XJ "Budget Build"

[raptor314]

Next up was the roof rack. I used some 1X1 square to make the frame and then added some strips of sheet metal that I dimple died with my HF press. I added mesh to the bottom. I added some light tabs-front, back and sides. It wouldn't fit in the oven so it got the rattle can treatment

 

[raptor314]

I looked at a couple of different methods for attaching roof racks, and in the end decided on something totally different. I saw where some folks made roof sliders to protect the gutters and the tops of doors. I thought that was kinda cool so I decided to make roof sliders that would also double as a solid place to achor the roof rack.

It started with a straight length of 1 1/4" pipe, but when placed along the top of the gutter I quickly realized how much contour the roof had. I used the HF pipe bender to make a couple light bends. I think I got it pretty close.

 

[raptor314]

I removed the factory rails and transfered the holes onto legths of some 3/16" flat bar which I bolted onto the roof. I then welded some flat bar to the roof sliders.

If you look closely, you will see each little piece connecting the slider to the roof mount has a hole drilled in it that has been tapped.

One thing I learned from doing this is that you have to protect your glass from welding splatter. All of my windows are a little F'ed up from from welding this stuff up.

 

[raptor314]

Next I bent up some "L" shaped legs for mounts and drilled a hole in the lower part of the "L". I then welded the legs to the rack making sure that the holes were lined up so I could bolt it to the slider.

The rack is secured with 4 bolts per side.

 

[raptor314]

My wife bought me some cheapie HF lights for my birthday. It was a few years ago before you could get affordable LED's. Anyhow 4 up front, 2 small ones on each side, and 2 small ones to the rear.

You may have noticed the green roof in the last pic, it might give a clue as to what's to come in the way of paint.

 

[raptor314]

After doing the 8.8 swap, I still hadn't done shock mounts yet. I had consideredd going through the floor but in the end decided against it because I could see myself sleeping in the back at some point and shocks through the body would kinda wreck that.

So I decided to use the stock upper mounts and then fabbed some lowers. They hang down a little lower that stock, but I was trying to balance ground clearance with shock length/travel.

 

[DeftwillP]

Love the roof slider idea.

 

[raptor314]

Next I wanted to figure out my ideal shock length/bump stop situation, plus make sure nothing binds.

 

[raptor314]

This is the time I started really thinking about tire size. I have an old set of 36X12.5X16 Swampers on 8 lug rims. I mocked it up to see where I would be at ride height...

...at with the rear sitting on the bumpstops...

I think 36's are just a tad too big. The tire is rubbing on both sides.

 

[raptor314]

I decided on some Swamper 35X12.50X15 LTB's. They're bias ply, but I figured it would be on for a non daily driver.

I mounted them on some Punisher DIY beadlocks I bought on craigslist for $150. I painted the rims and powedercoated the rings

Here's what they look like mounted

 

[raptor314]

I also bought some ruffstuff diff covers for the D30 and 8.8.

And of coarse baked them in the EZ Bake oven

 

[raptor314]

Also did a hack-n-tap on the NP242 and ordered up a rear drive shaft for the rear

 

[raptor314]

33's in front, 35's in the rear.

35's front and rear

And from the front

 

[raptor314]

So after spending a ton of money, I thought I would do something cheap...like paint.

I knew from the beginning that I was going to camo it or do OD green Mostaliner or Raptor...

I decided I would try to stencil Multicam. Here are some of the stencils...

 

[raptor314]

I did the rear hatch...

But it looks like kids pajama print, so I sanded it down and went with a woodland camo...

 

[raptor314]

And more camo paint.

 

[raptor314]

Then I started thinking about some armor for the quarters and fenders. I liked the idea of 3/16", but I doubted I could contour it to the shape.

I ended up settling on cardboard, well actually 11 guage sheetmetal...I bought a sheet and had my metal supplier sheer it to my desired widths in 4' lengths. I then cut it out on the bandsaw.

 

[raptor314]

For the rears, I decided to ditch the stock tail lights and work in some cool LED'S.

I made the armor longer and created a sheetmetal box.

 

[raptor314]

And then off to the EZ Bake oven...

I din't care for the glossy green so I sanded it down and hit it with OD green

 

[raptor314]

To get the armor to match the shape of the quarters/fenders, I set the panels over a 1X2 wooden garden stake and stood on it. I used my body weight to bounce/bend it into shape.