Well after doing a few upgrades to my XJ I decided I was going to update my post I started a long time ago and to my surprise it has been lost in last server update (per Lance)

So I am gonna post up a quick overview of what I did with a lot less pics but you will get the gist.

Specs:
1998 Jeep Cherokee
chopped back half
with exo cage

Engine/Drivetrain:
• 4.0L, I-6 engine
• 4-speed automatic transmission
• NP231 t'case w/ 2 low kit
• Dana 44/Ford 9" axles (front/rear)
• 4.88 gears

Suspension:
• Rockkrawler 6" coils in front
• Tomken 2" blocks / Rusty's 4.5" Leafs in rear
• Custom made shackle mount in rear
• Ford custom Radius arms
• Rusty 6" Shocks
• 6" steel braided brake lines.
• Custom Belly up skid

Wheels & Tires:
• 38" TSL Swampers
• 15x10" Alum Rims's w/ welded rock guard
• Inner Air Lock Beadlocks

Armor:
• Custom built Front High Clearance Winch Bumper
• Custom built Rock Guards
• Rusty's OffRoad steering box brace
• Skid Plates (front, transfer case, and rear gas tank)
• Exo Cage

Accessories:
• Suspension seats
• 5 point harness
• Redneck Ram Hydro assist steering
• custom made driveshafts
• Warm 9000i Winch
• Radio Shack CB
• 2 fire extinguisher
• 48" Hi-Lift jack
• Full set of spare shafts fro front and rear
• 10LB CO2 tank in back

Well when I decided to do this fullwidth build up I was running 35's on stock axles and I wanted to go bigger So I sold my axles and got under way.

1st pic is most current pic after last project update
http://www.impaks.com/images/ken/100_4184.jpg

2nd pic is how it sat before I started the Full Width build up

First thing I did was take out 30/8.25 and get rid of them

then I found a 9" local and a 44 on ebay
tore them apart and rebuilt them
and slapped the 9" under rear of jeep

then started build up of front 44

front pic

front pic 3

then I took the radius arms cut them up added control arm bushings to them/braced them.

I also made my own driveshafts

made new rear shackle hanger

made rear shock mounts


http://www.pirate4x4.com/forum/attachment.php?attachmentid=185870

http://www.pirate4x4.com/forum/attachment.php?attachmentid=185869

finally got it rolling

pic.

then it was onto the steering.

decided I wanted Hydro assist... so I enter the Rednceck x-mas drawing and son of a b*itch I WON

Yes I won a full asssit set up

So I got a J-20 steering box had it tapped and set up REDNECK RAM steering
using Posion Spyder inserts to make all my own steering

I also made a diff guard for the 44

Peace sign part was just for looks the protection is the tampoon behind it :)

pic

After wheeling it a few times I decided 36's were not big enough so I found a guy on drugs and bought his 38 TSL on rims for $400 :) ( always looking for a deal ).

but then I needed beadlocks

So I made my own.. here is first attempt

and here is finally design on the Jeep

and then getting it on the trail this past weekend.

I did learn that I should have trusted my beadlocks and aired down a lot more.. oh well there is always next time.

and now the next thing on the list is the cage...

I just started drawing up what I want and have decided to do an internal with some exo bracing... I hope to have it in and done by end of summer.

Looks good. What trails ya on there?

Looks good. What trails ya on there?

Last pics was at the club Beginner ride at Uwharrie in Troy , NC

but last year was at Tellico with the 36's

looks god ken!! its come a long way...

sweet, keep the pics coming

nice! maybe someday I'll learn to wheel something other than "begginers" uwharrie trails. :laughing:

are you using the stock ford steering knuckles?

got any close up shots of them and how you worked the steering?

i am working on this swap (HP 44) and thinking out my steering setup and it seems that no one runs the stock ford knuckles...

send a boatload of pics to opiebennett@gmail.com if you fell the need...

thanks

nice! maybe someday I'll learn to wheel something other than "begginers" uwharrie trails. :laughing:

Yup every year we our club does 2 beginner rides to uwharrie to help educate the new folks that are just getting into 4x4ing.

Maybe you should come along and learn some stuff :flipoff2:

are you using the stock ford steering knuckles?

got any close up shots of them and how you worked the steering?

i am working on this swap (HP 44) and thinking out my steering setup and it seems that no one runs the stock ford knuckles...

send a boatload of pics to opiebennett@gmail.com if you fell the need...

thanks

Yes I am using stock knuckles.
I drilled and tapped them and add a high steer arm to the passenger side so the draglink goes to high steer arm, and tie rod goes straight across on top of original knuckle location. (sorry no pics of it) if i get a chance I will take some pics..

Can I ask why you decided to build new rear shackle hangers?

The rig looks good. Nice work.

2 things...

it rotated rear axle to correct location for driveshaft angle and is easier for shackle to flex without hitting inside of original location... I am looking at putting boomerang shackles on...

I guess I've never had a problem with my shackle hitting the stock hanger....nor have I seen anyone that has. And I welded my spring perches on to correct my pinion angle. But if it works for you....I'm cool with it. :D

Nice build up.

I'm not a leaf guy but why would you angle your rear shocks in like that? It kills the effective rate of the shock which on a coil rig cripples stability, is it not a big deal on leaf sprung rigs?

Hopefully I'll get a chance to see your rig work on the trail this summer.

are you using the stock ford steering knuckles?

got any close up shots of them and how you worked the steering?

i am working on this swap (HP 44) and thinking out my steering setup and it seems that no one runs the stock ford knuckles...

send a boatload of pics to opiebennett@gmail.com if you fell the need...

thanks

Not to hi-jack, but here's a pic of my set-up using the stock Ford knuckles:

http://img.photobucket.com/albums/v202/muddyjeep1/front.jpg

I reamed out the knuckles from the top and used 1 ton TRE's. I didn't feel I needed high steer, and the added cost would have set me back too far.

That steering set-up will work great, I ran almost the exact one on my TJ and only managed to hit it a couple times.

Nice build up.

I'm not a leaf guy but why would you angle your rear shocks in like that? It kills the effective rate of the shock which on a coil rig cripples stability, is it not a big deal on leaf sprung rigs?

Hopefully I'll get a chance to see your rig work on the trail this summer.


1. I can still use the same shocks without limitation, or buying new ones ( they would have been to short if i mounted them to stock location.

2. It does not hurt stability at all.. and with my shocks like this the move in andover very nicely.

Not to hi-jack, but here's a pic of my set-up using the stock Ford knuckles:

http://img.photobucket.com/albums/v202/muddyjeep1/front.jpg

I reamed out the knuckles from the top and used 1 ton TRE's. I didn't feel I needed high steer, and the added cost would have set me back too far.

thanks - i have been looking for something like that...

Nemo and/or Ken -
are there any dead spots in your steering systems?

Ken - i would really like to see the passenger side Ford knuckle and how you drilled and taped it -

What did you two do to allow the wheels to turn stop to stop. I did a full width swap in my Tj and I can't get a long enough pitman arm to allow the wheels the full range of motion. I was thinking about building a fully adjustable heavy duty steering system with heims and assist, but I would like to sort out the steering problem first.

What did you two do to allow the wheels to turn stop to stop. I did a full width swap in my Tj and I can't get a long enough pitman arm to allow the wheels the full range of motion. I was thinking about building a fully adjustable heavy duty steering system with heims and assist, but I would like to sort out the steering problem first.

nothing my pitman arm goes from full lock to full lock.

questions: is your pitman arm on straight,, not off one notch??
and what stops it from going full lock??? is it hitting something??

thanks - i have been looking for something like that...

Nemo and/or Ken -
are there any dead spots in your steering systems?

Ken - i would really like to see the passenger side Ford knuckle and how you drilled and taped it -


I have no dead spots in my steering...
I also have hydro assist so that helps with making it easy to steer on the trail.

I will do my best to get pics soon

found one more pic from this weekend


Full Version of Pic (http://www.averdyne.com/albums/uwharrie%20spring%20fling%20'05/Hpim0215.jpg)

What did you two do to allow the wheels to turn stop to stop. I did a full width swap in my Tj and I can't get a long enough pitman arm to allow the wheels the full range of motion. I was thinking about building a fully adjustable heavy duty steering system with heims and assist, but I would like to sort out the steering problem first.

You need a steering arm that matches your pittman arm. Its much easier to get a steering arm drilled then to make a special pittman arm.

To get a steering arm that will match, I will have to get flat top knuckles. Right now I have a ford HP44. I was hoping to find something like a GM pitman arm that was about 1/2 longer than the jeep pitman arm. I just didn't know if there was one that was common for people that do swaps. My gear box is what is stopping me now. I turn it stop to stop and my wheels are still a long way in both directions from the stop. I tried a Ford F350 pitman arm ( had it laying around) and it turns stop to stop, but doesn't fit the gear box or the tie rod end.

a Waggy arm is longer, but very flat. A Waggy drop pitman arm is longer and has about the same drop as an XJ pitman, maybe more... i dunno, but i'll find out soon.

a Waggy arm is longer, but very flat. A Waggy drop pitman arm is longer and has about the same drop as an XJ pitman, maybe more... i dunno, but i'll find out soon.
Is the hole in the waggy pittman arm larger than the stock xj pitman arm? I need one with a larger hole so I can use the correct drag link.

What did you two do to allow the wheels to turn stop to stop. I did a full width swap in my Tj and I can't get a long enough pitman arm to allow the wheels the full range of motion. I was thinking about building a fully adjustable heavy duty steering system with heims and assist, but I would like to sort out the steering problem first.

My long arms are the limiting factor for how far the wheels are able to be turned. When the tires start to rub the LCA, it's time to stop turning. I have a drop pitman arm came with the suspension kit (Full-Traction) which I had to ream out to accept the larger TRE.

BTW- nice rig Ken.

My long arms are the limiting factor for how far the wheels are able to be turned. When the tires start to rub the LCA, it's time to stop turning. I have a drop pitman arm came with the suspension kit (Full-Traction) which I had to ream out to accept the larger TRE.

BTW- nice rig Ken.


hmm now that you say that I do remember... that I turned my steering stops out about 1 or 2 turns because my tires were also hitting the radius arms and I did not want to spend more money on rims :)

add since a few folks have asked about the snorkle

I used a Sami airbox and some home duct work.
and the top cone part is PVC I cut down.

here are a few pics:

pic 2

pic 3

Steering pics

pic 2

pic 3

Well Since I finally finished my Trailer build up I decided to take the Jeep out for a weekend wheeling....

Everything worked great.. Jeep walked Lower 2 and Upper 2 like a gravel driveway

Trailer pulled awesome too.

and it just happened that the same weekend I was planning to go wheeling I got invited to wheel with Xtreme4x4 TV.

that write up is here:
http://www.impaks.com/xtreme4x4tv_writeup.asp

Set up going down the road
http://www.impaks.com/Extreme%204x4%20TV/Tellico%20June%2016,%202005/DSC00012.JPG

here are a few pics of Jeep at Crawford's

http://www.impaks.com/Extreme%204x4%20TV/Tellico%20June%2016,%202005/DSC00018.JPG

and on the trail

http://www.impaks.com/Extreme%204x4%20TV/Tellico%20June%2016,%202005/DSC00112.JPG

all PICS are here:
http://www.impaks.com/xtreme4x4tv.asp

Looks good .Are you running the stock axles in the 44 or did you upgrade? I am doing the same axles swap in my 95 cherokee. I like how you made the new rear spring hanger. Been trying to figure out to how get rid of the 2" block on mine other than in boardin the springs. I think that will work out good.

Looks good .Are you running the stock axles in the 44 or did you upgrade? I am doing the same axles swap in my 95 cherokee. I like how you made the new rear spring hanger. Been trying to figure out to how get rid of the 2" block on mine other than in boardin the springs. I think that will work out good.

Yes stock axles in 44 and 9"

I do have the new water prrof u-joints from REEL to put on and test...
they were supposed to be in before this trip but I ran out of time...
and since I am planning to go back to tellico in July I am hoping to have the new u-joints and to test them

but so far I have been fine on all stock stuff

Looks good .Are you running the stock axles in the 44 or did you upgrade? I am doing the same axles swap in my 95 cherokee. I like how you made the new rear spring hanger. Been trying to figure out to how get rid of the 2" block on mine other than in boardin the springs. I think that will work out good.

Yes stock axles in 44 and 9"

I do have the new water prrof u-joints from REEL to put on and test...
they were supposed to be in before this trip but I ran out of time...
and since I am planning to go back to tellico in July I am hoping to have the new u-joints and to test them

but so far I have been fine on all stock stuff

That thing is sick!!!!.Great job!.

thanks for the steering shots...

finally got it rolling




What backspacing and size wheels where you running when u had 36's on there?

What's your opion on the engine/gear/tire combo?
I have the I6, hp44/9" with 4.88 gears running 35's and I would like to move up to 37's without regearing. I haven't been able to get opinions from anyone with a similar setup though.

What's your opion on the engine/gear/tire combo?
I have the I6, hp44/9" with 4.88 gears running 35's and I would like to move up to 37's without regearing. I haven't been able to get opinions from anyone with a similar setup though.
Sounds good. Most guys (myself included) run/ran 35's with 4.56 and feel its a good match. With 4.88's, I would say that you'll be happy with the 37's. If its trail only, then lower would be nice. But if you run the highway at all, the 4.88 will be about perfect. :cool2:

What backspacing and size wheels where you running when u had 36's on there?

when I had 36's I ran 15x8 with 4" backspacing

Now I run 15x10 w/ my beadlocks and backspacing is i thnk 4" still

What's your opion on the engine/gear/tire combo?
I have the I6, hp44/9" with 4.88 gears running 35's and I would like to move up to 37's without regearing. I haven't been able to get opinions from anyone with a similar setup though.


I wish I had 5.13 with my 38's....

when I had 36's it was fine but I wish i had a lower gear... or a 4 to 1 in transfer case.

but for the stock I6 and the axles I have it does work very well....so I really can not complain

What's your opion on the engine/gear/tire combo?
I have the I6, hp44/9" with 4.88 gears running 35's and I would like to move up to 37's without regearing. I haven't been able to get opinions from anyone with a similar setup though.
I have the same axle & tire combo....But I run 5:43's in the rear and 5:38's up front. At 70 MPH my Rpms are at 2650 with the 242 T-case.

I have the same axle & tire combo....But I run 5:43's in the rear and 5:38's up front. At 70 MPH my Rpms are at 2650 with the 242 T-case.

Same here. I had nice power on the drive from San Diego to Sacramento. I think 80 mph was just under 3K RPMS. I have 37" MTRs on 15x8" rims.


http://www.pirate4x4.com/forum/attachment.php?attachmentid=196007&stc=1

http://www.pirate4x4.com/forum/attachment.php?attachmentid=196008&stc=1

What brakelines did you use for the front calipers? Tryin to get mine finished and the banjo bolt seems to small for the SS Skyjacker extended lines I have on my XJ. Any help on what you used?

What brakelines did you use for the front calipers? Tryin to get mine finished and the banjo bolt seems to small for the SS Skyjacker extended lines I have on my XJ. Any help on what you used?
I used my braided XJ lines.........they bolted right in

I used my braided XJ lines.........they bolted right in


Yup same with mine...

Thanks Guys just the answer I was lookin for.

Mark

Well took the beast out for a relaxing weekend.. no bit changes yet but I have started to plan out the cage I am gonna start building :)

Also I was very surprised at how much my rear tire flexed when the weight is on it.. and My Bead locks are working awesome...

2

3.. My buddy standing next to jeep

4 - hey you got pose once in a while.... these are the only resent pics I have because recently when wheeling we have not stopped to take pics we just kee on driving.. it is nice to wheel with other capable rigs :)

Did you order a weld on beadlock kit?, or did you make these you'r self?
If you made them could I see some pics , or let me know how you did it.
You'r beadlocks look real good and I would like to build a set as well. Thanks .

I am doing the same thing to mine as we speak. I just got my new front out of a 79' ford but I'm going to 8 lug it with chevy outers and flattop knuckles for the highsteer and I have a D60 for the rear. Thanks for the pics.

Did you order a weld on beadlock kit?, or did you make these you'r self?
If you made them could I see some pics , or let me know how you did it.
You'r beadlocks look real good and I would like to build a set as well. Thanks .
He built them himself...They look awesome!!! :skull: .

Did you order a weld on beadlock kit?, or did you make these you'r self?
If you made them could I see some pics , or let me know how you did it.
You'r beadlocks look real good and I would like to build a set as well. Thanks .

Yes I built them myself..

More pics are here:
http://community.webshots.com/album/275972756iREgjD


If you want a set I can make more....but just and FYI it take me a few weeks to get them completed :)

I am doing the same thing to mine as we speak. I just got my new front out of a 79' ford but I'm going to 8 lug it with chevy outers and flattop knuckles for the highsteer and I have a D60 for the rear. Thanks for the pics.


NIce...

I used Rockkrawler 6" coils in front nad the Leafs I made using many different brands put together.. so far it all works great..

I have to admit I was very surprised when my XJ walked up lower 2 and upper 2 at Tellico with out any problems at all.. It was sweet..

Well took the Jeep out again and it did very well until I broke a front axle :ouch:


I wish I had video of that but oh well maybe next time..

Pretty much floored it jeep bounced once to the side and tire caught tree and pop there goes the axle.

I have split the videos the best that I could and have loaded them onto my website for all to watch.

PLEASE do not open and watch them from website but please save them to your pc then watch them..
This will help in load times.

Some of the videos will overlap

http://www.impaks.com/callante_fall_05.asp

Enjoy

Nice video!!

Hey Ken,

Is that just the stock trackbar mount at the frame? Just drillied for a bolt/heim? If so, what size bolt and how is it holding up?

Thanks:cool2:

Hey Ken,

Is that just the stock trackbar mount at the frame? Just drillied for a bolt/heim? If so, what size bolt and how is it holding up?

Thanks:cool2:

Yes it is the Stock mount and it sucks :)

I am going to be making or buying on of those RE brackets that turn it 90* so that way there is less stress on the joint..

I have broke 1 grade 8 bolt and another one came loose even with lock tight
so I am going to be changing that very soon...

Bruiser,

Did you go on the trail run with the yellow Cheap jeep and "AJ?" from the TV show Extreme 4x4? There was a quick flash of an XJ I think with the same hood intake as yours on the show. It was on this weekend I dont know if its an older re-run.

Anyway have fun. :flipoff2:

Bruiser,

Did you go on the trail run with the yellow Cheap jeep and "AJ?" from the TV show Extreme 4x4? There was a quick flash of an XJ I think with the same hood intake as yours on the show. It was on this weekend I dont know if its an older re-run.

Anyway have fun. :flipoff2:

Bruiser,

Did you go on the trail run with the yellow Cheap jeep and "AJ?" from the TV show Extreme 4x4? There was a quick flash of an XJ I think with the same hood intake as yours on the show. It was on this weekend I dont know if its an older re-run.

Anyway have fun. :flipoff2:

I caught the tail end of the show here in Sacramento, CA this last weekend. I saw a few glimses of your XJ. It looks great. Man, lots of pics of Jesse changing that tire, huh. Nice tats. :D

Do you rub very bad in the back? I'm having some rubbage with my 4.5" RE leafs, 2" blocks, and 1.75" RE shackle with my 37" MTRs. Up front I run 8" SJ coils with RE drop brackets and RE adj CAs. I'm trying to get a hold of 8" BOR springs and just run my RE shackles with them, then maybe use spacers on top of my 8" SJ coils to even it out, unfortunately I'll be at 10" or so of lift by then. I cut out my front fenders pretty good to the body line and it has helped. Thanks for the pics and info. :D

Please post this info on NAXJA.org if you haven't already.

I bought and sold the big off road 8" rears. They are very nice but they were gianormous. I'd opt for the 6" BOR. My friend bought the 8's from me and the shackle box isn't big enough for the spring to travel its full arc. I have 4" deavers and RE shackles on mine with 37" krawlers and I just trimmed the bottoms. They are close but no rub.

Rubbage? Add More Bumpstop!!!
Going taller only raises the COG and can create more problems, depending on the application. Our XJ's run 4.5 to 5" of lift for 35" tires. I wouldn't personally go taller than that for a trail/DD rig, unless I was running larger than 35" tires AND full width axles. JMO...

Just an FYI-
We run 4.56 gears on one of our XJ's with 35's and 4.88's on another.
The 4.88's are perfect on the road/highway.

The 4.56's cause more power loss and downshifting on long uphill grades. For 35's, I'd be all about the 4.88's. The 4.56's are liveable, but not the best, IMO.

For 37's, I'd run the 5.13's to 5.38's if it were mine.

I run 5.38's in my TJ on 40's. (5 speed) Its good, but sometimes I think just a tad bit deeper gear would be nice. The bigger the tire and lift height and weight, the deeper you oughtta go, gearwise, since you're creating more rolling resistance and wind resistance.

Bruiser,

Did you go on the trail run with the yellow Cheap jeep and "AJ?" from the TV show Extreme 4x4? There was a quick flash of an XJ I think with the same hood intake as yours on the show. It was on this weekend I dont know if its an older re-run.

Anyway have fun. :flipoff2:


Yup I rode with them and I must admit the AJ Jeep did very well when it was not broken :)

Here is my write up about ride with them
http://www.impaks.com/xtreme4x4tv_writeup.asp

The coolest part was they were both very laid back folks.. NO Stuck up TV attitudes...

Oh course the bad part was I walked up lower 2 like nothing but they did not get it on film :(

Do you rub very bad in the back? I'm having some rubbage with my 4.5" RE leafs, 2" blocks, and 1.75" RE shackle with my 37" MTRs. Up front I run 8" SJ coils with RE drop brackets and RE adj CAs. I'm trying to get a hold of 8" BOR springs and just run my RE shackles with them, then maybe use spacers on top of my 8" SJ coils to even it out, unfortunately I'll be at 10" or so of lift by then. I cut out my front fenders pretty good to the body line and it has helped. Thanks for the pics and info. :D

Please post this info on NAXJA.org if you haven't already.

Nope.. I do not rub in the rear at all.. My rear leafs are home made mix and match to make them work.. I do run just a little bit on front fenders when fully flexed.. bu oh well no biggy..

I would say do not get more lift if you can help it..
Use more bumpstops and cut fenders more if you can..

My jeep sit about 6' 4" talll my belly skid is 24" off ground and this works perfect for me.. Most people are surprised that my roof line is shorter then most TJ's and YJ's I wheel with :)

Ken, what is the vehicle that you got your axles from?

I'm dreaming and drooling over that setup.....

Thanks

Ken, what is the vehicle that you got your axles from?

I'm dreaming and drooling over that setup.....

Thanks

Front 44 is out of a '79 Ford F-150
Rear 9" is out of a '85 Ford F-150

Well I have not updated this in a long while.. so here we go..


Well Dave Andersen, John Herr and myself went to Callentee this weekend for one of the hardest and worst damage
wheeling trips I have ever had..

Lets see if I can recall all that took place…

First I must say I now understand why once you go Diesel you will not go back to a gas tow rig.
well we made it to Mountain City with no problems (except for some taillights on dave’s trailer)

So onto the Great damage day of Saturday..
We checked in paid our $11 for the day and headed out to the trails about 10am..
we decided heck if it is just our two rig why not hit Armor All 1st and then swing back to welder and other trails
so we got to Armor All and dropped in and I immediately saw a different look at the trail a hug tree had fallen and the roots were
kinda in the trail.. (you will see the pics of dave door) well I got past it with just a little new pin stripping and dents..
so dave came down in and he got a little up and close with it (again see pics)..
so as dave was trying to get around the roots he then got hung up on a rock and we had to use his winch , which then took out his rear driveshaft
but being where we were there was no easy way to get him to go backwards so I hoped in my Jeep and drove up ahead to see how far the 1st exit would be
and to my surprise there was not much trail left to wheel.. there were trees down all across the trail and there was no way for us to go forward
so we decided we had to turn around and go bck the way we came…

Well this is the fun part..(It is to much to type so you will have to ask in person to here all the details)

Short story.. we started at 10am and got off the trails at 4:30pm.. and we went about 200 yards total

The damage:
I broke both front u-joints, all the front axle shafts and my winch cable…

Dave broke rear driveshaft.. popped a bead (a few times) got a bunch of body damage…

We learned:
How to use every piece of recovery gear we had with us..
and having to much recovery gear is never a bad thing..
Oh ya and the water was rushing down the trail and we all ended up walking and standing in FREEZing water all day…

Pics are here:
As you can see we did not take many on the trail..(we were a little busy)

http://community.webshots.com/album/548274303LiMFrJ

NOw it is do I decide to put a 60 in front or beef up this 44.. hmmm only time will tell :)

Sorry to hear about all the breakage. Are you running stock u-joints/shafts?

Sorry to hear about all the breakage. Are you running stock u-joints/shafts?

I had my passenger side with stock u-joint and axle shafts and they all broke..

the driver side had alloy shafts and the strong u-joint from REEL and as I looked at it last night I think that is the only thing that held up.. it looks like it just lost the cap on one side when the ear of the axle shaft broke ( DAMN )

I wil know more once I pull shafts..

I must say that looks like a LOOOOOOONNNNNNGGGGG day. And your buddy has got one saweet tow rig, just I want when I grow up:D. I looks like either you have to step up to a 60 or throw some 35 splines in that 44 with their new 35 spline 44 air locker. When you run 38's, 760 size u-joints only take so much before they don't want to play anymore.

I must say that looks like a LOOOOOOONNNNNNGGGGG day. And your buddy has got one saweet tow rig, just I want when I grow up:D. I looks like either you have to step up to a 60 or throw some 35 splines in that 44 with their new 35 spline 44 air locker. When you run 38's, 760 size u-joints only take so much before they don't want to play anymore.


Yes Very Very lOng day ....

As for the Tow Rigs.. Yes his F-350 is Pimp but my '92 Dodge W250 stayed with him the entire time with no problems at all :)

As far as Axle upgrade I am gonna but in my spare shafts this weekend or next .. but I am keeping my eyes open for other ideas :)

Yes Very Very lOng day ....

As for the Tow Rigs.. Yes his F-350 is Pimp but my '92 Dodge W250 stayed with him the entire time with no problems at all :)

As far as Axle upgrade I am gonna but in my spare shafts this weekend or next .. but I am keeping my eyes open for other ideas :)


No doubt about you keeping up with him. But that SD is PIMP, though you are rollin' old school, so I give you props. Nothing like the sound and power of a 12v cummins.

great thread, what are you thinking about for front end choices now? ..although i do like to see carnage, you deffintealy need to go beefier.

I also made a diff guard for the 44

Peace sign part was just for looks the protection is the tampoon behind it :)


i am thinking on doing the same type of set up on my XJ, why is the passenger side spring bowed out, but the drivers straight? or is that just a trick of the camera?

i am thinking on doing the same type of set up on my XJ, why is the passenger side spring bowed out, but the drivers straight? or is that just a trick of the camera?


they are both bowed.. it is just the camera shot...

they are bowed due to the fact that the 44 mounting plate is wider then cherokee stock location and i was to lazy to move the mount on axle

great thread, what are you thinking about for front end choices now? ..although i do like to see carnage, you deffintealy need to go beefier.

not sure yet.. still trying to decide

they are bowed due to the fact that the 44 mounting plate is wider then cherokee stock location and i was to lazy to move the mount on axle


I'm doing this swap right now and am using the stock ford mounts on the axle also.Do you notice any unwanted affect on your articulation having them lightly bowed like that?Or is it still nice and smooth with full travel?

I'm doing this swap right now and am using the stock ford mounts on the axle also.Do you notice any unwanted affect on your articulation having them lightly bowed like that?Or is it still nice and smooth with full travel?

NO problems at all with flex.. I stil have full flex even with the coils bowed..

I know everyone and there mama have a story about them breaking but ive got yukon4340 shafts and ctms in my 44 with 39.5 pitbulls and so far it has held up and i have beat the everloving piss outa mine

NO problems at all with flex.. I stil have full flex even with the coils bowed..


Thanks.Thats what I wanted to hear.

I know everyone and there mama have a story about them breaking but ive got yukon4340 shafts and ctms in my 44 with 39.5 pitbulls and so far it has held up and i have beat the everloving piss outa mine



Thanks

I am putting in some spare stock shafts so that way it can have working 4x4.. for now.. I guess the decision comes down to which way to spend more money?? on 44 in jeep or find a 60 and build it.. hmmm decisions, decisions..

yea i thought about that too, but by the time i realized i should have bought a 60 i already had too much money in the 44 and i figured whats another 800 to get the shafts. Besides as long as you take care of them you can for the most part get some of your money back if you decide to upgrade

hope that your control arms dont break i know someone that did that and and the welds didnt hold on the ford radius arms and he lost his life and dont say it was his welds he was a certified welder and had been working in the industry for 8 years

hope that your control arms dont break i know someone that did that and and the welds didnt hold on the ford radius arms and he lost his life and dont say it was his welds he was a certified welder and had been working in the industry for 8 years


First I am very very sorry to hear about your loss.. and I wish my best to his family and freinds...

Second.. Being that I do not drive mine on the road at all and I am hardly ever going faster then 15MPH.. all I can say is I pray this does not happen to my arms or anyone elses...

http://www.silvercityelectric.com/media/DSC00112.jpg

Hey That's that dude on TV!

Very Nice Work on the Jeep. I can only dream, and look at pics like this.

Hey That's that dude on TV!



Yup that is IAN

Here is my write up about ride with them
http://www.impaks.com/xtreme4x4tv_writeup.asp

The coolest part was Ian and Jessi were both very laid back folks.. NO Stuck up TV attitudes...

Oh course the bad part was I walked up lower 2 like nothing but they did not get it on film :)

Well I changed the tracj bar mounted and adjusted a few things and took the XJ out to Tellico again..

This time it worked awesome..

I made it up School Bus, Guard Rail, Helicopter Pad, Lower 2, Upper 2, and every other trail to get to all these with no issues..

I did break Passenger side rear glass and denter rear passenger quarter panel and front fender.. so Yes it is finally time to get my cage in it and add a little protection..

Pics of others that were with me:
http://good-times.webshots.com/album/560446254JBwgNX

Video of me on Guard rail:
http://video.google.com/videoplay?docid=-108465077936515598

rest of my videos are at:
http://video.google.com/videosearch?q=cnc4x4+@+Tellico&hl=en

nice set up. makes me wish i didnt narrow my hp44 and 9inch.

i wouldn't run steal braided brake lines on a crawler. They don't flex as much as rubber line and the fact they don't expand is pretty irrelevant in a crawler unless you race. They also don't just slowly fail like rubber but just completely fail and leave you with no brakes, inside is just Teflon.

i wouldn't run steal braided brake lines on a crawler. They don't flex as much as rubber line and the fact they don't expand is pretty irrelevant in a crawler unless you race. They also don't just slowly fail like rubber but just completely fail and leave you with no brakes, inside is just Teflon.

That is why you make sure when you install them they are long so that your rig can have the flex you want it to have with no issues...

I did not just throw a pair of brake lines on cause they looked cool.. I measured, etc.... come one..:shaking:

as for failing i will take a steel line over a rubber line any day of the week racing or crawling..

its not that they fail anymore or less, they are must likely more durable but when they do fail the loss all pressure. I had a set on my four wheeler and the front one broke and now i have a barbed wire scar across my chest because the Teflon broke.

its not that they fail anymore or less, they are must likely more durable but when they do fail the loss all pressure. I had a set on my four wheeler and the front one broke and now i have a barbed wire scar across my chest because the Teflon broke.
I have never seen a rubber line fail slowly! If your brake system is working properly, when a line fails the diverter valve should stop most of the pressure from going to the front or rear depending on where the break is. Braided lines are far better IMO

I say to each his own my setup works and works great...

so I will stay with my steel braided lines..

Bruiser,

Are you a member of a local club? I just moved to Chapel Hill a month ago from Clemson, SC, and I don't know of any clubs around here.

I just started med school, so there wont be much time for willing, but sometimes i need my fix, ya know? anything remotely local?

where in Raleigh are you?

Kenny

Yes I am the current VP for www.cnc4x4.org
I was the Pres for 2 years but needed to step down since I have a little kid on the way in 3 months..

We have a bunch of folks in Chapel Hill, Raleigh, Apex, Durham, etc, areas..

check out the website and we can chat in PM's

Well after my last trip to Tellico I smashed the front fender, rear tailgate, rear fender, and rear passenger glass..I decided it was time to finally Chop the XJ .

But I have not liked the flat look of what I have seen on other XJ's that have been chopped so I took a differnet route.

I decided to use the XJ rear tailgate as my back glass to keep the factory curved angles, then once we got to looking at it we decided why not make the tailgate still open :)

so yup I cut the back used the rear tailgate and the tailgate will stil open ( just because ) :)

Here are some pics of before, during and hope to have it done by the end of this week.

We started Thursday night by stripping the interior, then Friday we started by cutting and getting to work.

Here we go.. I have lots of pics

Here are few pics of what it looked like when I started

http://www.impaks.com/images/ken/100_1963.jpg

http://www.impaks.com/images/ken/100_1967.jpg

http://www.impaks.com/images/ken/100_1968.jpg

http://www.impaks.com/images/ken/100_1969.jpg

So next we had to take out the glass, took off the rear hatch and then started cutting :)

http://www.impaks.com/images/ken/100_1970.jpg

http://www.impaks.com/images/ken/100_1971.jpg

http://www.impaks.com/images/ken/100_1972.jpg

http://www.impaks.com/images/ken/100_1973.jpg

Here is where it got interesting..

I grafted on the rear edge off the roof to my cut so that way we could keep the hinges and the angle of the tailgate so it would open correct.. I also kept the rear support beam inside the roof and moved that up so now the "c" pillar is stronger then it ever was..

http://www.impaks.com/images/ken/100_1974.jpg

http://www.impaks.com/images/ken/100_1975.jpg

http://www.impaks.com/images/ken/100_1988.jpg

http://www.impaks.com/images/ken/100_1989.jpg

So after we got the top of the tailgate fitted we then focused on the bottom half.. I decided to make the bottom half solid so to help with water and keeping the inside of the Jeep sealed.

http://www.impaks.com/images/ken/100_1992.jpg

http://www.impaks.com/images/ken/100_1994.jpg

http://www.impaks.com/images/ken/100_1996.jpg

Come on :mr-t: - Need More Pics!!! I want to see the pics of the bed sides skinned.

after much debate I finally decided how I wanted to make the sides of the bed and we went at it.

You can see from the pics we used a brake to bend the steel so it fit the curves I wanted correct and we also bent a lip at the top for strenght that attached to the inside of the outside fender.

http://www.impaks.com/images/ken/100_2001.jpg

http://www.impaks.com/images/ken/100_2002.jpg

http://www.impaks.com/images/ken/100_2003.jpg

http://www.impaks.com/images/ken/100_2004.jpg

Ken - Isn't the corner armor supposed to be on the outside??? :grinpimp:

Ok, enough of me being a smart ass.

Please continue... it is looking awesome.

The last 2 pics so the tailgate off getting ready to get plated so it will seal against the bottom panel we made

also last pic shows the bottom half with the lip we welded on so the weather stripping can be connected to seal the hatch

http://www.impaks.com/images/ken/100_2006.jpg

http://www.impaks.com/images/ken/100_2008.jpg

Nice job. Very different.

Nice job. Very different.

Thanks.. I have been putting a lot of thought into making this look good..

that thing is gonna be nasty!

Well we got about 90% of all welding done tonight.

we also finished the rear Cargo area, sealed it with autobody sealer then bedliner spray

http://www.impaks.com/images/ken/100_2009.jpg

http://www.impaks.com/images/ken/100_2011.jpg

Thats pretty sweet. Get an overall side pic outside.

Thats pretty sweet. Get an overall side pic outside.

If all goes well I plan tohave it finished by this weekend so I will get pics then

Ok so tonight was one of those nights were it looks like you got nothing done but in all reality you did.

we got rear hatch mocked up with weather stripping, got all bondo on(will sand that tomorrow night), and a bunch of grinding, smoothing, etc on the metal for hatch

http://www.impaks.com/images/ken/100_2012.jpg

Well here are some updates :)

http://www.impaks.com/images/ken/100_2013.jpg

http://www.impaks.com/images/ken/100_2016.jpg

http://www.impaks.com/images/ken/100_2018.jpg

http://www.impaks.com/images/ken/100_2022.jpg

http://www.impaks.com/images/ken/100_2023.jpg

Well here are some updates :)

http://www.impaks.com/images/ken/100_2024.jpg

http://www.impaks.com/images/ken/100_2025.jpg

http://www.impaks.com/images/ken/100_2026.jpg

Great news is we got it DONE in 7 days :)

yup it is all back together..
Back hatch opens, closes, locks, has struts to hold it open..

it came out very well and I am very happy with a 7 day deadline..

http://www.impaks.com/images/ken/100_2029.jpg

http://www.impaks.com/images/ken/100_2030.jpg

http://www.impaks.com/images/ken/100_2032.jpg

http://www.impaks.com/images/ken/100_2033.jpg

http://www.impaks.com/images/ken/100_2034.jpg

http://www.impaks.com/images/ken/100_2039.jpg

here is a shot video showing how it works..

we reused the original latch and lock from the tailgate so it locks and unlocks..

I still need to get unlock mechanism to work.. but atleast for now I can reach inside and just unlock it by hand

http://video.google.com/videoplay?docid=7338570673824170046

lastly I want to Thank.. John H, Scott R, Steve F and others for helping to pull this off in 7 days.. I am still kinda surprised we got it done..

So THANKS GUYS

Nice

Well Drove it out of shop today

Here are finished " for now" pics

you can see I did not fix all the dents on passenger side..i figured they would probably get smashed again

http://www.impaks.com/images/ken/100_2040.jpg

http://www.impaks.com/images/ken/100_2041.jpg

http://www.impaks.com/images/ken/100_2042.jpg

http://www.impaks.com/images/ken/100_2043.jpg

sweet rig. i fell in love with the chopped back end readin vetteboys thread and to see one that integrated the rear hatch is tits. im a student at ncsu and would love to see ur rig in person and if you dont mind just come over whenever you do future mods to watch and learn. pm me whenever you do anything else to it, id love to lend a hand.

andrew

sweet rig. i fell in love with the chopped back end readin vetteboys thread and to see one that integrated the rear hatch is tits. im a student at ncsu and would love to see ur rig in person and if you dont mind just come over whenever you do future mods to watch and learn. pm me whenever you do anything else to it, id love to lend a hand.

andrew

thanks..

if you are not on www.nc4x4.com yet you should check it out.. there are a bunch of local raleigh guys on there.. as for more projects.. I am gonna be taking a little break since I am a new dad now..

also check out www.cnc4x4.org, it is a local 4x4 club in raleigh..

That look great, did it come out water tight?

thanks..

if you are not on www.nc4x4.com yet you should check it out.. there are a bunch of local raleigh guys on there.. as for more projects.. I am gonna be taking a little break since I am a new dad now..

also check out www.cnc4x4.org, it is a local 4x4 club in raleigh..


yeah im on nc4x4 but i rarely post, im like a registered lurker. lol. i will have to check it out more often though and find some folks in raleigh doin builds who wouldnt mind me sittin in on a build in order to learn. as far as cnc4x4, i met a couple of the guys in it at the fair (we had a car in the demo derby) and they were pretty cool. i would like to join a club some time but im pretty busy with work, school and the fraternity right now, so i dont have much time or moolah for another commitment. if you dont mind, let me know when any one in the area is plannin on doin some work and maybe i could stop by and watch.

andrew

http://www.impaks.com/images/ken/100_2041.jpg

http://i75.photobucket.com/albums/i285/VR-92/vol740___.jpg

:laughing:haha

That look great, did it come out water tight?

Thanks..

and yes it is water tight.. I washed it on saturday at car was with power washer and NO water got inside :)

yeah im on nc4x4 but i rarely post, im like a registered lurker. lol. i will have to check it out more often though and find some folks in raleigh doin builds who wouldnt mind me sittin in on a build in order to learn. as far as cnc4x4, i met a couple of the guys in it at the fair (we had a car in the demo derby) and they were pretty cool. i would like to join a club some time but im pretty busy with work, school and the fraternity right now, so i dont have much time or moolah for another commitment. if you dont mind, let me know when any one in the area is plannin on doin some work and maybe i could stop by and watch.

andrew

not a problem I wil keep ya in mind in the future..

http://i75.photobucket.com/albums/i285/VR-92/vol740___.jpg

sweet I always loved Volvo's glad I copied the look correct :)

here are 2 pics showing the lock inside the tailgate

http://www.impaks.com/images/ken/100_2089.jpg

http://www.impaks.com/images/ken/100_2090.jpg

and her are 2 pics of the inside.. you can see I did not get all the inside panels screwed back in, but they all fit except for 2..

http://www.impaks.com/images/ken/100_2092.jpg

http://www.impaks.com/images/ken/100_2088.jpg

Wow man looks awesome hope mine comes out half as good, my xj is in the process of gettin the same axles under it right now! I like the way you did the rear window thing but my only concern would be when or if you ever have people sittin in the rear are they going to bang there heads aginst the window when leaning back?
-Glen

http://img207.imageshack.us/img207/4718/hahajaypeglc0.jpg

http://img207.imageshack.us/img207/4718/hahajaypeglc0.jpg

it was funny the 1st time.. now it just looks stupid..

but hey what do you expect from a newbie :flipoff2:

Well took the XJ out and it worked great.. stayed DRY inside.. it was weather tight and kept me warm all weekend

here is what we went wheeling on ICE:
http://i144.photobucket.com/albums/r190/mp4141/MtCityJan08/0125081323.jpg

http://i98.photobucket.com/albums/l257/LennySEC/IMG_0097.jpg

small video of XJ after my buddies Bronco
http://s144.photobucket.com/albums/r190/mp4141/MtCityJan08/?action=view&current=0126081226.flv

differnet angle
http://s144.photobucket.com/albums/r190/mp4141/MtCityJan08/?action=view&current=Video05.flv

then loaded up heading home
http://inlinethumb17.webshots.com/27600/2826472220010396380S500x500Q85.jpg (http://rides.webshots.com/photo/2826472220010396380iYyKNO)

next is Exo cage and keep on wheeling.. I hope to be starting exo in about 2 weeks

nice work,looks like a very capable rig:D

next is Exo cage and keep on wheeling.. I hope to be starting exo in about 2 weeks

lemme know when you get started, i need sum knowledge. :D

with this style tail gate did you have to do any stiffiners.
nice build.

with this style tail gate did you have to do any stiffiners.
nice build.

I welded on some 3x3 1/4 plate on the unibody many years back.. my rear bumper is bolted and welded on, and so is front bumper.. plus i have a beefy cross member and almost a 4x4' flat belly skid under XJ so far I have had no issues.. and now with all the 1/8" plate i added to the rear to make the pickup bed. i am even less worried about flexing on XJ unibody

BUMP!!!!:beer:

If I see this correctly, the Factory Ford Radius Arms do not need moved on that axle? Just refabbed to mount in the Jeep holes?

If I see this correctly, the Factory Ford Radius Arms do not need moved on that axle? Just refabbed to mount in the Jeep holes?

if I understand your question.. I think you are asking if the radius arms move on axle side or not?

answer: ford radus arms do not move on the axle side..

yes I cut off the radius arm bolt on frame side and welded on a Jeep control arm, then I made a new bracket for the control arm bushing to go into.. and now it flexs great.

you answered perfect, thanks

broke the rear last weekend..

but I figured out what broke.

I broke the pin inside my rear axle..

here is pics of shaft broke
http://inlinethumb16.webshots.com/42447/2702229970084447596S600x600Q85.jpg (http://good-times.webshots.com/photo/2702229970084447596ueSlSK)

http://inlinethumb46.webshots.com/40685/2866456950084447596S600x600Q85.jpg (http://good-times.webshots.com/photo/2866456950084447596EKlbnW)

Mini spools suck. Seen too many break exactly like yours did.

Throw in a full spool and wheel on worry free :D

AARON

Well I am back at it.. :)

Jph0913 and myself spent 3 hrs thursday, and then today jph0913, thegriz, thecarman, bsrober, and myself spent about 9 hrs and we got almost my entire exo cage done..

we need to finish weld the top cross bars in, the bottom windsheild bar, and then make a bar for windshielf from top to bottom.. then after I get some new suspension seats I will be adding the B pillar support inside the cab.

I will get better pics once I get my camera over there.. but here are a few from my cell phone.

http://www.impaks.com/images/ken/IMG00012-20081219-1637.jpg

http://www.impaks.com/images/ken/IMG00009-20081219-1636.jpg

http://www.impaks.com/images/ken/IMG00014-20081219-2050.jpg

http://www.impaks.com/images/ken/IMG00015-20081219-2156.jpg

Awesome thread, I have been searching for a while now, And was wondering, for this set up did you have to relocate spring buckets up front?
It looks like you are wider on the axle than on the jeep.

thanks
94xj 4.0
stock axles 4.5" lift 31" truxus' (but not for long)
already have getting ready to install d44/9" w/ true trac/ det locker and 4.88 gears
37x13.50x17 xterrains.
6.5" bds front coils. rear spring TBD.

Well today we got everything welded up and then painted it.. no pics of it without plastic, as it got to dark

here are a few pics:

me welding on hood
http://www.impaks.com/images/ken/100_4181.jpg

before paint
http://www.impaks.com/images/ken/100_4185.jpg

http://www.impaks.com/images/ken/100_4184.jpg

http://www.impaks.com/images/ken/100_4188.jpg

http://www.impaks.com/images/ken/100_4187.jpg

we wrapped the jeep in plastic and then painted it.. I still need to do a little touch up in a few areas..

next is to get some suspension seats and make a "B" pillar support bar inside the cab

http://www.impaks.com/images/ken/100_4192.jpg

http://www.impaks.com/images/ken/100_4191.jpg

http://www.impaks.com/images/ken/100_4190.jpg

pics of it painted

http://www.impaks.com/images/ken/100_4207.jpg

http://www.impaks.com/images/ken/100_4206.jpg

http://www.impaks.com/images/ken/100_4208.jpg

http://www.impaks.com/images/ken/100_4209.jpg

http://www.impaks.com/images/ken/100_4210.jpg

like the exo cage looks good

I like that exo. Mine had tube under the fenders, but your will protect the front end better.

like the exo cage looks good

Thanks..

I like that exo. Mine had tube under the fenders, but your will protect the front end better.

I actually almost put the front fender bars into the fender..

I also made a diff guard for the 44

Peace sign part was just for looks the protection is the tampoon behind it :)

that diff guard you made there , did you use well head ring gaskets to make it ??

Lookin good man. I can see the C pillar bar goes into the rear fender....How is it tied into the frame? Pics?

that diff guard you made there , did you use well head ring gaskets to make it ??

I just took an old diff cover and traced it onto some thick steel, then cut it out with a plasma

Lookin good man. I can see the C pillar bar goes into the rear fender....How is it tied into the frame? Pics?

i have not taken any pics of inside.. but will soon.. once I get shop I am building done and have sometime to get back to the XJ..

once again, you have inspired me lol

looks good. are you not worried about the front tube around the 1/4 panel bending in on a hard flop?

looks good. are you not worried about the front tube around the 1/4 panel bending in on a hard flop?

once I get the "b" pillar installed then I am not worried a bit.

but of course like anything you never know until you actually flip :)

about how much tubing did you use for your cage? would love to see your b pillar supports when you get them done,

about how much tubing did you use for your cage? would love to see your b pillar supports when you get them done,

I used 100' so far.. once I get my new shop up I will be doing the "b" pillar support.. so I will post pics once it is in

Well Took the XJ out to Rausch Creek for the weekend .

I mounted a Flip Video Camera on my exo cage for Rock Creek here are some vids:

entering Rock Creek
YouTube - CNC4x4 at Rauch Creek Memorial day 2009 (http://www.youtube.com/watch?v=uilpPf0YW8o)

Randall in front of me on rock creek
YouTube - CNC4x4 at Rauch Creek Memorial day 2009 (http://www.youtube.com/watch?v=LRtW5HE8EC0)

Craig and Randall in front of me
YouTube - CNC4x4 at Rauch Creek Memorial day 2009 (http://www.youtube.com/watch?v=GgMM2hc4Sss)

JOhn in front of me
YouTube - CNC4x4 at Rauch Creek Memorial day 2009 (http://www.youtube.com/watch?v=D7C64X2qfVk)

this one is long but shows good part of creek
YouTube - CNC4x4 at Rauch Creek Memorial day 2009 (http://www.youtube.com/watch?v=nmp6vZbygPw)

and a few more of my XJ:

Me on Trail 5
YouTube - Trail 5 hill climb at Rausch Creek 05/2009 (http://www.youtube.com/watch?v=76sJ_owJMLg)

me on CV
YouTube - Rausch Creek 05/2009 (http://www.youtube.com/watch?v=uGrr2fnwXA0)

me on Tombstone
YouTube - Tombstone at Rausch Creek 05/2009 (http://www.youtube.com/watch?v=6mfgKEGXGLU)

Your truck is awesome man. A nice truck with a reasonable budget. Your still on the 44 and 9 inch correct? Are you still running stock shafts? I read the whole thread but got confused about wether or not you switched them out.

Doing the same swap myself right now. Only difference is I wristed one of my radius arms and added a ballastic joint on the end. That one guys comment kind of scares me now. About his buddy with the failed radius arm.

Awesome truck!

Paul

Your truck is awesome man. A nice truck with a reasonable budget. Your still on the 44 and 9 inch correct? Are you still running stock shafts? I read the whole thread but got confused about wether or not you switched them out.

Doing the same swap myself right now. Only difference is I wristed one of my radius arms and added a ballastic joint on the end. That one guys comment kind of scares me now. About his buddy with the failed radius arm.

Awesome truck!

Paul

Thanks for the compliment.

Yes I still have the 44 / 9 combo in it.. yes with stock shafts.

But I do have a 60 front sitting in my garage just waiting to go in :)
and this past weekend I ripped the factory weld on the 9" so I am gonna pull the rear axle and shave it while I have it out and then plate it up..

while doing all this I need to address the suspension it works but as you can see in the vids it does bounce and I want to address that.. so not sure where it will end up.. but I have a lot of work that I want to do to it..

the never ending story , right :)

I know where your coming from. One more question are you still running stock skids? Did you build a gas tank skid?

I believe he has the mopar gas tank skid, and a homebrew "flat belly" skid for the trans/t-case.

I believe he has the mopar gas tank skid, and a homebrew "flat belly" skid for the trans/t-case.

this is correct.. stock Mopar gas skid all others I made.

Well test out that exo, get it on its side so we can see them! lol.

JOhn in front of me
YouTube - CNC4x4 at Rauch Creek Memorial day 2009 (http://www.youtube.com/watch?v=D7C64X2qfVk)

Needs more cowbell!!!! :flipoff2::laughing::laughing:

did you move your front axle forward at all? I'm doing a comanche on 38's and thinking the front axle is going to have to go forwards a little bit so the tires clear the back of the fender or really the floorboards.

did you move your front axle forward at all? I'm doing a comanche on 38's and thinking the front axle is going to have to go forwards a little bit so the tires clear the back of the fender or really the floorboards.

the front axle was moved only about 1" forward.. then I cut as much as possible in the fender so it would not rub

Never a dull day in my garage

XJ has been leaking some fluid.. so we ripped out skid plate and found transfer case is cracked( oops. I guess hitting a ditch at 35 is not a good thing)

Then we tried to take cross member off and bolts were stripped so we had to rip carpet out of jeep ( which is soaking wet I have a leak) that smelled nasty.

Cut hole in floor to get to bolt inside frame rail. So we decided to just weld them in so they will never have issues again.

Then we took bolls off cross member but it would not drop down due to me building reinforcement brackets for control arms.. ( oops again had to pull out cut off wheel)

So tomorrow night I hope to drop transfer case and rebuild it, and if I can find it I am gonna install the 2 low range kit also.

I guess since seats are out may be a good time to get suspension seats and build internal cage bracing

Never a dull day in my garage

XJ has been leaking some fluid.. so we ripped out skid plate and found transfer case is cracked( oops. I guess hitting a ditch at 35 is not a good thing)

Then we tried to take cross member off and bolts were stripped so we had to rip carpet out of jeep ( which is soaking wet I have a leak) that smelled nasty.

Cut hole in floor to get to bolt inside frame rail. So we decided to just weld them in so they will never have issues again.

Then we took bolls off cross member but it would not drop down due to me building reinforcement brackets for control arms.. ( oops again had to pull out cut off wheel)

So tomorrow night I hope to drop transfer case and rebuild it, and if I can find it I am gonna install the 2 low range kit also.

I guess since seats are out may be a good time to get suspension seats and build internal cage bracing

man all i can say is, "WOW that really sucks!"

I saw the rear shock in boarding kit on the xj is this something you made our what company is it from

I saw the rear shock in boarding kit on the xj is this something you made our what company is it from

I made it..

took piece of tube welded it to flat stock and welded flat stock to unibody frame. it ties the frame together and has mounting points for shocks

Would it be somthing you would like to create for me ive got a 93 cherokee 4door All i would have to is weld it to the frame

Would it be somthing you would like to create for me ive got a 93 cherokee 4door All i would have to is weld it to the frame

If you can do the welding, you can make this piece......


How did I miss those videos the first time around? Looks good, where were you for the Unibody run up there??

Ever make it up to Crozet or Big Dogs?

If you can do the welding, you can make this piece......


How did I miss those videos the first time around? Looks good, where were you for the Unibody run up there??

Ever make it up to Crozet or Big Dogs?

no I missed the unibody run.. I was up there with my local 4x4 club from NC.. we try to go to Rausch atleast once a year.

Well got half a 231 case from a friend so I could rebuild mine.. then I remember I had a 2 lo kit.. so I pulled that out and found the plastic guides all wore down.. after so calls no one had one.. so I took a stock shift fork and cut it up and made my own 2 low shift fork ( I should have taken pics)

Here are some pics of case back in and also of cracked case..

I also got some new shoes for XJ.

and I also cut the rear 9" and plated it with 3/8" steel.. not gonna have to worry about sliding on rocks anymore

also ripped out interior and found a little rust but not to much..

http://www.impaks.com/images/ken/xj/100_5678.jpg

http://www.impaks.com/images/ken/xj/100_5683.jpg

http://www.impaks.com/images/ken/xj/100_5686.jpg

http://www.impaks.com/images/ken/xj/100_5682.jpg

http://www.impaks.com/images/ken/xj/100_5679.jpg

http://www.impaks.com/images/ken/xj/100_5681.jpg

http://www.impaks.com/images/ken/xj/100_5687.jpg

http://www.impaks.com/images/ken/xj/100_5688.jpg

well next I need new shackles with better angle to them.. so I got a joint end and welded it on, made shackles and got those on last night.. also took apart front radius arm last night to check on bushings and they still look brand new ( not bad after 6 years of romping on them

http://www.impaks.com/images/ken/xj/100_5689.jpg

http://www.impaks.com/images/ken/xj/100_5690.jpg

looks nice. id like to hear how those johnny joint shackle mounts work. id tossed the idea around, but had heard that it can cause axle tracking issues, especially on the road.

i like the Jonny Joint thing..
I wonder if there's a way you could replace the bushing with another joint on the front of end of the leaf?????

looks nice. id like to hear how those johnny joint shackle mounts work. id tossed the idea around, but had heard that it can cause axle tracking issues, especially on the road.

well my jeep hardly ever sees the road so not to worried about that..

i like the Jonny Joint thing..
I wonder if there's a way you could replace the bushing with another joint on the front of end of the leaf?????

ya i thought about that also. but I figured the little bit more flex in the rear should help..and getting a better shackle angle should help also.. my last shackle setup the shackle was almost straight up and down at ride height .

I would think taking off those spring clamps would give more flex. Mine have deaver spring liner between each leaf, full length. And I have the clamps facing up. In this picture you can see.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep013.jpg

I get all the flex I could want.

How much wider or skinnier were the 9" spring perches compared to the stock 8.25? Have you noticed any problems having not relocated the spring perches? Would you feel comfortable running that setup on the road?

How much wider or skinnier were the 9" spring perches compared to the stock 8.25? Have you noticed any problems having not relocated the spring perches? Would you feel comfortable running that setup on the road?

the 9" perches were about 1/2" wider the 8.25 was..

was not a big deal to bolt springs down at al.. and yes I ran it like that for 4 years with no issues.. on road or off

well time has come to start some more upgrades..

1st: I took off the steel beadlocks and I am going to run aluminum rims with Inner Air Locks to save some weight.

since I could not make up my mind on rims I now have 8 Aluminum rims :)
496595

I also got a set of Chromo Shafts from ECGS I originally went with just stock u joints but I have no convinced myself that I should just pony up and get some good ones.. So I guess I need to call ECGS again :)
496596

found out my ball joints are bad so I am going to put all new ball joints in and while i have it apart I am going to replace all the tie rod ends on steering

here is how it sits now :)
496597

Looking good!

well with a sick son at home I had no time to work in garage.. but I did weight a few things..

steel beadlock wheels with bolts weight = 57lbs each

alum rim plus Inner Air lock = 24lbs each

that is a 33lb per corner weight saving, total = 132lbs :)
plus I am switching out spare tire with steel rim to alum rim so about another 20lbs savings..

well 152lbs is better then none :)

well I decided to rip off the rear hatch and the doors..

still trying to cut weight..
504475

504476

Did some more weight measurements and this is what I took of so far

(2)64lb - front doors
(2)48lb - rear doors
45lb - rear hatch

so these total = 269 lbs of Jeep
plus 152lbs of rims I did also

So I am down 421lbs.. my original goal was 1500lb loss but the more i weight things I am now aiming for 1000lbs.

What was your weight before you started the diet?

What was your weight before you started the diet?

last time I weighted it, it still had the full roof on it and I was at 5500lbs

it will be interesting to see what I end up with since even though I have taken stuff of I do need to add some stuff also.

last time I weighted it, it still had the full roof on it and I was at 5500lbs

:eek:

Wow I was 4600 trail ready with a spare, tools, spare shafts & full tank of gas.

i have been working on and off on my half doors and decided to weigh them the other day. my front driver door was 75lbs! after i stripped everything out of it - glass, motor, latch, everything. its now @ 40 lbs. so hopefully ill shave another 10 after i make my cuts.

doors are heavy.

did you think about the hood? maybe get one thats made out of fiberglass or something?
just an idea.

edit: youll save a few more getting rid of those drum brakes too.

:eek:

Wow I was 4600 trail ready with a spare, tools, spare shafts & full tank of gas.

yup.. it is a lot..

that was me, fuel, spares, tools, etc..

got a little package today:

Thanks to Shawn @ innerairlock for making my alum rock rings

http://www.impaks.com/images/ken/100_6215.jpg

http://www.impaks.com/images/ken/100_6216.jpg

total weight of 5 rings is 10lbs

last time I weighted it, it still had the full roof on it and I was at 5500lbs

it will be interesting to see what I end up with since even though I have taken stuff of I do need to add some stuff also.

I'll be interested to see what you end up with...I've never weighed mine but I'm afraid it's in the same ballpark.

well got one rim welded up and other 4 should be done this week.. then I can mount the inner air locks and get them back on jeep..

also ripped apart front to replace ball joints wow they were bad..
511993

511994

any pix of the rims finished? would love to see them once they are. great build:D

This build is so awesome. Keep up the good work! Longest active thread ever...lol

Well got all rims back and they all came out great.. guy did an awesome job.

I got one mounted today with inner air lock installed and I also weighted it..

108lbs is rim, tire, inner air lock. / 38 TSl with 15x10 alum rims.
if all goes well I am going to try to mount 3 more tomorrow so jeep can move.
515161

515162

Well all 4 tires are now double beadlocked..

hope to have ball joints and tie rod ends done this weekend and then put it all back together for next weekends URE ride..

Well Jeep is getting back together finally..

Got rear tires on


found what the noise was last time at the flats oops
517780

517781

I also took out air bags so my son can ride in front seat with me.
I also added a cool little item into place where air bad was.. now I can see my rear axle with out getting out of jeep :
517782

517783

517784

Do you still have stock shafts?!?

Do you still have stock shafts?!?

the ones that broke were stocks yes.

I now have chromo shafts

well took Jeep out and of course I did not get any pics on trail but here is what I did get..

inner air lock seem to work great with no issues
518551

518552

518553

518554

Nice build! How does your boy like wheeling?

My daughter just turned 2 and she loves it.

Nice build! How does your boy like wheeling?

My daughter just turned 2 and she loves it.

he seemed to love it :)

which is great

Thanks for the build thread. Looks good!

Yeah I have pictures of my kids sleeping when wheeling too. They'll love it.

Decided I need to update a few things..

list of stuff I am doing:
Suspension seats - front and rear
5 pt harness
finish exo cage and B pillar
move fuel tank
new shocks front and rear
and maybe some sort of a door or door bar..

Here is what I got done last night.. more to come over next few weeks

528335

did a little more work..

added passenger seat
http://www.impaks.com/images/ken/xj/100_6852.jpg

took off rear bumper and gas tank skid plate
http://www.impaks.com/images/ken/xj/100_6853.jpg

pic showing rear with no tank
http://www.impaks.com/images/ken/xj/100_6854.jpg

temp location of gas tank
http://www.impaks.com/images/ken/xj/100_6855.jpg
http://www.impaks.com/images/ken/xj/100_6858.jpg

and put rear seat to see how it looks with front seats in
http://www.impaks.com/images/ken/xj/100_6857.jpg

How much did those front seats set you back?

I've ALWAYS thought a camera set up just like that would be an awesome idea..

what camera did ya get? waterproof? how much??

How much did those front seats set you back?

$300 with harness.. i bought them used

I've ALWAYS thought a camera set up just like that would be an awesome idea..

what camera did ya get? waterproof? how much??

i got it for my tow rig and then used it for this.. it is supposed to be water proof, so we will eventually see :)

cost $100 from a snap on truck :)

option 2 for gas tank

http://www.impaks.com/images/ken/xj/100_6861.jpg

http://www.impaks.com/images/ken/xj/100_6863.jpg

Love the build, glad to see you ditched the doors. Looks like your boy fell asleep from the long ride home? :D

well after pricing out the fittings for the fuel cell I decide for the time being to just modify the stock tank location and gain some clearance.

I cut the floor so the skid plate would drop down in between the frame rails. then place skid plate in place welded it in, dropped tank into skid plate and used stock hold downs just on top of the tank instead of on the bottom.. I gained almost 5" of clearance.

http://www.impaks.com/images/ken/xj/100_6947.jpg

http://www.impaks.com/images/ken/xj/100_6949.jpg

http://www.impaks.com/images/ken/xj/100_6942.jpg

http://www.impaks.com/images/ken/xj/100_6939.jpg

here is a side shot showing difference

before
http://www.impaks.com/images/ken/xj/100_5689.jpg

after
http://www.impaks.com/images/ken/xj/100_6945.jpg

Not sure if its just me but it doesnt really look different.

Not sure if its just me but it doesnt really look different.

you're on crack

ya not sure how you an not see the difference :)

I have to admit it took me a couple of times looking at the picture to see it