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unrealtrip
January 21st, 2007, 23:30
Well, I got the first 2 coats of Durabak down on the XJ today. Will finish off with another two coats tomorrow. I wanted to continue but it was just getting too dark to realistically keep going. So far I'm pretty happy with the results.

At first I was using sandpaper, after a while I was like f-that and I got out the wire wheel for my drill.
http://secretreality.com/jeep/xj/tech/durabak_images/durabak001.jpg

The shiny spots are where I had to completely polish out some rust spots. Thanks to the passenger floor having been totally underwater, there was a lot more to deal with than I suspected.
http://secretreality.com/jeep/xj/tech/durabak_images/durabak002.jpg


http://secretreality.com/jeep/xj/tech/durabak_images/durabak003.jpg

All ready to be washed down.
http://secretreality.com/jeep/xj/tech/durabak_images/durabak004.jpg

First I used the shop vac, then hit it with some air to blow away all the fine dust.
http://secretreality.com/jeep/xj/tech/durabak_images/durabak006.jpg

With acetone and Icee in hand I'm ready to roll.
http://secretreality.com/jeep/xj/tech/durabak_images/durabak005.jpg

I didn't feel like taking these out so I took the lazy approach.
http://secretreality.com/jeep/xj/tech/durabak_images/durabak013.jpg

unrealtrip
January 21st, 2007, 23:36
Masking off the areas I want to keep clean.
http://secretreality.com/jeep/xj/tech/durabak_images/durabak007.jpg

http://secretreality.com/jeep/xj/tech/durabak_images/durabak008.jpg

Using a drill bit attachment, you can get a nice even mixture.
http://secretreality.com/jeep/xj/tech/durabak_images/durabak009.jpg

http://secretreality.com/jeep/xj/tech/durabak_images/durabak010.jpg
Waiting for the next few coats

http://secretreality.com/jeep/xj/tech/durabak_images/durabak011.jpg
You need to pull your masking off after the second coat. I'll have to redo it tomorrow when I continue.

http://secretreality.com/jeep/xj/tech/durabak_images/durabak012.jpg
Note the color difference between the last two shots. The real color is somewhere in between, it was totally dark by the time I could take those pics and the first was with flash, the second was with my work light, but it casts a weird glow.

Anyway, there you have it. I'll wrap it up tomorrow, finish routing my wires, put the seats and trim back and get some more pictures.

XbajajeepX
January 22nd, 2007, 00:00
looks great so far.

NoCoastFocus
January 22nd, 2007, 02:02
That looks like a whole lot of work, but it is coming along nicely. Good job.

unrealtrip
January 22nd, 2007, 06:50
Thanks, yeah the prep work takes a lot of time. :) I can't wait to get my trim and console back in there. I've had it all out for the last few weeks. I just got finished wrapping the downpipe and making a heat shield for the muffler so I could get on with this project.

93_xj
January 22nd, 2007, 07:44
Are you planning on reinstalling carpet?

I would like to hurculine my interior, but I would want to reinstall new carpet.

Anyone know where they sell cheap replacement carpets for pre 97 XJs?

unrealtrip
January 22nd, 2007, 09:03
Are you planning on reinstalling carpet?

I would like to hurculine my interior, but I would want to reinstall new carpet.

Anyone know where they sell cheap replacement carpets for pre 97 XJs?

Well my carpet got pretty much destroyed, so if I was to do carpet, I'd be putting in something aftermarket. The cheapest I've seen was somewhere around $250-$300, I think it was like $400 or so off of quadratec.

I decided to just run the durabak and floor mats, which actually works out well too because of the snow/mud/etc that gets tracked in. There was a link floating around for a while for that cheaper place but I don't know what I did with it.

rehab
January 22nd, 2007, 11:13
looks good, let us know how it holds up!

jrowell
January 22nd, 2007, 11:40
You sure did a great job at staging those photos! No text needed with those!

aparke4
January 22nd, 2007, 12:36
nice good prep work goes a long way... nice that the color matches too just put in some small drain holes and you can hose it out no prob thats what i do with mine anyways! nice work

SteveT
January 22nd, 2007, 15:39
Don't mix up your ICEE and your acetone. Both are very useful, but not at all interchangable.

WVXJ
January 22nd, 2007, 16:47
www.stockinteriors.com

They had a nice price last time I checked, i think they have vinyl too.
I plan on sealing mine up with something like the durabak, looks good by the way, and then putting some carpet or vinyl on top of that for sound reasons. My fuel pump whines like a banshee!

ddeadserious
January 22nd, 2007, 19:12
looks excellent, but why did you coat over the hole plugs? When I bought my XJ, the interior was herculined over the plugs, so I has to cut out the old plugs, cut new holes, and buy new plugs. It's nice to hose the interior out.

Brian Strickland
January 22nd, 2007, 19:18
yeah i did that to my jeep last winter, it is quite a pain in the ass project. you definately prepped alot more than i did. my forest green kinda looked like a christmas tree at fist, but then once i put everything back in it mellowed it out some. mine took like 2 weeks to fully cure, there was the odor that remained inside for awhile. i guess it took alot longer to cure because i live and work on the washington coast, lots of moisture in the air. the center console will shake on you alittle without the carpet under it now, it is definately much louder on the road, but i like it.good luck.

BGXJ
January 22nd, 2007, 21:05
did you do the rear cargo area? if so does the older model have the sound deadening material mated to the floor? kinda like dynomat? i wanna do this to my interior and i guess that has to be removed?

Gaius
January 22nd, 2007, 21:58
What is the purpose of doing this? Are you not going to run carpet? Does it have any deadening properties?

A few of the Wrangler guys do it but it's more because they get rid of the carpet., plus an open-top Jeep.

IslanderXJ
January 22nd, 2007, 22:15
What is the purpose of doing this? Are you not going to run carpet? Does it have any deadening properties?

A few of the Wrangler guys do it but it's more because they get rid of the carpet., plus an open-top Jeep.

Water fording, kids with sodas, girlfriends with coffee, tracking in mud, snow and sand. Just pull the drain plugs and hose it out!



What Color/Type of Durabak is that? I've got the same color interior and it seams to match really well.

unrealtrip
January 23rd, 2007, 09:01
looks excellent, but why did you coat over the hole plugs? When I bought my XJ, the interior was herculined over the plugs, so I has to cut out the old plugs, cut new holes, and buy new plugs. It's nice to hose the interior out.

The hole plugs that aren't seam sealed open into the "frame" rail so I didn't like them. The ones that are in those grooves are a little bigger than I wanted to open up at first, but I do want holes that are in those groove areas so I can channel water out when I rinse it down. Anyway, until I could find/make a big enough plug for those holes (they are pretty big) I decided to just coat over them. I saved some of the Durabak so I can go back and recoat, plus I wanted to keep some for repairs etc.

unrealtrip
January 23rd, 2007, 09:03
did you do the rear cargo area? if so does the older model have the sound deadening material mated to the floor? kinda like dynomat? i wanna do this to my interior and i guess that has to be removed?

I actually only did the front passenger area, and honestly if you want a good solid coat, 1 gallon of the stuff isn't enough for the whole Jeep IMO. 1 gallon is plenty for the front, but I couldn't imagine doing the entire inside with only that much.

I don't have any sound deadening material on the floor, just the bare floor (like my YJ) it is a little louder, but it isn't that big a deal at all.

unrealtrip
January 23rd, 2007, 09:05
What is the purpose of doing this? Are you not going to run carpet? Does it have any deadening properties?

A few of the Wrangler guys do it but it's more because they get rid of the carpet., plus an open-top Jeep.

Basically doing it for the reasons mentioned by IslanderXJ. Not too long ago I knocked an entire big gulp over on the floor 44oz of Coke sloshing around while I was trying not to crash into other cars. Between spills, mud from wheeling, snow that gets tracked in, etc. It is just easier to clean. So anyway, I decided not to run carpet, but I still wanted the factory look so I'm going to keep my floormats for now.

It does have sound deadening qualities as well, the thicker you make it, the more it cuts down on noise. Not as much as carpet obviously, but since bare metal ain't too bad, I'm sure it will be fine.

unrealtrip
January 23rd, 2007, 09:20
Water fording, kids with sodas, girlfriends with coffee, tracking in mud, snow and sand. Just pull the drain plugs and hose it out!

What Color/Type of Durabak is that? I've got the same color interior and it seams to match really well.

We probably have the same Jeep lol. I have a 92' Limited, black with tan interior, 3" lift and 31s :)

Anyway, it is the sand color, it costs more, but I wanted to keep the factory color/look. It is $119 p/gallon and I ordered it directly from the Durabak company. The actual Durabak product is made by Cote-L industries (who also makes Herculiner) and is really called DURABAK-18.

Here's some more images of it with no flash.
http://secretreality.com/jeep/xj/tech/durabak_images/durabak014.jpg

http://secretreality.com/jeep/xj/tech/durabak_images/durabak015.jpg

http://secretreality.com/jeep/xj/tech/durabak_images/durabak016.jpg

Tonight I'm putting the trim, console and seats back in. And since someone tipped me off that the console will now potentially vibrate, I'm going to have to make some sort of braces for it to keep it steady as well.

Rob Mayercik
January 23rd, 2007, 09:36
Tonight I'm putting the trim, console and seats back in. And since someone tipped me off that the console will now potentially vibrate, I'm going to have to make some sort of braces for it to keep it steady as well.

Why do that? Cut the under-console part of the carpet out and put it back under the console. Probably an inch of protrusion around the console would be sufficient to ensure that it damps out the vibes without being a PITA to align, and "should" be above the high-water mark.

Hmm, how about door-style weatherstripping attached to the console lower edge?

Rob

unrealtrip
January 23rd, 2007, 09:42
Why do that? Cut the under-console part of the carpet out and put it back under the console. Probably an inch of protrusion around the console would be sufficient to ensure that it damps out the vibes without being a PITA to align, and "should" be above the high-water mark.

Hmm, how about door-style weatherstripping attached to the console lower edge?

Rob

Hrm, that is a good idea, it is above the high water mark that carpet is still good, I could trim that out. Although it might look goofy with a 1" carpet edge all the way around the console. I like the weatherstripping idea a lot though. I'll have to fit everything back up and see how much of a gap there is now.

IslanderXJ
January 23rd, 2007, 09:54
We probably have the same Jeep lol. I have a 92' Limited, black with tan interior, 3" lift and 31s
We do have the same Jeep!!
Started like this:
http://i50.photobucket.com/albums/f301/Islanderx6/99_1.jpg
Now its like this:
http://i50.photobucket.com/albums/f301/Islanderx6/68626658_213611665_0.gif

Sand colored DURABAK-18... $119 gal, perfect!
EDIT: I couldn't find sand on their website... got a link?

unrealtrip
January 23rd, 2007, 10:06
We do have the same Jeep!!
Started like this:
http://i50.photobucket.com/albums/f301/Islanderx6/99_1.jpg
Now its like this:
http://i50.photobucket.com/albums/f301/Islanderx6/68626658_213611665_0.gif

Sand colored DURABAK-18... $119 gal, perfect!
EDIT: I couldn't find sand on their website... got a link?

lol, that's exactly what mine looked like when I got it too. I'm in the progress of building it up, but lots of little projects here and there going on getting things right as well, (headlights, trimming, electric fan, etc)

Anyway, here's where I ordered from: https://www.durabakcompany.com/secure/order.htm

You want the SAND / TEXTURED / UV one.

Here's the color chart sample page:
http://www.durabakcompany.com/colorchart.htm

unrealtrip
January 23rd, 2007, 22:11
Ok got the console, trim etc back into the Jeep and everything looks good. Only one spot I didn't really think of remains exposed, that's the area around the transfer case selector, but itisn't that big of a deal. I coul din theory make something to cover it but I think it looks fine as it is. Anyway, I'm pretty happy with it overall. The color is awesome and with the floormats it's fairly stock looking. It also does a pretty good job of sound deadening and it really is not very loud at all, except for sound from the xfer case, but as it was mentioned, I could cut out that section of the carpet and lay it under the console, which I think I will do. The bolts that hold the console in are actually plenty to keep it nice and stationary and it doesn't rattle at all.

Overall I'm quite pleased with the way it turned out and would definitely do it again. 2 thumbs up.

Sorry color balance is all jacked, it was dark by the time I could nab pics so they're lit by my shop light.

http://www.secretreality.com/jeep/xj/tech/durabak_images/durabak100.jpg

http://www.secretreality.com/jeep/xj/tech/durabak_images/durabak101.jpg

http://www.secretreality.com/jeep/xj/tech/durabak_images/durabak102.jpg

http://www.secretreality.com/jeep/xj/tech/durabak_images/durabak103.jpg

http://www.secretreality.com/jeep/xj/tech/durabak_images/durabak104.jpg

http://www.secretreality.com/jeep/xj/tech/durabak_images/durabak105.jpg

Gaius
January 23rd, 2007, 22:21
Looks real good. I expect those mats to move around, though. Mine do in my TJ.

XbajajeepX
January 24th, 2007, 00:26
How hard would it be to reinstall the carpet after coating it? I am thinking of puting a nice thick coat down if I can reinstall my carpet fairly easy. Im sure it would be cheaper than going the dynomat or something similiar to that route....

BGXJ
January 24th, 2007, 07:15
that looks real good. I'm debating whether or not to do this in my 2000. I have water leaking in the door i think, and i can see some rust starting. I'm afraid it won't be so nice inside once i do this so i am going back and forth. My interior is gray. What do you guys think?

unrealtrip
January 24th, 2007, 07:33
Thanks for the compliments, I'm pretty happy with how it turned out.

Xba: You could put the carpet back with ease, although I wanted the hose out value that it gives.

BGXJ: If you have the proper heat shielding in place I say go for it, worst case scenario if you don't like it, just put your carpet back. Check out the grey color options: http://www.durabakcompany.com/colorchart.htm

http://www.durabakcompany.com/images/colorchart/dark-grey.jpg

and

http://www.durabakcompany.com/images/colorchart/grey.jpg

Starscream
January 24th, 2007, 10:56
How hard would it be to reinstall the carpet after coating it? I am thinking of puting a nice thick coat down if I can reinstall my carpet fairly easy. Im sure it would be cheaper than going the dynomat or something similiar to that route....
Cut your carpet into small, removable chunks:

Driver floor, passenger floor, under front seats, a long strip for the rear foot area, a strip under the rear seat, and then the entire cargo area.

That's how I did mine and I can have it out in about 10 minutes taking my time.

Power5
January 24th, 2007, 11:01
Looks real good. I expect those mats to move around, though. Mine do in my TJ.

My '99 has clips that hold the front rubber mats in place. I plan on using those when I remove my carpet. You should find some hold downs from the local parts store.

Did you do 2 coats? How much did you have left over? How much and where did you purchase?

XJPhoenix
January 24th, 2007, 11:35
Very cool.

Great, another project for when spring comes!

J/K... I like it a lot! It should keep the floor from rusting from the top-down up here in the icy north! (I already have the underside and inner structures rust-proofed.)

Good write-up!

:)

unrealtrip
January 24th, 2007, 11:52
My '99 has clips that hold the front rubber mats in place. I plan on using those when I remove my carpet. You should find some hold downs from the local parts store.

Did you do 2 coats? How much did you have left over? How much and where did you purchase?

all: Thx for the compliments, I'm very happy with it. :)

Actually because the surface is basically like a rough grit sandpaper (I racked my knuckles on it putting my seatbelts back in when my hand slipped) the floor mats don't seem to move around. I may do a clip/velcro thing however if it turns out to be an issue. thx for the tip.

Anyway, I did 3 coats, the 3rd was really more of a light finding thin spots one and I have a little less than 1/4 of the can left. Which is good, I wanted to keep some so I could do repairs if need be, etc.

I paid $119 directly from the Durabak company. I did call them to check about what effects the heat insulating ceramic bead paint additive would have on the Durabak and they seemed to be pretty cool guys. I ended up not using it in the end as it didn't seem to be necc.

https://www.durabakcompany.com/secure/order.htm

53guy
January 24th, 2007, 18:38
How much louder is your Jeep now with all your carpet out and that stuff in its place?

smccollamjr
January 24th, 2007, 19:23
How hot does the passenger side floor above the exhaust get?

northwestxj
January 24th, 2007, 20:44
How much louder is your Jeep now with all your carpet out and that stuff in its place?

I'm sure he will probably reply back as well regarding the loudness...but I PM'd him something similiar about the noise and he responded back to me with:

There is definitely some more noise, mostly from the tcase really, but honestly I don't think it is that bad at all and I would definitely do it again. I'd also consider the year though, I mean I have a 1992 so my carpet was like 16 years old and had water damage so I really didn't have much choice.

53guy
January 25th, 2007, 02:41
Yeah, I was figuring. I had to pull my rear carpet because it was moldy and it's pretty noisy back there now.

unrealtrip
January 25th, 2007, 03:35
How much louder is your Jeep now with all your carpet out and that stuff in its place?

It's not too bad, I'm going to try to record some audio on minidisc today so people can hear for themselves what it sounds like.

unrealtrip
January 25th, 2007, 03:36
How hot does the passenger side floor above the exhaust get?

No heat at all, I made heatshields for my cat and muffler and I'm using header wrap on my downpipe. I waited until I finished that stuff before doing the liner. My floorboards are cool to the touch. :)

NCCherokee
January 25th, 2007, 05:21
what did you make your heat shield out of for the cat and muffler, and how did you attach it?

Where did you get your downpipe wrap? did you install the wrap with the downpipe still in the jeep?

thanks,
kenny

unrealtrip
January 25th, 2007, 05:48
http://www.secretreality.com/jeep/xj/tech/heatshield_images/08-cool.jpg

The heat shields are made out of aluminum and are attached by bolts that drop through the floor. As you can see in the pix, I need to trim the length down a bit. Yes I know I could have used aluminized heat shielding, but those things are costly at about $80+ I got the aluminum at the local osh for under $20. Before the shields the bare metal of the floor got so hot you could not hold your hand to it, now there is absolutely no heat whatsoever. :D

http://www.secretreality.com/jeep/xj/tech/heat-shields.htm

I'm using header wrap on my downpipe made by ThermoTec, you can get it at quality parts stores like Monument or order online. To prevent rust, I first spray painted the pipe with high heat paint, then wrapped it up with it in place because I'm lazy. You secure it with hose clamps.

missouri
January 25th, 2007, 06:20
Hey I have that same knife.

mine is 16 years old and yours Nice work I have that ahead of me.

Well, I got the first 2 coats of Durabak down on the XJ today. Will finish off with another two coats tomorrow. I wanted to continue but it was just getting too dark to realistically keep going. So far I'm pretty happy with the results.

At first I was using sandpaper, after a while I was like f-that and I got out the wire wheel for my drill.
http://secretreality.com/jeep/xj/tech/durabak_images/durabak001.jpg

The shiny spots are where I had to completely polish out some rust spots. Thanks to the passenger floor having been totally underwater, there was a lot more to deal with than I suspected.
http://secretreality.com/jeep/xj/tech/durabak_images/durabak002.jpg


http://secretreality.com/jeep/xj/tech/durabak_images/durabak003.jpg

All ready to be washed down.
http://secretreality.com/jeep/xj/tech/durabak_images/durabak004.jpg

First I used the shop vac, then hit it with some air to blow away all the fine dust.
http://secretreality.com/jeep/xj/tech/durabak_images/durabak006.jpg

With acetone and Icee in hand I'm ready to roll.
http://secretreality.com/jeep/xj/tech/durabak_images/durabak005.jpg

I didn't feel like taking these out so I took the lazy approach.
http://secretreality.com/jeep/xj/tech/durabak_images/durabak013.jpg

unrealtrip
January 25th, 2007, 09:38
Ok so here's a quick road test audio for you. Not the greatest but it will help somewhat to those who are unsure of the road noise that you'll get. (Most of what you hear is wind noise btw)

http://www.secretreality.com/jeep/xj/tech/durabak_images/recording_setup.jpg

setup:
Sony Minidisc and a powered Sony high sensitivity stereo mic.

(RIGHT CLICK AND SAVE TARGET AS)
http://www.secretreality.com/jeep/xj/tech/durabak_images/durabak_road_test.wav

It is ~50MB and is a semi-compressed WAV file @64kbps.

I used the configuration as shown in the photo. I idled for a sec, drove 25mph down the street, took a turn, got up to 35mph, took another turn, got up to 45mph. Slowed while I got onto the freeway, tons of traffic, I could just barely hit 50 on a very groove freeway. I nailed it when I took the long offramp clearing 4k rpms at about 55mph. Turned around, got back on the freeway in the other direction and got it up to 65mph for a short while.

I have the sensitivity cranked so you can hear everything and decide for yourself. The Jeep isn't really that creaky, ok well maybe a little, it's just the mic. Base the road and wind noise amplification level off of the sound of familiar things like the turn signal.

Rob Mayercik
January 25th, 2007, 10:33
The heat shields are made out of aluminum and are attached by bolts that drop through the floor. As you can see in the pix, I need to trim the length down a bit. Yes I know I could have used aluminized heat shielding, but those things are costly at about $80+ I got the aluminum at the local osh for under $20. Before the shields the bare metal of the floor got so hot you could not hold your hand to it, now there is absolutely no heat whatsoever. :D

http://www.secretreality.com/jeep/xj/tech/heat-shields.htm



Doggone it, I LIKE this shield - easy to do, and looks to be tucked up nice and out of the way for wheeling. I may just do this when I pull my carpet out in a month or so...

Rob

rehab
January 25th, 2007, 13:52
wow that looks really really good!

unrealtrip
February 15th, 2007, 13:47
I just wanted to followup now that it has been a few weeks with the Durabak in on my dd.

1- When masking, go higher than you think you need to, I'm going to go back and brush up a little higher as the console doesn't cover quite as much as a I thought it would.

2- Road noise is basically negligable, however the tcase chain rattle is definitely more prominent, especially after driving for a long time as the oil thins. At the same time, its not terribly loud, no worse than my YJ.

3- Heat, non-issue. The heat shields work great and the header wrap on the downpipe works well enough. The header wrap doesn't stop the heat like the shields do, but it cuts it down enough that it isn't an issue.

4- Daily comfort: I put in floormats to retain the stock look and so things that are on it don't get messed up since it basically has a sandpaper like quality. Seems to work well.

I am also glad I went with Durabak for both the UV protection that is already in it, and for the fact that I was able to go with a factory like color scheme rather than black.

Overall, I'm pretty happy with it and I can't say I really have any complaints at all. I would definitely do it again and I'd recommend it to anyone thinking about it.

joecool
February 15th, 2007, 22:01
Looks really nice. I used herculiner to do the inside of mine, but sometimes I wish I would have painted mine to match my interior. Anyway, while I really like it, I find that the jeep turns into an oven during the summer. The transmission tunnel gives off a lot of heat, especially when your off-road and dont get much air flow. Hopefully, it wont be as bad for you, but if it is and you find a cheap solution please let me know.