Project Mini XJ

[Mr.Shrek]

Well as some of you may have known or seen, I've been kicking around the idea and collecting parts to build a crawler for my 2 sons (Hunter 7 and Grayson 4). My point of inspiration for this project was found in a great build: The Honda Powered Kid Buggy (http://www.pirate4x4.com/forum/showthread.php?t=633445).
Now in the process I've been dealing with a few issues: 1)I don't have a huge budget to run out and buy some of the specialty tools needed to reproduce that buggy and 2) I don't want to copy his design. Well my answer for both of those issues showed up to my garage Saturday afternoon thanks to KGP416. Kris had a body that he was needing to get rid of, not only did he give me the body, he delivered it! Thanks again Kris. Needless to say that was a big boost to the budget for this build. At first I had planned to chop the front off and make it into a camper like a few others have done. Then I got the idea of why not use it to build the crawler. Not only does this cut cost but it ties it right into one of my loves...XJ's.
Here are a few points on what this crawler will include:
2 seater with PRP Preteen suspension seats
Drivetrain from an early-mid 90's honda (automatic)
32" Mud terrains
Willys axles front and rear
Front drum to disc brake conversion
Stock International wheels (need the 5X5.5 lug pattern)
Coilovers all around
Hydro steering
The body will be sectioned to shorten and narrow the body. Currently plan to dovetail the rear. The body will be shortened by about 4' and narrowed at least 1'. Numbers will be more exact once I have the drivetrain and seats mocked up.
This will be a budget build and the first couple of months will consist of striping the XJ down, planning, measuring , re measuring, cutting, and welding. All items I can do with only cost of consumables (cut off wheels/blades and wire) Once we have everything striped down and mocked a few things in place we will generate a rendering to share. (I say we but I really mean I sit in a chair and watch Crystal do her magic and bug her with stupid questions)

Enough blabing, here are a few pics from the first night of work:
Here is our lucky victim
http://naxja.org/forum/%3Ca%20href=%22http://www.flickr.com/photos/90613762@N00/3615378337/%22%20title=%22IMG_9717%20by%20glennbowron3,%20on% 20Flickr%22%3E%3Cimg%20src=%22http://farm3.static.flickr.com/2480/3615378337_0937e5ba79.jpg%22%20width=%22500%22%20h eight=%22333%22%20alt=%22IMG_9717%22%20/%3E%3C/a%3Ehttp://farm4.static.flickr.com/3566/3616200458_04a092a5cd.jpg
http://naxja.org/forum/%3Ca%20href=%22http://www.flickr.com/photos/90613762@N00/3616200458/%22%20title=%22IMG_9721%20by%20glennbowron3,%20on% 20Flickr%22%3E%3Cimg%20src=%22http://farm4.static.flickr.com/3566/3616200458_04a092a5cd.jpg%22%20width=%22500%22%20h eight=%22333%22%20alt=%22IMG_9721%22%20/%3E%3C/a%3Ehttp://farm3.static.flickr.com/2480/3615378337_0937e5ba79.jpg
First order of business was to pull a few parts that Kris needed back. Rear 8.25, console, AC compressor...
http://naxja.org/forum/%3Ca%20href=%22http://www.flickr.com/photos/90613762@N00/3616201872/%22%20title=%22IMG_9724%20by%20glennbowron3,%20on% 20Flickr%22%3E%3Cimg%20src=%22http://farm4.static.flickr.com/3637/3616201872_39c03a496f_b.jpg%22%20width=%221024%22% 20height=%22683%22%20alt=%22IMG_9724%22%20/%3E%3C/a%3Ehttp://farm4.static.flickr.com/3637/3616201872_39c03a496f.jpg
Then started to clean up the engine compartment
Before
http://naxja.org/forum/%3Ca%20href=%22http://www.flickr.com/photos/90613762@N00/3615380765/%22%20title=%22IMG_9723%20by%20glennbowron3,%20on% 20Flickr%22%3E%3Cimg%20src=%22http://farm4.static.flickr.com/3561/3615380765_b03bf8fc73.jpg%22%20width=%22500%22%20h eight=%22333%22%20alt=%22IMG_9723%22%20/%3E%3C/a%3Ehttp://farm4.static.flickr.com/3561/3615380765_b03bf8fc73.jpg
Clean out step 1
http://naxja.org/forum/%3Ca%20href=%22http://www.flickr.com/photos/90613762@N00/3616202550/%22%20title=%22IMG_9725%20by%20glennbowron3,%20on% 20Flickr%22%3E%3Cimg%20src=%22http://farm3.static.flickr.com/2472/3616202550_f29a8f2a0e.jpg%22%20width=%22500%22%20h eight=%22333%22%20alt=%22IMG_9725%22%20/%3E%3C/a%3Ehttp://farm3.static.flickr.com/2472/3616202550_f29a8f2a0e.jpg
Here are a shot of the front and rear Willys axles I'll be using.
http://naxja.org/forum/%3Ca%20href=%22http://www.flickr.com/photos/90613762@N00/3615378573/%22%20title=%22IMG_9719%20by%20glennbowron3,%20on% 20Flickr%22%3E%3Cimg%20src=%22http://farm4.static.flickr.com/3556/3615378573_65c3c82e24.jpg%22%20width=%22500%22%20h eight=%22333%22%20alt=%22IMG_9719%22%20/%3E%3C/a%3Ehttp://farm4.static.flickr.com/3556/3615378573_65c3c82e24.jpg
http://naxja.org/forum/%3Ca%20href=%22http://www.flickr.com/photos/90613762@N00/3615379223/%22%20title=%22IMG_9720%20by%20glennbowron3,%20on% 20Flickr%22%3E%3Cimg%20src=%22http://farm4.static.flickr.com/3297/3615379223_cd96abd134.jpg%22%20width=%22500%22%20h eight=%22333%22%20alt=%22IMG_9720%22%20/%3E%3C/a%3Ehttp://farm4.static.flickr.com/3297/3615379223_cd96abd134.jpg
(Sorry for the blurred pics here and there)
Hope y'all enjoy the build. Please throw in any questions or comments.

[JeepAddict85]

nice progress...whens the wrenchfest?

[YJ-GENRAL]

how do you plan on using/locating the honda engine?

mid engine and have both shafts just go straight to the axles? or

front engine with one shaft to a trnsfer case and close off the other side??

im curious because honda engines pretty much have the transmission underneath and then go to either side of the car...

[Mr.Shrek]

It will be located in the former cargo area of the body. I will be turning the Honda motor/trans side ways like in the Honda Powered Kid Buggy. Like that buggy I am using axles that are both passenger side drop to accommodate for the drive shafts being on the passenger side.

[bgwyllys61]

Which front axle is that? The 25 or 27? Stock 5.38 gears as well? Should be sweet! Keep up the work

[Mr.Shrek]

I think it is a 25 w/ warn locking hubs. Not sure what gears they are, I know they match though. I was able to trade rredalty a pair of subs I had waiting in the garage, so they were the right price, width, and passenger drop like I needed.

[YJ-GENRAL]

i just read the honda buggy thread... man that thing is the sweetest. you will definately be dad of the year when you finish it... :D

[Mr.Shrek]

Yeah he did a quality job to say the least, I ran across that thread about 6 months ago and have been craving to build something like this for my boys. First day I brought home thier Jeep Power Wheels they rolled it. So I'm going to make sure that this is built strong and simple to keep them safe.

[shortxjdoug]

so are you gonna chop up the body and just use the firewall and floorpan? wheres all the xj gonna go to?s

[Mr.Shrek]

Ok here is a quick VERY rough idea of what we are going for. These proportions may not be right but close. The photoshopped version will be much clearer and to scale. In one attachment I have highlited the areas that would be cut out. Alot of the floor pan is going to be removed to clear the motor and trans in the rear. The firewall will most likely be removed for leg room.

[PacificEd]

Where did you find the original image before you modified it?

That is sure going to be a lot of cutting and welding. Keeping everything is plumb will also prove to de a challenge too.

[KGP416]

How bout a mini V8 engine ? http://www.weberprecision.com/, just kidding, lol

i like the buggy idea, i didnt see it when i was dropping it off but, but the illustration helps, definitely cool.

[Mr.Shrek]

Where did you find the original image before you modified it?
http://www.ausjeepoffroad.com/forum/showthread.php?t=67840

[trail rate this]

How bout a mini V8 engine ? http://www.weberprecision.com/, just kidding, lol

i like the buggy idea, i didnt see it when i was dropping it off but, but the illustration helps, definitely cool.

That V8 is awesome.

[JeepFreak21]

This is very exciting. Subscribed. http://www.slicky.net/smilies/cool.gif
Billy

[muddyrocks]

I foresee only one problem... the build completed, you will undoubtedly take it for a shake down


and your kids will never see the left side of it again! lol

[MELKORsXJ]

those axles have 5.38s...

had i known i wasn't gonna use any of this... i could have sold my old parts as a rolling chassis.

http://c4.ac-images.myspacecdn.com/images01/127/l_9b5d7b2d4deb67069538c08018f7fb77.jpg

...this was the very first time i drove the willys!!!

http://c3.ac-images.myspacecdn.com/images01/83/l_2d19d832d7c6a8535345a5c597745e12.jpg

i had pulled the heads off the engine, and connected the starter motor to a battery, and used a battery disconnect switch to turn the starter on and off. i ran around the yard at 3MPH! in 2H, 2WD... hit a tree because i had vise grips to steer with, and when i hit the tree, the rear tires started churning dirt!!! so... it's geared pretty LOW!

hope the axles work out well for ya!

[bigalpha]

I'm glad you're doing this instead of the trailer. It'll be so BA when you and your boys are out wheeling.

[Mr.Shrek]

muddyrocks-Yes i foresee that as being tempting, to bad I won't be able to fit in it.
MELKORsXJ- Thanks for testing out the axles before hand.
bigalpha- Yeah I figured the trailer's been done before. I figured it's pretty easy to find another body if I want to still build one when the buggy is done.

[Mr.Shrek]

Well last night the whole family hung out in my favorite room in the house, the garage! Fiona, was enjoying the music while playing around on her laptop editing some of the June Photo Challenge Pics. I got the boys involved on their jeep by arming them with a pair of screwdrivers and a trash can. They went through the interior clearing out the trash and pulling any phillipshead screws they found. I helped them out in a few spots. While they were busy I pulled the fuel lines, brake lines, brake booster, AC dryer, lines, and misc clips from the engine compartment. After the garage was clear of people with short attention spans or AADD I removed the front windshield. I would like to say it came out clean, but that would be a lie. Here are a few pics I grabbed last night. (Sorry for the poor quality. Stupid camera phone!)
http://farm4.static.flickr.com/3360/3619001141_ed48fc9dc1.jpg
http://farm4.static.flickr.com/3358/3619001167_e4f8667816.jpg
http://farm3.static.flickr.com/2448/3619001195_16963dc856.jpg
http://farm4.static.flickr.com/3639/3619001215_9e7da83cdd.jpg

[MELKORsXJ]

that's really cool!
way to get the kids involved :clap:

[Mr.Shrek]

Alright so now that I'm back from vacation it is time to get back on the project. Last night the family and I headed out to PacificEd's. Ed was kind enough to donate 4 15" international wheels. I had to go with non-Cherokee wheels due to the axles being a 5 x 5.5 bolt pattern. The price sure as heck fits right along where I needed it.

For those of you who are following this build her is the current build cost:
Jeep body: $20 for gas to get it down here (Thanks KPG416 aka Kris)
Willys axles: 2 10" Eclipse DVC subs (Thanks rredalty aka Matt. Also thanks to High2by aka Mark for hauling them back from Windrock.)
32" Mud Terrains: $40 used (Thanks rredalty aka Matt)
International Wheels: $10 in gas to go pick them up, otherwise Freebie. (Thanks PacificEd aka Ed)
Total Cost to Date: $70

Things to do before I spend anymore money:
1) Finish striping down the body
2) Mock up axles and wheels to body
3) Make the mock up seats
4) Measure, plan, tape, and cut body
5) Mock up body and axles
6) Set up suspension and check for travel
7) Tear down axles for service, Lincoln lockers, brake rebuild/conversion, and brackets
8) Wheels: take old tires off, sand blast, paint, mount 32's and maybe bead locks all though I don't think they'll be needed.

That should keep us pretty busy until we have the extra cash for the Honda.
Last time trail rate this and I were out at the junk yard i found a stock Chevy coilover in the trunk of a caprice.
http://farm3.static.flickr.com/2446/3676020758_43eea51a09_o.jpg

I did some searching around the web and found out what year/model Chevy the are from. I plan on using the coilovers form an El Camino rear due to it not havening the weak threaded end like the other models. I think they may work better and cost less then the ones made on the Honda Powered Kid Buggy mentioned before.
http://farm4.static.flickr.com/3577/3675454067_bfabba2958.jpg

Again thanks to all those who have contributed to the build.

[bigalpha]

Now's a good time to give it a killer paint job.

[Mr.Shrek]

Well tonight I made some progress on item #1. Removed the dash, ac/heater, dash harness, fire wall insulation, shifter, parking brake, trim, and carpet.
http://farm3.static.flickr.com/2513/3677446850_dd9310f197.jpg

[trail rate this]

forgot the door panels

[rredalty]

looks like the driver side front made it off one way or another...

[Mr.Shrek]

Yeah the body showed up with no driver's door.

[trail rate this]

You've got a spare in the shed

[Mr.Shrek]

I know, it is going to get sacrificed when the cutting and welding starts up.

[trail rate this]

How many posts do you think this thread will have? I think it will be about 10k post over the next 8 or 9 years while the buggy is being built.






I just hope the boys get to use it before they graduate.

[Mr.Shrek]

Alot less if you would keep your thoughts and stupid questions to yourself!



Screw that, if that's the case this thing is will have just one seat.

[trail rate this]

You must've subscribed. That was a quick reply.

[Mr.Shrek]

So today at work stunk. After a wonderful dinner, made by Fiona of course, I spent the rest of my evening in my meditation chamber. Man it's great to throw on some music and thrash on a project for a few hours. It don't know about you guys, but it does a world of good for me. Enough gibber jabber.
Tonight's progress on Project Mini XJ:
More progress on item #1
Removed: remaining trim, headliner, sound bar, carpet, all electrical harnesses, quarter glass, rear hatch, tail lights, and bumper.
http://farm4.static.flickr.com/3427/3727977567_6e0bc72173.jpg
Remaining items to be removed: 3 doors, 1 fender, hood, front axle/suspension, rear springs and any other misc. parts left under the jeep.

[KGP416]

looking good !

i might build a little something too with the remains of this incoming 98

your photos inspire me

[bigalpha]

Trailer.

[jeepcomj]

following closely

[MELKORsXJ]

i like the progress! keep it up... :clap:

...on your "to do" list, i would skip one step, and that's mocking up the axles to the body (before cutting it). when i first read that, i figured that'd be a waste of time, because to me mocking up would be taking measurements, and a couple tack welds to hold on brackets and such. but if you're narrowing the body... you probably don't wanna waste an evening jacking up the jeep, and rolling the axles under for that purpose...
but i could be wrong, when i built my Willys, the axles and other parts got installed several times to test fit... it's all apart of the build process...

[Mr.Shrek]

Thanks for the input Melkor. The reason for getting the axles in place for measurements is to have a better idea of how narrow I will need to make the front and dovetail.

Last night I cleaned up the shop a bit from the different piles of parts that had collect on, around, and under the jeep. Now that the front end is clear I can move on to getting the front disassembly completed.

[Swamprat]

updates?

[Mr.Shrek]

Nope, I got side tracked with the DIY Cowl Hood. Once I have that finished I'll take it off of the buggy and cut off the entire front clip (firwall forward), floor and most of the fire wall. Then we will start planning out the cuts for sectioning the body.

[Swamprat]

sweet!

[bigalpha]

Updates?

[Mr.Shrek]

Big changes lined up but those are under wraps for now. I've got a paying job in the garage I have to get turned out first.

[bigalpha]

That's exciting!

[JeepFreak21]

Anything new with this? My wife and I had a baby last week and I'm itching to get started on a project for her! ;)
Billy

[garth93xj]

what about all that grey interior??? what ya got planned for it...I want I want!!!

[Mr.Shrek]

Most of the interior is gone. On the project I scraped the body and plan on just going tube chassis.

[MELKORsXJ]

Scrapped it?... c'mon trailer coulda still been an option :)

[Mr.Shrek]

Nah to redneck for my liking.

[jeepgeek2002]

soooooo 4 pages of nothing ... wheres the reset button for project mini xj?