The Rise, Fall, And Rebirth (In Progress) Of An XJ

The BarneyMobile when I purchased it in November 2003 (6 years ago):



How it looked in February 2007 after I joined :



1996 Jeep Cherokee Sport
4.0L H.O. engine
AW4 automatic transmission
AMC (Dana) 30 non-disconnect front differential (3.55:1)
Chrysler 8.25" 27-spline rear differential (3.55:1)
NP231 transfer case
Advanced Adapters Heavy Duty slip yoke eliminator
Tom Wood custom double cardan driveshaft
Rubicon Express 3.5" Super-Flex lift kit (netted 5")
Rubicon Express .75" coil spacers
Rubicon Express Generation 2 disconnects
Old Man Emu nitrogen-charged shocks
Rubicon Express adjustable track bar
Torq Flo 10,000# transmission cooler
31-tooth factory speedometer gear
32X11.50X15 BF Goodrich Radial T/A KO tires
Cragar 15X8 Soft 8 wheels with 4" backspacing
Optima "Red Top" battery
CSF triple-core radiator

Fast forward to October 29, 2009 when this 4-point buck stepped into my path:





In late November after I was done with deer season, I tore into it:



I replaced the OEM plastic-tanked radiator with an all-metal triple-core CSF radiator, and also had to replace the AC condenser, the entire header panel assembly, mechanical fan shroud, electric fan, power steering pump pulley, serpentine belt, radiator hoses, and bumper.

A friend in the metal fabricating business came out to my house and straightened my lower radiator support with a come-a-long, hammer, and dolly.

A work in progress:





I got a heavy-duty bumper from JCR Offroad, which arrived here Christmas Eve. It's the Stage 2 with a lean-forward hoop, D-rings, and uni-body tie-in brackets. I'll be ordering the matching Stage 2 rear bumper after the first of the year.

Tonight, my friend went to work on it some more:

My friend Alan cutting my driver's side fender off to match the passenger side, which he cut off moments before:



The Jeep after both fender fronts were cut off. Alan used a laser level to get the correct lines, then cut them off with a cutting wheel:



The unfinished bumper sitting on a forklift:



The bumper attached for a test fit:



Tomorrow, Alan is going to fabricate side protection pieces for it. JCR Offroad said that they could get the bumper to me quicker if it came without side protection, and Alan said he could make them for free (what a good buddy.) Then we'll paint and primer it, and she'll be road worthy again. :sunshine:

Hopefully next week I'll be ordering 4.56 gears and master kits, possibly Detroit True Tracs front and rear, and a rear bumper.

Nice work.

I bought my XJ smashed a little in the front like yours was after the deer. Mine was more the front end and the P side fender rather then the Radiator.

Lookin good man keep us posted...

Today's progress:

Alan tacking on the side protection pieces that he fabricated:



Alan finishing up the final welds:




The bumper ready for primer and paint:



With the holiday weekend coming up, Alan is going to take a little break (I'm working him like a borrowed mule), so it will probably be next week before it's mounted and I'm back on the road. By the way, he's a member here, but I don't know what his screen name is.

Pretty cool lookin bumper

I would add some longer frame tie-in's to the bumper, All the way back to that big hole in the unibody.

garr said:

I would add some longer frame tie-in's to the bumper, All the way back to that big hole in the unibody.

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Longer than the ones I bought from JCR Offroad?

M4Madness said:

Longer than the ones I bought from JCR Offroad?

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Nice!, Did not see those in the photos !

Looks great! Just FYI, I believe welding or modifying JCR's bumpers voids their warranty. They may or may not notice it, but hey. I only mention this because I had to send one back for repair after finding a tree the hard way.

FallibleXJ said:

Looks great! Just FYI, I believe welding or modifying JCR's bumpers voids their warranty. They may or may not notice it, but hey. I only mention this because I had to send one back for repair after finding a tree the hard way.

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Thanks for the heads-up. I understand that they have a "no fault" warranty, but if it is damaged by my own foolishness, I have no plans to make them repair or replace it. They shouldn't be held accountable for me breaking it. If it is ever damaged, I'll either have my friend repair it, or I'll buy a new one. :rof:

Well, thanks to help from my friend Alan, I now have both JCR Offroad bumpers installed. Yesterday I installed two new Timken hubs and new front axle u-joints as well. I also had it regeared with 4.56's recently. Slowly but surely this thing is coming back together better than it was before the deer crossed my path. Sort of like "The Six Million Dollar Man":

"Barney, '96 XJ. A Jeep barely alive. Gentlemen, we can rebuild him. We have the technology. We have the capability to build a purple mall crawler. Barney will be that XJ. Better than he was before. Better, stronger, faster."

:roflmao:

should have done the late model front end swap...

but thats purely oppinion. great looking rig.

Nice license plate. Why/how do you have a front plate too?

CherBear said:

Nice license plate. Why/how do you have a front plate too?

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Since I own a registered M16 rifle, I have had that state-issued personalized plate for many years. A couple of years ago, the BMV decided that it was no longer a "politically correct" message, and denied my claim for renewal. My state senator put the pressure on them, and got them to change their mind and approve it. I just put my new plates on the rear each year, and put the expired ones on the front. Now that I no longer have a front license plate holder, that tradition has come to an end.