Holy shat! Those are some serious fab skillz that I could only dream of....I'm creative but geez, that would take a lot of practice and some T&E :)

Ya wanna sell it? :D

Very cool stuff :D

Holy shat! Those are some serious fab skillz that I could only dream of....I'm creative but geez, that would take a lot of practice and some T&E :)

Ya wanna sell it? :D

HAHA, he would have to sell it with his house attatched for the top storage. :laughing:

Sorry gents this rig is not for sale... I'll be driving it till I die!!

More progress on the heater/blower box mods...

http://inlinethumb61.webshots.com/43004/2423411670032428117S600x600Q85.jpg

http://inlinethumb43.webshots.com/41450/2793469310032428117S600x600Q85.jpg

It also might be a good idea to use a marine sub or amp since its going to be semi out in the weather. This would also mean you could reduce the amount of sheet metal around everything for better sound. You pretty much have a sub blasting into a metal box, which I would imagine sounding very 'tinny'. Crutchfield has a bunch of marine stuff for good prices.

Also check out the shallow mount subs, which only require very small sealed enclosures.

Wow....tons of dedication and skill....a really impressive build sir!

Started working on the framework for the dash...

http://inlinethumb63.webshots.com/5758/2944934560032428117S600x600Q85.jpg

http://inlinethumb53.webshots.com/44532/2969669810032428117S600x600Q85.jpg

Well, I'm a huge fan of your rig; I'm glad you re-built after the roll, love that commitment! :cool2:

Quick question on your gas tank: it seems to be MIA.
Are you still running a stock tank?
Did you relocate it?

I just went back through the entire build and I didn't see it mentioned but in the most recent rear long-arm shots I don't see it there...

(I'm getting ready to stretch my rear axle and I'm trying to figure out what to do with my tank - would rather not have it in the trunk.)

Some pics of the gas tank... cut the stock tank & plated with 3/16". Did that mod probably 4 years ago and still holding up without any leaks.

http://inlinethumb58.webshots.com/43513/1089550229032428117S600x600Q85.jpg



http://inlinethumb23.webshots.com/46486/1089550515032428117S600x600Q85.jpg


http://inlinethumb26.webshots.com/44185/1090387752032428117S600x600Q85.jpg

http://inlinethumb22.webshots.com/45397/1090955161032428117S600x600Q85.jpg


http://inlinethumb33.webshots.com/45600/1090388473032428117S600x600Q85.jpg


http://inlinethumb11.webshots.com/14602/1090388146032428117S600x600Q85.jpg

http://inlinethumb40.webshots.com/43303/1090955522032428117S600x600Q85.jpg

More progress on the dash...

http://inlinethumb38.webshots.com/45285/2354083100032428117S600x600Q85.jpg


http://inlinethumb30.webshots.com/44893/2971382050032428117S600x600Q85.jpg


http://inlinethumb26.webshots.com/45017/2093900090032428117S600x600Q85.jpg


Ordered this receiver...
http://www.onlinecarstereo.com/CarAudio/p_22082_Clarion_CMD5_5cRB.aspx

Great build! Your fab skillz are amazing and your attention to detail is motivating.

One question on the dash (love the idea btw, I've already though about how to build one if/when I do a V8 swap) how do you take it back out? Looks to be welded in :confused:

Just amazing how this started and were it has been going.
Great build and some great skilzz!!

Some pics of the gas tank... cut the stock tank & plated with 3/16". Did that mod probably 4 years ago and still holding up without any leaks.

Thanks for the pictures - did you put RTV/Silicone on that lip and then weld it to the skid?

Very impressive. :cool2:
Dash is looking sick as well, I'm looking forward to seeing it painted up with gauges.

The gas tank skid was welded to the angle braces inside the tank... sealed the inside with a can of POR15 tank sealer. From what I can tell its held up well, no leaks but not sure what the inside of the tank looks like.

crazy build!! i everytime i got on my comp today i had to read more!!:grinpimp:

More progress on the framework for the dash.

http://inlinethumb31.webshots.com/43870/2007632970032428117S600x600Q85.jpg



http://inlinethumb13.webshots.com/31820/2840353870032428117S600x600Q85.jpg



http://inlinethumb26.webshots.com/45145/2973248320032428117S600x600Q85.jpg

http://inlinethumb36.webshots.com/46563/2062481560032428117S600x600Q85.jpg

That is awesome. I only have one question how much does this thing weigh. Jesus Christ that is alot of metal. But hey Ive not seen better fab skills ever dude....

Those are some great fab skills . my only question is why haven't you installed a v8?

But overall a awesome build :smokin:

Yeah its a lot of metal and is probably 4x heavier than it could be... I did use quite a bit of aluminum to help but really not overly concerned with weight cause its a pig anyway. Had I done it out of fiberglass it still would have been rather heavy and probably more complicated.


No V8 for this rig... gonna keep the I6 and build a mean 4.6L stroker... in time.



Some more progress on the dash... fabbing up the mounting plate for the center stack. Really like the Clarion CMD5 as its a marine unit and should handle the weather OK... plus I got it for $150 brand new.

The switches below the stereo will be for seat heaters and the center will be for the blower motor. In between the switches will be pulls for the heater & defrost... gonna use generic choke cables, more to come.


http://inlinethumb23.webshots.com/35158/2834085670032428117S600x600Q85.jpg



http://inlinethumb12.webshots.com/45899/2420871960032428117S600x600Q85.jpg


http://inlinethumb17.webshots.com/43920/2675503580032428117S600x600Q85.jpg

... how do you take it back out? Looks to be welded in :confused:

So...???

So...???

Why hell would he want to take it out? Looks killer.

So...???

probably the same way all the other tube would come off. with a torch or a grinder :flipoff2:

dude. wow. i look at this build and all i can do is drool.

Why hell would he want to take it out? Looks killer.

ever fired up your vehicle and had antifreeze pour out into your floorboard? shit breaks, that's why...

Yes the dash will need to come out... or at least parts of it.

The framework is all welded in place but many of th panels are aluminum and just unbolt. I can get to anything behind the dash to service... heater core, blower motor, wiring, etc.

If I need to get to anything else then... out comes the saw & grinder!!

I am kinda surprised after that roll i haven't seen some specialty seats with a 4pt setup or something like that?
As far as the build im speechless

Making good progress on the dash and nearing the home stretch with painting and wiring.


Glove box door is 1/4" aluminum with factory Jeep decals and then painted with Duplicolor bedliner... gives it a "molded in" look.

http://inlinethumb48.webshots.com/46895/2034505960032428117S600x600Q85.jpg

http://inlinethumb38.webshots.com/46757/2851142590032428117S600x600Q85.jpg



For the front speakers I'm using Polk 5.25"... painted the grills with bedliner too. Using foam baffles behind the speakers to help improve sound.

http://inlinethumb54.webshots.com/43253/2255869070032428117S600x600Q85.jpg

http://inlinethumb21.webshots.com/45460/2473719870032428117S600x600Q85.jpg




Switching all the HVAC controls from vacuum to cable actuated... using generic choke cable setup that I found in the "HELP" section of auto parts store.

BEFORE:
http://inlinethumb36.webshots.com/45219/2895127330032428117S600x600Q85.jpg


AFTER:
http://inlinethumb52.webshots.com/45875/2334894900032428117S600x600Q85.jpg

http://inlinethumb45.webshots.com/4972/2802872640032428117S600x600Q85.jpg



Starting to come together...

http://inlinethumb43.webshots.com/45162/2007801360032428117S600x600Q85.jpg

So when are you going to show some updates? I made an account just to see some more of this.

How does the audio sound?

Haven't posted any updates as I've been busy setting up a nursery... we're gonna have a boy!!! :D Very Exciting Times!!



As for the Jeep...

Got some small details done... converted the heater valve from vacuum actuated to cable driven. Same thing as I did with the defrost controls, used generic choke cable from Autozone.



Stock heater valve with vacuum actuator...

http://inlinethumb20.webshots.com/45395/2997118810032428117S600x600Q85.jpg


Modified to be cable actuated...

http://inlinethumb28.webshots.com/24667/2955956770032428117S600x600Q85.jpg






As for the stereo system... it sounds awesome!!! I am very pleased with the quality and volume of sound that the Polk speakers/sub and amp provide... good enough to still rock out even at hwy speeds in a topless, doorless, jeep on 35s. When the engine is off the stereo sounds great and really hits all the highs/mid with the front speakers and the output from the 8" sub is surprising.

Also there are absolutely no rattles or vibrations with the sub in a sheetmetal ensclosure... solid welds and lots of dynomat help!

http://inlinethumb13.webshots.com/8460/2916483110032428117S600x600Q85.jpg

http://inlinethumb50.webshots.com/45553/2953125810032428117S600x600Q85.jpg


http://inlinethumb10.webshots.com/45641/2188431260032428117S600x600Q85.jpg

http://inlinethumb07.webshots.com/3014/2977791940032428117S600x600Q85.jpg




Had to put getting the autometer gages on hold... need to spend the $$ on some beadlocks, currently Al rims are trashed and have cracks & gouges from all the rock beatings.

Also finished all the wiring for the lights, fan blower motor, compressor clutch, front ARB, engine fans, etc...

http://inlinethumb50.webshots.com/43057/2339307300032428117S600x600Q85.jpg


Next update will probably be with making some DIY beadlocks using AtoZ rings... http://www.atozfabrication.com/store/home.php?cat=282

I'm really glad to hear the sub works well. I'll look into a sheetmetal box for my next project.

looks great congrats on the baby

Congrats on the new baby. Your jeep days have now ended. LOL
Love the build.

Started working on the beadlocks. 15x8 Cragar "soft 8" wheels with AtoZ Fab DIY beadlock kit. For 5 wheels w/shipping.... $226 for the wheels from Summit racing, $374 for beadlock kit with grade 8 hardware... so $120/wheel isn't too bad.


Nothing like getting a bunch of new stuff!!

http://inlinethumb48.webshots.com/42607/2945839650032428117S600x600Q85.jpg


The AtoZ kit was laser cut from 1/4" steel & fit great, I did need to take a bit of time to put a chamfer on the edges as they were pretty sharp. Put a small countersink on the holes while I was at it.

http://inlinethumb62.webshots.com/893/2511098630032428117S600x600Q85.jpg

http://inlinethumb26.webshots.com/41817/2471264360032428117S600x600Q85.jpg


Removed all the paint and bt a nice chamfer on each of the edges so I could get good weld penetration and hopefully no leaks...

http://inlinethumb27.webshots.com/44250/2515310360032428117S600x600Q85.jpg

http://inlinethumb52.webshots.com/33075/2891302920032428117S600x600Q85.jpg


Sanded all the welds and now ready for some paint...

http://inlinethumb22.webshots.com/43669/2545251050032428117S600x600Q85.jpg

Old Aluminum rims were in rough shape... Al + rocks is not good for the long term.

http://inlinethumb05.webshots.com/45572/2291473460032428117S600x600Q85.jpg

http://inlinethumb12.webshots.com/47691/2584804500032428117S600x600Q85.jpg



Finally got them all put together... what a tedious job but no leaks! 5 tires, 160 bolts and it felt like I had to torque each one about 20 times before they held torque... jeez. The rubber continues to compress and also the beadlock ring starts to "cone" as the bolts squeeze the ring together.

I was also very pleased with how well a pint glass full of plast BBs in each tire worked at balancing the tire/rim combo... I had my doubts but it definitely works!!

http://inlinethumb06.webshots.com/43653/2915610570032428117S600x600Q85.jpg


http://inlinethumb27.webshots.com/27674/2210722690032428117S600x600Q85.jpg

http://inlinethumb15.webshots.com/46414/2915879220032428117S600x600Q85.jpg

looks great man, i just did 15x10 d windows with weld on 1/4 inch bead locks
no matter how much people talk about bead locks being a pain to put together, its far worse than you expect haha

I was also very pleased with how well a pint glass full of plast BBs in each tire worked at balancing the tire/rim combo... I had my doubts but it definitely works!!


You just put plastic BBs in the tires? That's really it?

I was wondering how the heck you would balance a beadlock.

How are you liking driving with them? Lastly are they considered street legal?

i did the same thing, 8oz of air-soft pellets is what i used in each tire
theres a guide somewheres that tells you how much weight to run for what size tire/wheel you are running
im on 15x11 locks on 35's

i did the same thing, 8oz of air-soft pellets is what i used in each tire
theres a guide somewheres that tells you how much weight to run for what size tire/wheel you are running
im on 15x11 locks on 35's

That's crazy, I never would have thought of doing that.

I thought it would just be a huge PITA to get them balanced.

http://www.innovativebalancing.com/BigTirechart.htm

I know you have been told that you have an awesome Jeep but the attention to detail is great. If you could post some pictures of the rear coil spring set up that would be great also likes verses dislikes on coils verses leafs in the rear

Thanks

http://inlinethumb48.webshots.com/46895/2034505960032428117S600x600Q85.jpg

http://inlinethumb38.webshots.com/46757/2851142590032428117S600x600Q85.jpg

Nice touch, I might steal that.

Yeah that glove box door is a nice touch.

+1 I don't know how I missed the glove box door the first time through.
Cool idea to make it look molded using the stock emblems with the bedliner.
Neat trick :grinpimp:

So when are you going to post some pics of the updated cab? Still looking forward to seeing it done.

Don't have much to update on the build... too busy going wheelin!!!

I am really lovin the beadlocks and being able to run lower pressures with confidence, one of those things I wish I had done sooner.

The dash has hit a stall point and I am out of $$ so the gauges will have to wait.

Some trail pics from recent trip to Harlan, KY... most of the shots are at "Lion's Den". Didn't get many of my rig but some good ones of my wheelin buddies. Nice chopped XJ with lots of new cage work and other mods... and a turbo diesel Toyota pickup that is always a blast to watch out on the trail!

...the yota is only locked in the rear, open front diff.

http://inlinethumb37.webshots.com/40164/2839019630032428117S600x600Q85.jpg

http://inlinethumb50.webshots.com/47665/2986044230032428117S600x600Q85.jpg

http://inlinethumb19.webshots.com/11858/2611884470032428117S600x600Q85.jpg

http://inlinethumb33.webshots.com/24288/2630290400032428117S600x600Q85.jpg

http://inlinethumb19.webshots.com/23378/2143723070032428117S600x600Q85.jpg


The weather was perfect and just enough rain to make a few puddles and keep the dust down...

http://inlinethumb63.webshots.com/46206/2044630200032428117S600x600Q85.jpg

AlteredXJ,

As for the rear coils...

Some of things I have noticed running coils & links compared to leaf springs

- Rides much smoother with coils both on the road and on the trail, especially on higher speed stuff on rough trails, feels like a squishy marshmellow over all but the harshest stuff but a lot of that is due to shock valving.
- Body roll with coils is greatly increased but adding a rear sway bar makes it as stable if not more than with the leafs. Its not so bad that I would call it unstable or unpredictable but you can feel the roll especially when switching directions thru turns, lots of roll at the transition point but then settles in.
- No axle wrap with the links and improves control of tire spin and during climbs
- More articulation with coils & links... shock length limited

If I were to do it again I would go right to coilovers instead of seperate coils and shocks... easier to dial in the spring rate and shock valving. I would also run a double triangulated 4 link instead of a 3 link wishbone upper... the wishbone arm is not all that easy to adjust and it takes a lot of abuse that would be nice to distribute to 2 seperate arms.

Some pics of the coils...

http://inlinethumb18.webshots.com/5329/1403588954032428117S600x600Q85.jpg

http://inlinethumb44.webshots.com/363/1403517527032428117S600x600Q85.jpg

http://inlinethumb43.webshots.com/44650/1403517460032428117S600x600Q85.jpg

Some shots of the mods to the stock Ford explorer sway bar that came with the 8.8...

http://inlinethumb11.webshots.com/74/1403518589032428117S600x600Q85.jpg

http://inlinethumb01.webshots.com/46336/1403538273032428117S600x600Q85.jpg


I have had good luck with running the lower links with minimal angle... not triangulated so they do very little work locating the axle laterally. I can easily redo them and mount them off this crossmember...

http://inlinethumb06.webshots.com/389/1099870781032428117S600x600Q85.jpg


Did have some issues in the beginning with the springs walking around in the buckets, added some tabs around the coil OD to help...

http://inlinethumb47.webshots.com/46446/1444104222032428117S600x600Q85.jpg

http://inlinethumb14.webshots.com/14669/1450956462032428117S600x600Q85.jpg

Coil mount crossmember...

http://inlinethumb28.webshots.com/2075/1088493679032428117S600x600Q85.jpg



Would like to push the upper shock mount into the cab to get a little more length but works OK as is...

http://inlinethumb16.webshots.com/46927/2533667060032428117S600x600Q85.jpg


http://inlinethumb01.webshots.com/33664/1436197695032428117S600x600Q85.jpg

Thanks for the info I like how you made your coil mounts. What are you running for rear springs? I think this may be next winters project. I was thinking of doing more of a triangulated 4 link and making adjustable upper coils brackets to help dial in ride height. I wish coil overs were in the budget but its not going to happen soon.

thanks again

Rear coils are stock WJ front springs. The spring rate works out pretty well and is not too stiff, if anything they might be a bit soft.

Haven't made any progress on the XJ, but we did have a little boy on 6/4... he was 8weeks early and only 2.5lbs but doing great!

http://inlinethumb22.webshots.com/44245/2423258380032428117S600x600Q85.jpg

Congrats & good luck!!!

Best of luck to your little guy in getting big and healthy. Hope your wife recovers well, and enjoy any bit of sleep you can get man. Nice build!

Congratulations on your future wheeler. watch out though they grow up fast then take over.

this is the first ever forum message for me and im glad to wish you congrats on the new baby.
as a fellow ME student i to been having thoughts of this very mod to my xj. my own personal cad program in my head wont shut up about it. when i saw this thread it looked just like what i had been visualizing for weeks now. i hope to T-top front and fully remove rear, and like you be able to replace as hard top. any input on the multi-piece removable top from you would be an honor.

Congrats on the baby, and your skills are awesome dude.

Congrat's, raise'em up right!

Thanks all, little Jack is doing well and should be able to come home from the hospital today!

Red'83 - I'm digging the idea behind your T-top XJ but tough to answer questions or give advice without seeing some of your ideas first.

Finally got a little $$ and dropped some on a Speed, Tach, and water temp gauge... Autometer Ultra Lites.

http://inlinethumb53.webshots.com/45748/2655210720032428117S600x600Q85.jpg

http://inlinethumb11.webshots.com/46410/2429575340032428117S600x600Q85.jpg

Decided to drill and tap the thermostat housing to put the new water temp sender... could have removed the factory temp sender but wasn't sure if it would impact the fuel injection system so just left it alone.

Before...
http://inlinethumb29.webshots.com/46812/2204235840032428117S600x600Q85.jpg


After...
http://inlinethumb21.webshots.com/45012/2124485170032428117S600x600Q85.jpg


More pics to come of the gauges wiring harness, updates will be slow as $ and baby allow.

Finished up the installing all of the gages. Temp gages on the left... Oil, trans, water. Fuel pressure, air pressure, volts, and oil prssure on the right.

http://inlinethumb24.webshots.com/46807/2006406470032428117S600x600Q85.jpg

http://inlinethumb57.webshots.com/47800/2757218340032428117S600x600Q85.jpg

http://inlinethumb16.webshots.com/46927/2963683860032428117S600x600Q85.jpg


Oil temp and pressure sending units... replaced the factory pressure sender with the auto meter one. The temp sender installs in a T fitting off of my oil filter adapter piece.

http://inlinethumb09.webshots.com/43784/2064903160032428117S600x600Q85.jpg

The wiring wasn't too bad but it looks a little messy...

http://inlinethumb28.webshots.com/6555/2873800880032428117S600x600Q85.jpg

Pulled fuel pressure off the main rail... took out the valve core and ran -4 AN line to the mechanical gage.

http://inlinethumb24.webshots.com/45271/2718174290032428117S600x600Q85.jpg

Really incredible work. I was sent here from another post to look at the dash pics and it was almost the last thing posted. But it was worth reading all the way through. The only question i have is what is the weight? I know you have built this thing like a tank and just curious if you have ever weighed it. Love the ingenuity and the attempt at keeping thre truck looking factory from the outside. I am guessing you still havent decided on a color yet, or did the primer grow on you? haha

Josh

By far one of my favorite threads. Nice work on the whole build its cool to see all the different things you have done to a XJ.

Finished up the installing all of the gages. Temp gages on the left... Oil, trans, water. Fuel pressure, air pressure, volts, and oil prssure on the right.


Its been a while since you did this, but do you happen to still have the info on where you got the gages, and sending units? I'm really wanting to add all those when I make a custom dash in my YJ. Also does the speedo you added have an easy way to adjust it? (Mike is 15-20 off)

Its been a while since you did this, but do you happen to still have the info on where you got the gages, and sending units? I'm really wanting to add all those when I make a custom dash in my YJ. Also does the speedo you added have an easy way to adjust it? (Mike is 15-20 off)

On your YJ you should be able to replace the gear on the end of your speedo cable right inside the t-case output housing where it reads from. Search "Jeep yj speedo gear" on google and it pulls up all kinds of good info. Hope this helps.

Josh

On your YJ you should be able to replace the gear on the end of your speedo cable right inside the t-case output housing where it reads from. Search "Jeep yj speedo gear" on google and it pulls up all kinds of good info. Hope this helps.

Josh

Yes it does have a gear, but when I make a custom dash it will most likley be turned into an electric speedo rather than the current mechanical one. Otherwise yes changing the gear would solve my delema.

Yes it does have a gear, but when I make a custom dash it will most likley be turned into an electric speedo rather than the current mechanical one. Otherwise yes changing the gear would solve my delema.

I just assumed that an electric speedo would still have to read off of your transfercase the same way so instead of being attached to end of the cable it would be attached to the sending unit that reads the speed and tranfers that data to the new speedo. My apologies.

Josh

I got all of the gauges (senders included) from here... http://www.egauges.com/

I have still not gotten the electric speedo to work correctly. The factory transfer case has a sender on it but the pulse signal is not clean and makes it difficult to calibrate the autometer speedo. The speed is fairly accurate but sender noise causes it to bounce all over the place, even when stopped sometimes. I am planning on making a signal generator with a couple of magnets picking up on the tcase rear output flange... got a buddy into rally racing and they use something similar so hoping it will hold up to wheelin.

I have also removed the aftermarket oil cooler since it really wasn't needed and with it I pulled the adapter/takeoff block from underneath the oil filter. So I needed to relocate the oil temp and oil pres senders... pulled the factory sender out from above the oil filter adapter and put a T in, both gauges now work very well with no rapid fluctuations.


Been busy travelling for work and rest of the time with the baby so not much time to work on the XJ... with fall coming its getting into prime wheelin season, looking forward to a least 2 good outings already planned!!

dash looks fuggin sick man, i love havin shit loads of gauges.

congrats on the baby too

Haven't posted for a while as I haven't got too much time to work on the the XJ. Been doing a bit of wheeling and finding that stuff breaks a lot more with 35s than it did with 32s... shredding tires, numerous D30 shafts, busted D30 ARB, steering box & pump, etc...

I know I need to upgrade the front axle but $$ is just not there right now... thinking about a beefed up JK D44... no need for a D60 as 37s would be the biggest I would go.

http://inlinethumb12.webshots.com/23435/2805730140032428117S600x600Q85.jpg

http://inlinethumb24.webshots.com/46999/2812589060032428117S600x600Q85.jpg


After burning up an AGR super pump (no cooler) I decided to drop some $ on a PSC pump, remote resovoir, a cooler and get a bigger steering box out of a '99 durango. All of these upgrades are working very well and I should have done this a while ago... hydro assist will come later as this setup is doing ok for pushing around 35s.

Had a minor issue with pulley alignment on the PSC pump but all I needed to do was pull the pulley about 3/8" off the shaft (PSC recommendation).

http://inlinethumb25.webshots.com/46616/2946164360032428117S600x600Q85.jpg

http://inlinethumb11.webshots.com/32714/2704864000032428117S600x600Q85.jpg

http://inlinethumb04.webshots.com/46979/2457443120032428117S600x600Q85.jpg

http://inlinethumb22.webshots.com/26005/2516892870032428117S600x600Q85.jpg


Got my son his first jeep too... working on upgrading the flinstone power! :shaking:

http://inlinethumb38.webshots.com/13733/2236738430032428117S600x600Q85.jpg


Also spent some time putting the top and full doors back on for the winter... not an easy task since it hasn't been on since the rollover... need to get the pic uploaded.

awesome work man i dig it!

What did you decide to go with for a front axle? I am in the same boat, I trashed my R&P at the last ride.

altered,

Still pushing the D30 for now as I was able to repair the ARB and get it back rolling... however, I'm leaning toward a beefed up JK D44 as a longer term fix.

What direction are you leaning... run with the big dogs and build a D60??

Bad ass, man! When I get my buggy done, we'll have go to Windrock! Hit me up on facebook: 5 Brothers Fabrication...

you got any better pics of the cage actually tying the cage into the a,b,c pillars?

No 60 Yet but I acquired a set of Waggie D44s. Drawbacks I don't want to change my wheels. So for now a new R&P for the 30 Like you it's the cheapest way out

Some pics of the cage... sorry so crappy pic quality

http://inlinethumb45.webshots.com/36268/1160293532032428117S600x600Q85.jpg

http://inlinethumb55.webshots.com/35254/1159447080032428117S600x600Q85.jpg

This is looking at the connection to the windshield frame/A-pillar... 1/2" plate running out the the edge of the body to help keep the windshield frame from flexing when leaning it into something...

http://inlinethumb34.webshots.com/2209/1160296285032428117S600x600Q85.jpg

http://inlinethumb45.webshots.com/45036/1159447794032428117S600x600Q85.jpg

http://inlinethumb43.webshots.com/23082/1147705891032428117S600x600Q85.jpg


http://inlinethumb38.webshots.com/2341/1348122706032428117S600x600Q85.jpg


http://inlinethumb02.webshots.com/15745/1348122769032428117S600x600Q85.jpg

Your thread inspired me to register so I could say:

What a great THREAD on so many levels.

I appreciate your work & more thank you for taking the extra time for the pics & explanations.
It is great to see so many fresh ideas for an XJ. Its also great to see a rig built to show & go. (Not just once but twice after rolling it)

LASTLY, Congrats on the liitleman. You will have much fun together in your jeep, I am sure.

I like how you did the rear portion of the cage...

Iam kinda throwing around the idea of designing my cage to end up being more of a buggy set up later on.. boatside it to the "Uni-rails" along with having sliders.. That way if i deside to cut the charokcar off of it, The links n shocks will all be tied into the frame itself... Idea's are fun at first..

This is really awesome! You did the a great job :)

I like how you did the rear portion of the cage...

Iam kinda throwing around the idea of designing my cage to end up being more of a buggy set up later on.. boatside it to the "Uni-rails" along with having sliders.. That way if i deside to cut the charokcar off of it, The links n shocks will all be tied into the frame itself... Idea's are fun at first..

Will never happen....... fix your junk :flipoff2:

Started working on a new center console...

http://inlinethumb40.webshots.com/42471/2589720690032428117S600x600Q85.jpg

http://inlinethumb35.webshots.com/45986/2447149640032428117S600x600Q85.jpg

http://inlinethumb25.webshots.com/42840/2675235090032428117S600x600Q85.jpg




can i have fries with that jeep:D lol

Haven't posted in a while... it got crazy cold down here this winter so put the top back on it. It took a little work to get it to fit since it hasn't been back on since the rollover. Overall it fit back on pretty well and confirmed my hopes that the cage wasn't tweaked in the roll. The extra weight of the top/rack/full doors really puts a strain on the tired 4.0 but it seals up fairly well.

Out wheelin in Royal Blue National Forest in Tn...

http://inlinethumb38.webshots.com/46053/2326222890032428117S600x600Q85.jpg


Added a new magnet & sensor to the rear output flange to control the Autometer Speedo... it didn't like the pulse counts coming from the factory sensor in the t-case.

http://inlinethumb08.webshots.com/47879/2999476000032428117S600x600Q85.jpg


Really became apparent with the extra weight of the top and doors that the rear coil springs were under some load and needed a little help... air bags. They seem to work pretty well and totally supported a 500lb load of concrete block that I was hauling in the back. Doing the same thing previously and the shocks were completely bottomed out... this time had a good 3" of travel left.
It does make it ride significantly more firm even with 20psi in the bags, max is about 60psi.

http://inlinethumb07.webshots.com/48966/2487424500032428117S600x600Q85.jpg


Took about 6 hours to do the whole install and that was mostly spent fabricating the upper bag mounts and lower bump stops

http://inlinethumb56.webshots.com/46263/2974981070032428117S600x600Q85.jpg


How to inflate/deflate, came with the Air Lift kit... worked for testing... working on a better control system.

http://inlinethumb43.webshots.com/45994/2219415910032428117S600x600Q85.jpg

Finished up the control panel for the air bags. There are two paddle valves to control each side independently... isolating them helps control roll/pitch. The gauge is a dual needle so I can watch both sides and keep them even. The problem is that the gauge reads to 200psi and it gets used in the 10-20psi range... +/- 5psi is about the best accuracy one can hope for. Plus the gauge is too low so it makes reading it a challenge when driving... other than that it works great!

sorry for the crappy phone pics...

http://inlinethumb61.webshots.com/19196/2121178660032428117S600x600Q85.jpg

http://inlinethumb18.webshots.com/45009/2205428790032428117S600x600Q85.jpg

http://inlinethumb48.webshots.com/47535/2584806350032428117S600x600Q85.jpg

another cool idea, as per usual hey

Got out and did some wheeling last weekend and I was very pleased with how the rear air springs did... not only on the high speed sections but also when crawling around on some big boulders.

The bags act like a progressive bumpstop and they eliminated all of the bottoming out that I was having before. They also do not limit the travel (with 10psi in them). I ran it very hard and there is no sign of wear on the bags, hope they hold up for the long run!

http://inlinethumb04.webshots.com/30787/2820205660032428117S600x600Q85.jpg

http://inlinethumb38.webshots.com/45861/2215279320032428117S600x600Q85.jpg

A couple videos from the weekend...

http://rides.webshots.com/video/3062126580032428117xOfmYa

http://rides.webshots.com/video/3061451380032428117hFEAbj

Awesome fab work! I have been thinking of doing something very similar with the removable hard top. I live in new england so a roof is very important to me. When I get to it I will probably borrow a few ideas from your build if thats cool. And again awesome work! Great build! Congrats on the kid!

I'm new to this forum,but I gotta say what a sick ride. My 98 is in the early stages and you've completed idea's I've only thought of. Nice work

Flexy email me at jedzillmer@hotmail.com I'm stationed at fort campbell Id like to chat a little bit about your fab skills. Your located in TN right? Ever been out to LBL?

Im sure this thread is dead, but I joined this forum specifically to tell you that you have the cleanest xj Ive ever seen, and thanks for the inspiration!:beer:

Thread is not dead... been wheeling but not much else being done to it until $$ allows.

http://rides.webshots.com/video/3020608980032428117TRMApj

I don't see any pics??? Me, or??

I can

All I see are red x's.

It looks cool without top and doors!! I have a question about you moving axle forward 4 inches, what changes to steering did you have to do?

Man awesome determination and ingenuity.

As has been said before, I am absolutely astonished. I stumbled across this thread last year because I was wanting to do a soft-top conversion for my WJ. I couldn't find a WJ with the top cut, but I did find your killer XJ.

Your fab work is nothing short of amazing. If you don't mind me asking (I'm totally new to metalwork) what tool do you use to cut your steel and aluminum? I ask because your cuts are always so clean and straight.

Really incredible work you've done man I have been following since the start and just felt the need to post that. :grinpimp: Keep it up!

Looks good!

all i have to say is WOW!!!!!

Last time out I busted the remaining grill mounts...

http://inlinethumb34.webshots.com/49569/2120654350032428117S600x600Q85.jpg


For some time now I have been wanting to eliminate the grill and sink the front bumper up to the radiator for improved approach angle.

Also, the ARB with winch mounted in it was a pain to take on/off so I wanted a new winch mount as well.

I cut out the factory cross member and mounted the winch as far back as I could... the before shots...

http://inlinethumb46.webshots.com/48877/2262602220032428117S600x600Q85.jpg

http://inlinethumb19.webshots.com/50386/2235870570032428117S600x600Q85.jpg


Ran into lots of clearance issues with the Mustang electric fan so ended up mounting the winch more forward and lower than I wanted... still tucked up about 5" closer to the motor.

http://inlinethumb31.webshots.com/34654/2344545830032428117S600x600Q85.jpg

http://inlinethumb02.webshots.com/16001/2496305440032428117S600x600Q85.jpg

Next it was time to cut up a perfectly good ARB bumper...

http://inlinethumb35.webshots.com/50594/2369535570032428117S600x600Q85.jpg


I wanted to reconfigure the brush guard to wrap tight around the headlights and trim them up for more clearance. LED turn signals and parking lights to come...

http://inlinethumb49.webshots.com/50352/2677670660032428117S600x600Q85.jpg

Cut the headlight buckets from the original grill and will remount them in the modified brush guard.

http://inlinethumb50.webshots.com/49329/2398410630032428117S600x600Q85.jpg

Progress to date... one side is getting close to being done

http://inlinethumb10.webshots.com/50057/2664842710032428117S600x600Q85.jpg

http://inlinethumb63.webshots.com/49982/2503546100032428117S600x600Q85.jpg


Saved about 5" hanging out the front... and about 4" vertically (at the outside edges)

http://inlinethumb54.webshots.com/37685/2866320580032428117S600x600Q85.jpg

http://inlinethumb34.webshots.com/49185/2229310190032428117S600x600Q85.jpg


Frame mount... will have attachment points in other locations too

http://inlinethumb51.webshots.com/46770/2029132710032428117S600x600Q85.jpg



Lots left to do... LED turn signals, LED parking lights, shackle brackets, grill, driver side brush guard, and working on a idea for a cool CNC milled JEEP badge.

Getting time to work on it has been an issue so probably take another month or so to finish.

Interested to see how it turns out mate. I'm no stranger to cutting up ARB bars as you know. ;)

Th is thread is awesome i love the work, i just signed up for pirate, this thread basically convince me to. lots of ideas i also had invisioned, now i have an example. Keep up the supurb work

Thats funny Marcus... was thinking about you when I was hacking that bumper apart! :)

... that "ARB" rear bumper you made is one of the best Ive seen on an XJ! :smokin:






Got the other brushguard upright and tube work mounted... trying to make progress when I can.

Got the LED lights for turn signal and parking lights, and a couple of honk'n 1" thick steel shackle mounts to weld on the front from AtoZ fab. ...I'm diggin the lights... get some pics later.

http://inlinethumb47.webshots.com/49326/2254225500032428117S600x600Q85.jpg

Thanks mate for the comments on the rear bumper. Is the only one I have not changed since its first build, but on my 3rd modified ARB front bar and made a 4th for someone else. Happy now though as it matches the rear perfectly what I have now. :)
Keep up the good work.

A shot of the CAD image for the badge that will be going front and center on the brushguard tube.

Its gonna be CNC cut from 1/2" thick aluminum plate, then black annodize the whole thing and finally skim cut the letters to remove the black and give the letters a nice contrast.

This is the kind of jewelery I can get into!!

http://inlinethumb27.webshots.com/32026/2348905950032428117S600x600Q85.jpg

I like it looking good.

Progress has been slow but steady...

Here are the LED lights that I am using for turn signals & parking lights.

http://inlinethumb16.webshots.com/47631/2962695680032428117S600x600Q85.jpg


http://inlinethumb51.webshots.com/32242/2218189290032428117S600x600Q85.jpg


Gonna have to lengthen the hood a bit to fill the void left by the old grill...

http://inlinethumb38.webshots.com/50085/2021431830032428117S600x600Q85.jpg


http://inlinethumb45.webshots.com/49004/2069554690032428117S600x600Q85.jpg

Looks tough, nice work on the grille/brushgaurd integration.

new bumper looks great.

Instead of lengthening the hood, why not just cut the top out of the header panel and attach it back to the core support?

I'm lovin your build. especially your consoles, and flares. I may just have to play with some flares like this. I saw this question earlier but didn't see an answer, what did you use for your cup holders?

Cup holders...

http://www.amazon.com/T-H-Marine-Stainless-Steel-Holder/dp/B000LC8SCE

I've said it before. Great build. All your missing is grill off of a peterbuilt.:grinpimp:

Finished the grill...

http://inlinethumb29.webshots.com/32220/2490114620032428117S600x600Q85.jpg


Struggled a bit with the headlight trim piece. Not so easy to get a tight fit and also function for headlight alignment. Now I gotta make one for the other side...

http://inlinethumb47.webshots.com/49582/2031416170032428117S600x600Q85.jpg


The lower LEDs cast a decent amount of light but they are not focused at all for the road to act like a "driving light". I can see them being used best as work/utility lights, with nice low power draw.

http://inlinethumb10.webshots.com/48137/2380650630032428117S600x600Q85.jpg

http://inlinethumb31.webshots.com/49758/2556261610032428117S600x600Q85.jpg

this whole thing is amazing! awesome work man. love the bumper, very clean and original

Nice job on the headlight surround. I always hated the stock plastic ones.

what is your approach angle now?

Gonna have to check my approach angle now... i'm curious too.

bit more progress... going ahead with doing the flat fenders and having them mount to the new bumper, should tie it all together nicely.

Cut the bulge out of the factory inner fender so that I can slide the axle forward another inch or two.

http://inlinethumb24.webshots.com/50647/2927378940032428117S600x600Q85.jpg

http://inlinethumb60.webshots.com/48827/2555006460032428117S600x600Q85.jpg

Replaced the battery with a Odyssey 1700 w/ metal jacket...

http://inlinethumb15.webshots.com/4046/2666886320032428117S600x600Q85.jpg


I see it's been about 5 years since you installed your Odyssey battery, care to share your experience? I'm trying to decide if the cost is justified...

Also, what made you go with the 1700 instead of the 1500, which is the standard replacement for a Cherokee? (I see it has slightly higher ratings on PHCA, MCA and CCA, but are there any other reasons?)

Thanks.

I have been very pleased with the performance of the Odyssey 1700.... it holds a charge very long even in storage, always cranks the motor over, and when needed for winching it has not let me down. I even left my parking lights on overnight and it still started up in the morning... granted it was slow to crank but it started!!

I am hoping to get 10yrs out of this battery (mfg suggested life) and if it makes it that long then I would say that I got my $$ out of it. As of now I have seen no indication that it will fail anytime soon.

As for choosing the larger 1700 over the 1500... I was looking for a single battery that acted like 2 or 1.5 batteries with the extra reserve if needed. So far I have not pushed it as much as planned (long winch pulls with dead motor, etc) but I think it would handle it.

It has lived it whole life on its side with no ill effects or leakage... I'm sure an Optima would do the same.

If it lasts as long as I hope then I will be buying another Odyssey.

Ten year battery, that's impressive.

I am extremely impressed with your skills and vision.... 1 quick question, what are you using to cut all your fab pieces, like the 3/16 plate, and all the flat metal stuff? torch, plasma, cut off wheels, band-saw or what... I need to upgrade my stuff, doing it all now w cutoff wheels and a grinder, and trying to decide best way to go for least amount of $$$$ Thanks

Unfortunately all of the cutting is done with cut off wheels or recip saw... sucks, so damn dirty and takes forever. A plasma cutter is next on my list for big tools for sure... if shop space is no issue then a nice vertical bandsaw would be nice.

Been working on making flat fenders that tie into the bumper...


Before:

http://inlinethumb17.webshots.com/46928/2637527540032428117S600x600Q85.jpg


Cut out the stock inner fender and bent up a replacement piece...
http://inlinethumb24.webshots.com/50647/2927378940032428117S600x600Q85.jpg

http://inlinethumb60.webshots.com/48827/2555006460032428117S600x600Q85.jpg



http://inlinethumb49.webshots.com/49968/2954987290032428117S600x600Q85.jpg

http://inlinethumb14.webshots.com/50381/2628745710032428117S600x600Q85.jpg

http://inlinethumb60.webshots.com/47803/2453355900032428117S600x600Q85.jpg

I was wondering what that bulge on the side of the brush guard was. That is ingenious.

So for my t top roof Idea is on hold, money, go figure.

shit noooo....it stopped!

http://www.cherokeeforum.com/attachments/f46/33982d1294805431-rollng-felony-story-thumb_i_want_moar.jpg

what did you end up doing with your emergency brake? I saw that you removed but said nothing as to where you put the new one?

The ebrake never worked anyway so after pulling it I replaced it with line locks front & rear.


Front line lock...

http://inlinethumb24.webshots.com/30295/2293012610032428117S600x600Q85.jpg

http://inlinethumb38.webshots.com/31269/2049415440032428117S600x600Q85.jpg


Rear line lock...

http://inlinethumb39.webshots.com/29798/2873631410032428117S600x600Q85.jpg

http://inlinethumb29.webshots.com/31388/2647728820032428117S600x600Q85.jpg


I have had good luck with using these high end compression fittings instead of flaring the brake lines. They are Yor-lock brand

http://inlinethumb07.webshots.com/32198/2540328030032428117S600x600Q85.jpg

I like that line lock setup, been thinking about doing something like that on my rig. Have you used it on the trail yet? The rear line lock would be nice for front digs, if you have a twin stick setup. Your front end is really coming along, looks great! Lots of time spent on this build for sure. Great job :smokin:

Been using the line locks for a couple years now and they work very well! The full mechanical locks work much better out in the woods than those electro-mechanical locks that drag racers use... they can fail after being on for a while... not what you want when holding on a hill.

Just hold the brake pedal to the floor, engage the locks, and it will hold pressure for days if not weeks. With the front and rear locked its not going anywhere.

No twin stick, yet.... that will come with the Atlas, whatever decade that happens in!

Hands down..... sickest XJ bumper I have ever seen. Simply amazing work. :eek:

It keeps getting better... totally thrilled with the Jeep badge...

CNC from 1/2" 6061, powder coated flat black, then fly cut the lettering to a almost polised finish.

http://inlinethumb20.webshots.com/47507/2318751290032428117S600x600Q85.jpg

http://inlinethumb06.webshots.com/49029/2439229900032428117S600x600Q85.jpg

http://inlinethumb04.webshots.com/47619/2719868420032428117S600x600Q85.jpg

http://inlinethumb02.webshots.com/51009/2458979380032428117S600x600Q85.jpg

http://inlinethumb29.webshots.com/51100/2824851840032428117S600x600Q85.jpg


Next shots should be with paint

Knocked out the hood vents this evening while bumper paint is curing.

Got 'em from Genright... $61 shipped w/rivets included

http://www.genright.com/ProductInfo.aspx?productid=LVR1000


http://inlinethumb30.webshots.com/51037/2490238400032428117S600x600Q85.jpg

http://inlinethumb31.webshots.com/50206/2404910370032428117S600x600Q85.jpg

http://inlinethumb55.webshots.com/43446/2150969460032428117S600x600Q85.jpg

More updates... bumper is 100% finished, painted, wired and mounted.

Painted the body an ultra flat olive drab... I'm diggin it compared to the primer grey that I had on there for years.

http://inlinethumb10.webshots.com/47433/2027494160032428117S600x600Q85.jpg

http://inlinethumb30.webshots.com/50845/2680565390032428117S600x600Q85.jpg

http://inlinethumb14.webshots.com/48973/2772259400032428117S600x600Q85.jpg



Remounted the computer with the new inner fenders...

http://inlinethumb08.webshots.com/51335/2037506210032428117S600x600Q85.jpg



Trim piece between the bumper and the hood... this was the stock grille header that I just cut to fit. It mounts to the radiator support.

http://inlinethumb05.webshots.com/48708/2339859250032428117S600x600Q85.jpg

http://inlinethumb52.webshots.com/50867/2830502520032428117S600x600Q85.jpg

Placed some new fender badges...

http://inlinethumb33.webshots.com/51424/2361097340032428117S600x600Q85.jpg


Hope to get a better shot of the whole rig once it stops raining...

http://inlinethumb45.webshots.com/50988/2447593140032428117S600x600Q85.jpg

http://inlinethumb51.webshots.com/20978/2089188340032428117S600x600Q85.jpg

wow:eek:

great work on the front end!!!

Come up well mate and the colour is much better than the primer. :)

Just read your thread from start to finish amazing!!! Love the bumper/grille you look at it and know it's not right but hard to figure out why love it jeep shoulda built them this way to start.

http://inlinethumb06.webshots.com/50949/2908923830032428117S600x600Q85.jpg

http://inlinethumb21.webshots.com/50580/2522207710032428117S600x600Q85.jpg

http://inlinethumb58.webshots.com/51513/2903817710032428117S600x600Q85.jpg

http://inlinethumb12.webshots.com/51083/2266130610032428117S600x600Q85.jpg

Best xj ever, I love your rig man. Keep up the good work

Jeep badge plate mounted on the rear bumper. Duplicate of the one on the front... hopefully I won't hear "What is that thing... a Toyota??"

I'm hoping the red locktite and epoxy under the plates will keep them in place in case someone likes them as much as I do! :flipoff2:


http://inlinethumb04.webshots.com/51523/2754619440032428117S600x600Q85.jpg

http://inlinethumb05.webshots.com/50308/2916690390032428117S600x600Q85.jpg




A good project is never done so some of the things I will be working on...
- Modifying my tow bar to work with the new bumper so I can get my rig to Harlan, KY for a trail ride 6/8-6/10
- Adjust suspension to push front axle forward another 1.5" - 2" depending on how much spline I have left on the front driveshaft
- Paint the half doors
- Fix a leaky air regulator (for front ARB)
- LED rock/work lights
- LED reverse/work lights
- scrounge some $$ for Wet Okole seat covers (fronts at least w/seat heaters :smokin: )

Thats what I can see getting done in the next few months before heading out run the RUBICON!!!!

For those that have run the RUBICON... link me to some good writeup and pics so I can see what were in for!

This is prolly the cleanest rig I have seen on here! I have said it before but I'll say it again, very nice work! I would like to do some fenders similar to yours. I have always wanted to run Rubicon, maybe some day.

Good job! Very excellent clean work! I like the flat fenders, be expecting to hear more people doing that as I probably will too.

What kind of fan did you replace the clutch fan with?

Replaced the mechanical fan with one from a 3.8L Mustang or I think Taurus fans are the same... pretty popular electric fan due to it draws a ton of air (and power). It has a HIGH and LOW speed both wired through big relays... the HIGH actually uses a starter solenoid due to the high ~80amp startup load, LOW speed is a 40amp relay.

http://inlinethumb07.webshots.com/37190/2327169990032428117S600x600Q85.jpg


Had to trim the heck out of the shroud to get it to fit next to the factory electric fan...

http://inlinethumb10.webshots.com/4297/2760579640032428117S600x600Q85.jpg

Replaced the mechanical fan with one from a 3.8L Mustang or I think Taurus fans are the same... pretty popular electric fan due to it draws a ton of air (and power). It has a HIGH and LOW speed both wired through big relays... the HIGH actually uses a starter solenoid due to the high ~80amp startup load, LOW speed is a 40amp relay.
Where are the fan installed photos and wiring schematics?

Dont really have any good ones of the fan fully installed, here it is with test fitting...

http://inlinethumb52.webshots.com/41203/2658423800032428117S600x600Q85.jpg


http://inlinethumb09.webshots.com/1544/2888037580032428117S600x600Q85.jpg


Here you can see some of the filler panels that I made from pieces of lexan and just mounted to the shroud with brackets/rivets and epoxy...

http://inlinethumb44.webshots.com/43307/2603134040032428117S600x600Q85.jpg


I'll see if I can put together a schematic on the quick...

smoked lexan