cold Air Intake
Exhaust
Custom bumpers
Custom sliders
Belly skid
Steering brace

This is what it looked like when I got it home.
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/michaelsphonepicts114.jpg
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/michaelsphonepicts115.jpg
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1001090858.jpg
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1001090908a.jpg
Not a single tire matched.
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1001090908.jpg

The reason the jeep was so cheap and not running. The previous owner broke a belt and it got stuck behind the harmonic balancer so he used a prybar on the balancer to get the belt out. :twak:
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1001091550.jpg

Then it was time to replace the rear main seal.
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1012091759-1.jpg

After that it was time to figure out why it was over heating.
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1002091113.jpg

The original plastic over flow tank from AMC wasn't going to cut it out in the desert heat so I found a shop in Oregon called Macs Radiators and they made this beauty that is tig welded out of diamond plate aluminum with a radiator cap on top of it. $120 shipped.
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/michaelsphonepicts017.jpg

Now time for some matching tires and new wheels. They are a well used set of toyo open country tires and well abused rock rashed wheels.
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1001091037.jpg

Just playing around testing flex and making sure 4x4 works
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1014092031.jpg
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1014092030.jpg

[gimike812]

Now some fun picts. This was a maiden voyage to a sand pit next to the pantano wash.
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/michaelsphonepicts0472.jpg
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/michaelsphonepicts0482.jpg
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/michaelsphonepicts0492.jpg

Now I figured out on that trip that the front bumper and brush guard is not going to work with my plans. The front receiver gets packed with sand when you noise in to the earth.
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/007.jpg

This was all that needed to be done to get it up and running. There is a lot more done that I dont have time to post tonight so stay tuned.

[KRAKER]

Good stuff. So when are you gonna break out the Sawzall? :D

[Brandoson]

I second that!

[AZXJ]

Keep at it.. Here's what it will look like once your at 3k..

http://i76.photobucket.com/albums/j14/azxj/Webber%20Creek/w34.jpg

:D

[gimike812]

Ok so more up dates.
I got board one day out in the shop when I was supposed to be cleaning up and came across these old shackles.
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/michaelsphonepicts042.jpg

They where brand new 3inch lift shackles from my old prerunner Dakota I never used them. With a little bit of modification they found a new home.
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/michaelsphonepicts0452.jpg
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/michaelsphonepicts0442.jpg

Well then I needed some shocks to make up for the difference. What would you know a set of stock JK rear shocks laying around the shop only had 235 miles on them before they where removed. These will work after removing the steel sleeve from the bottom eyelet.
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/michaelsphonepicts0432.jpg

So I had a rear lift of 2.5-3 inches for a total of $7.50 not bad in my book.

Well my son was born and it was time for a bigger truck so I had to sell my Dakota. I wasn't getting my money back on it so I pulled my 32" BFG MTs off the Dakota and they went on the XJ. But 32" don't fit so well with no lift and really crappy back spacing on the wheels. Time for SAWSALL!
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/MichaelPhonephotos041.jpg
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/MichaelPhonephotos042.jpg
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/MichaelPhonephotos037.jpg
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/MichaelPhonephotos036.jpg

Time to correct the back spacing issue so ordered a set of 4 15x8 Crager soft 8's. From Summit Racing. Only $42 a piece. New lug nuts and mount and balance a grand total of $248
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/MichaelPhonephotos053.jpg
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/MichaelPhonephotos054.jpg

[NW-ZJ-SCOTT]

cool build..

can i get pics of the ZJ in the background?

[gimike812]

You want picts of that piece or junk! lol Its my cousins ZJ he keeps parked at my place off and on. Check out his build thread over on a differant site.

http://www.tucsonoffroad.net/phpBB3/viewtopic.php?f=47&t=76

[cdhowell]

So where is the budget at this point?

[AZXJ]

looks like he's only spent $375 not including the Jeep.. with the cost of the Jeep he's at 1125.00 from what's been posted.. :D

he still paid $450 more then I did for my red 89.. :D

[gimike812]

Here is a budget break down as of whats been done in my post.
XJ Purchase 750.00
Towing home 46.00
New Battery 80.00
Coolant Tank 120.00
Oil, Filters, Gaskets,
T-Stat, Hoses, Wirering,
Battery cables 133.10
Wheels 171.80
lugnuts 40.69
Mount & Balance 40.00
Misc. Hardware for rear lift 7.50
------------------------------------
Total 1389.09

Stay tuned for more updates I have a pile of parts waiting to go on.

[POSJ]

Dang Mike you need to slow down I haven't even started building my turd yet. Send me a PM on what part of Tucson you are in and maybe we can meet up so we can hit an easy trail or something.

Tyler

[gimike812]

I needed a set of seat belts for my XJ and I seen a post of craigslist where some one was parting a cherokee but only for the weekend. I drove 45 minuets to check it out and the seat belts where the wrong ones.
But wait what is this. I think its a D44. :shhh:
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1284825544.jpg

I called my cousin to verify and yup. :yelclap:Ok so I asked what they where going to do with the whole jeep they said scrap it and get $200 for the steel. She then told me she needed $300 for her rent. Well the next day for $300 it was on the trailer.
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1284825550.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1284825546.jpg

I started parting it out. Only thing missing was the T-Case. Sold $610 worth parts and scraped the body for $112.82 For a total of $722.82. Then sold the front Brush guard off My XJ $100. So that gives me a total of $822.82 for Jeep parts.

Bought a Ford 8.8 with 4.10 gears. $225
D30 out of 4 Banger cherokee with 4.10s $300
RE 5.5 coils $100
A truck load of steel for bumbers, Sliders, Armor, Suspension Brackets $320.31
Misc Hardware for sliders $30
A box of old Liberty and wrangler parts including a K&N filter $50
Total $ 1025.31

So a Budget break down $1389.09 + $1025.31 = $2414.40 - $822.82 = $1591.58

So far out of my pocket is only $1591.58 not to shabby.
Just picts of the coils and steel
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/MichaelPhonephotos048.jpg
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1284782979.jpg
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1284782977.jpg

[gimike812]

Time for some progress. Pulled the front axle last week.
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1284241512.jpg
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1284241516.jpg

Then last night made a template for the D30 axle truss. Start out with a cardboard template.
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/MichaelPhonephotos023.jpg
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/MichaelPhonephotos024.jpg
Transfer it to the metal. 3/16 steel sheet
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1284782971.jpg

Get the plasma cutter out and go to town
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1284834560.jpg

Burn it in. :firedevil Oh that's not me its the hired help. My cousin. I cut the parts out he burned them in.
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1284782974.jpg
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1284782973.jpg
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1284782550.jpg
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1284782546.jpg
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1284782555.jpg
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1284782553.jpg

Welded the tubes to the pumpkin also. Still have some more work to do. Will also be installing LCA skids later on.

[POSJ]

So are you doing the 8.8 or 44?

[gimike812]

The 8.8 will be going in. I sold the D44 for more than I bought the parts jeep for. The 8.8 will get the tubes welded and a truss as well before it goes in.

[POSJ]

Mike if you are building your truss, keep your templates for me please. I would like to truss mine also. Tubes are already welded on it.

[gimike812]

Will do Tyler

[AZXJ]

Nice work Mike.. Keep at it! I like the way you wheel and deal!! reminds me of.. Me! haha!

[gimike812]

Lower control arm skids welded in.
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1286165894.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1286165896.jpg

All new break hardware. Rotors calipers and pads. New Upper Control arm bushings. Axle painted Flat Black accessories painted Castle Rock.
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1286172973.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1286172979.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1286172983.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1286237893.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1286172984.jpg

Oh its time for some long arms. Here is some shots of the new joints.
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1286238264.jpg

Currie Johnny Joints
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1286165888.jpg

Ballistic Tube Ends
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1286238264.jpg

You get the idea
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1286238266.jpg

Double Shear Track Bar start
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1286238269.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1286238272.jpg

Stay tuned for more.

[gimike812]

My $17.17 cold air intake. I had the k&n filter laying around from another project. I went to the auto parts store and picked up a 6" long 3" diameter exhaust pipe $6.99. Then to the hardware store to get a 90* three way elbow and a couple clamps $10.18. Drilled a hole and welded on the elbow. Hooked up the new filter and some hoses.

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1286829880.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1286829870.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1286829876.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1286829866.jpg

Now i have room for the second battery:)

[POSJ]

Coming along nicely Mike, any link to the K&N so I can copy your mod?

[gimike812]

Sorry no links. I have done many different setups over the years on tons of vehicles so just kinda did my own thing. Besides it was super cheap just what I needed for this jeep. Come on over some time and you can see it. It took me longer at the two stores buying the parts than it did to do the install. I deleted two vacum lines from the old air box and only had two that needed to go back to the cleaner. Remeber my engine is a renix system, I am not sure how may lines the newer engine setups have.

[gimike812]

Well finally got some more work done the axle has been ready for over a month and I just got some of the suspension on and it now sits on its own weigh again. At least till Saturday till I pull it all off and paint it all.

Crossmember with center drop out
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1286304592.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1286304590.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1290612265.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1290612261.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1290612268.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1290612250.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1290612501.jpg

Double Shear Double Adjustable Tract Bar
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1290612505.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1290612508.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1290612496.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1290612490.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1290612498.jpg

[gimike812]

Ok a big thanks to my Cousin DJ and (POSJ)Tyler we got some stuff done and got a chance to do a little flexing out it the front yard.

There is 25 inches from the ground to the bottom of the lifted tire.
http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1290925632.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1290925642.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1290925635.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1290925637.jpg

http://i289.photobucket.com/albums/ll215/Gimike812/project%203k%20xj/1290925639.jpg

[jeep pox]

Lookin good! Was that as high as the hoist would lift you?

[AZRockRunner]

Lookin good guys. We shall be wheeling SOOOON!!!!!!
:clap:

[POSJ]

No problem Mike, like I said before give me a call if you need help again. Thanks to you and DJ for teaching me some stuff too.

[tobiwon]

lookin' damn fine for 3 grand ! Let's wheel soon .

[gimike812]

Just ordered an aussie locker for the D30 and 8.8. Cant wait to get this rig on the trail. I have all the parts to install the 8.8 in the rear just waiting for the lockers to get here and do it all at the same time.

[POSJ]

Let me know if you need help Mike I need to repay you for helping with my SYE. You know when I work.