I am starting a new thread for this jeep since the old one has so much BS in it.

EDIT 9/24/11:ORSnow owns the stage two XJ and will be using it as an advertisment for the new stiffeners and skid plates we will be offering soon!

I am building this for a very good friend. Donnie (hillclimber227) has been one of those guys that has always been there no mater what. So as a token of my gratitude for all that he has done for me and my wife, I am building this for free. Of corse he is paying for the parts.

96 4 door
4.0/ AW4/ 231 SYE

1988 ford 60 front. 35spl. 4340 shafts with longfield 300M u-joints and driver flanges. 5.38's spartin locker. heavy shave.

rear 60 (unknown origin) 35spl. 4340 shafts, full spool, 5.38's, disk brakes, and heavy shave

40" LTB's on chrome H2's and inner air locks.

PSC hydro assist. with custom high steer.

3link front with ORI struts, and flipped rear XJ leafs. rustys shackle and superlift AAl.

And a hole bunch of custom body work.

So we started this 2/25/09 in Donnie's dad's shop.

He bought the XJ for $600 running and driving due to this and a cracked header which was an easy fix.
http://img18.imageshack.us/img18/1160/img2362x.jpg

First we stripped it down
http://img21.imageshack.us/img21/6712/img2372.jpg
http://img18.imageshack.us/img18/2828/img2335i.jpg

Droped the tank into the floor
http://img6.imageshack.us/img6/6145/img2369h.jpg

Then came the plate! caped the front crossmeber with 5/16's
http://img11.imageshack.us/img11/5563/img2337.jpg

then some 3/16 for the reast
http://img22.imageshack.us/img22/1139/img2340p.jpg
PS box prace and start of the bumper
http://img10.imageshack.us/img10/5773/img2344.jpg
http://img18.imageshack.us/img18/4222/img2351s.jpg
then caped the bottom
http://img14.imageshack.us/img14/710/img2360.jpg
http://img10.imageshack.us/img10/1560/img2364p.jpg

then started the bracing
http://img6.imageshack.us/img6/4160/img2367p.jpg

http://img21.imageshack.us/img21/4166/img2386.jpg

http://img12.imageshack.us/img12/1386/img2387y.jpg

http://img22.imageshack.us/img22/7619/img2390c.jpg

http://img16.imageshack.us/img16/8577/img2384r.jpg

http://img6.imageshack.us/img6/9869/img2388.jpg

http://img12.imageshack.us/img12/6254/img2389.jpg

http://img27.imageshack.us/img27/2804/img2382.jpg

http://img21.imageshack.us/img21/8981/img2383o.jpg

http://img21.imageshack.us/img21/9525/img2381a.jpg

Got the pass. side plates welded in and the bottom plating done.
http://img294.imageshack.us/img294/3135/img2394.jpg

http://img82.imageshack.us/img82/4306/img2397.jpg

Then I started the ever so tedious task of stripping off all the undercoating.
http://img294.imageshack.us/img294/6453/img2403.jpg

http://img379.imageshack.us/img379/5261/img2404.jpg

First side plate
http://img294.imageshack.us/img294/9092/img2405.jpg

Then the bace plate with nuts welded in for the flat belly pan.
http://img294.imageshack.us/img294/7845/img2407.jpg

got the pass. frame rail striped
http://img18.imageshack.us/img18/1106/img2416.jpg
I started on the inside of the frame... dont wory not done there yet.
http://img27.imageshack.us/img27/4647/img2415.jpg
and the rear frame plates... still not done there eather.
http://img13.imageshack.us/img13/214/img2414s.jpg
a picture of me welding, and vince pretending to work... :flipoff2:
http://img27.imageshack.us/img27/619/img2412v.jpg
http://img15.imageshack.us/img15/5240/img2413p.jpg
and the finished product as of tonight.:( wish the pace would pick up some.
http://img13.imageshack.us/img13/3969/img2418.jpg

The front HP60 that we picked up for $800 with matching rear thats not shown
http://img19.imageshack.us/img19/4112/img2448.jpg
And we got our pile of metal
http://img17.imageshack.us/img17/1932/img2445c.jpg
Got the shop all cleaned up
http://img18.imageshack.us/img18/5289/img2443.jpg
http://img13.imageshack.us/img13/7048/img2457g.jpg
http://img12.imageshack.us/img12/3650/img2450z.jpg
http://img27.imageshack.us/img27/3960/img2518f.jpg
http://img23.imageshack.us/img23/5260/img2517c.jpg
http://img6.imageshack.us/img6/4838/img2514m.jpg
http://img19.imageshack.us/img19/594/img2524b.jpg

http://img16.imageshack.us/img16/2685/img2525c.jpg
http://img14.imageshack.us/img14/546/img2526.jpg
http://img16.imageshack.us/img16/592/img2527.jpg
http://img16.imageshack.us/img16/8517/img2528.jpg

(The 8.8 is not staying)
Got the perches built shackles on, AALs installed and leafs mounted.
http://img14.imageshack.us/img14/5079/img2545u.jpg
started the rear bumper, D-ring mounts
http://img13.imageshack.us/img13/471/img2563p.jpg
2x4x3/16" tube
http://img14.imageshack.us/img14/7485/img2571s.jpg
1/2x1/2x1/8" tube
http://img13.imageshack.us/img13/1707/img2572n.jpg
the bumper is welded through the Dring mounts. Will also be welded to the rear quarters and have the exo tied in. Not to mention the gas tank skid that will be welded to the frame rails and to it.

last thing I did to the jeep while it was at Donnie's dad shop. 4/27/09
http://img21.imageshack.us/img21/6139/img2627s.jpg

Then 7/20/09 thing started back up at the shop I was working for.
frame side lower control arm mounts.
http://img512.imageshack.us/img512/968/img2845gyn.jpg

Axle striped, webbing cut and smoothed, and started shaving/plating the knuckles
http://img406.imageshack.us/img406/5600/img2846.jpg

http://img17.imageshack.us/img17/893/img2839quf.jpg

http://img401.imageshack.us/img401/8803/img2841.jpg

http://img512.imageshack.us/img512/6903/img2843.jpg

http://img174.imageshack.us/img174/7027/img2844.jpg

http://img401.imageshack.us/img401/5300/img2847m.jpg
http://img11.imageshack.us/img11/9530/img2850xeb.jpg
http://img521.imageshack.us/img521/1120/img2849m.jpg
http://img269.imageshack.us/img269/3566/img2851pvn.jpg
http://img521.imageshack.us/img521/3974/img2852.jpg

http://img401.imageshack.us/img401/6070/img2853u.jpg
http://img35.imageshack.us/img35/5033/img2854l.jpg
http://img129.imageshack.us/img129/6851/img2859.jpg

IMG]http://img31.imageshack.us/img31/9585/img2862w.jpg[/IMG]

http://img404.imageshack.us/img404/3856/img2864x.jpg

http://img195.imageshack.us/img195/147/img2865idc.jpg

Inner fenders are done. I added some vents for for the trany cooler to breath through. There will be a hood vent too, just above the driver fender well. I am mounting it just like I did my ZJ.

http://img36.imageshack.us/img36/6879/img2871e.jpg

http://img36.imageshack.us/img36/9653/img2874f.jpg

Will be mounting the cooler and fan the same way
http://img14.imageshack.us/img14/9137/img2302tw3.jpg

And started on the frame side link mounts
http://img269.imageshack.us/img269/7383/img2876d.jpg

just a start...
http://img36.imageshack.us/img36/6107/img2880c.jpg

upper link mount started. still going to add some cool trix to it...:smokin:
http://img263.imageshack.us/img263/186/img2890y.jpg

upper frame mount is done
http://img11.imageshack.us/img11/8066/img2888f.jpg

axle mount tacked in place
http://img263.imageshack.us/img263/7601/img2892t.jpg

upper link stared. It will be a fabricated link, but my dimple dies wont be here till friday. tube is 1.75 .120 with 1.5 .120 inside. It's bent 15* to clear the floor board and keep the JohnyJoint straight.
http://img407.imageshack.us/img407/9088/img2911.jpg

http://img11.imageshack.us/img11/3920/img2910q.jpg

http://img12.imageshack.us/img12/8663/img2908x.jpg

http://img228.imageshack.us/img228/8199/img2897c.jpg

sleaved the weld in bung with this 2" .250 DOM that I had milled to slip over.
http://img395.imageshack.us/img395/7618/img2919.jpg
then plug welded
http://img55.imageshack.us/img55/305/img2920n.jpg
started trussing the upper link
http://img373.imageshack.us/img373/1606/img2921.jpg
welds
http://img373.imageshack.us/img373/8530/img2923.jpg
mounted
http://img364.imageshack.us/img364/6311/img2927.jpg
lower mount, and link that I bent 25*. more work to come here when the dimple dies come in.
http://img55.imageshack.us/img55/2554/img2936.jpg
http://img395.imageshack.us/img395/886/img2937.jpg
lower clearance.
http://img266.imageshack.us/img266/2755/img2931u.jpg

http://img387.imageshack.us/img387/3950/img2942.jpg

http://img387.imageshack.us/img387/8076/img2939.jpg

http://img132.imageshack.us/img132/9730/img2949e.jpg

http://img387.imageshack.us/img387/6729/img2948.jpg

http://img258.imageshack.us/img258/8666/img2943.jpg

http://img383.imageshack.us/img383/69/img2945.jpg

http://img339.imageshack.us/img339/8461/img2963m.jpg

http://img517.imageshack.us/img517/3231/img2965b.jpg

http://img190.imageshack.us/img190/7673/img2969mry.jpg

I had the high steer arms drilled to 1" ID and a chromolly bushing machined to 5/8" ID 1.015 OD and pressed in to keep the hole from whallowing out whiththe hiems and 5/8" bolts.
http://img44.imageshack.us/img44/8343/img2982m.jpg
the upper CO mounts
http://img269.imageshack.us/img269/9909/img2988rfs.jpg
lower
http://img205.imageshack.us/img205/8585/img2986.jpg
http://img44.imageshack.us/img44/6281/img2984z.jpg
http://img44.imageshack.us/img44/237/img2989a.jpg


Bolted up the high steer arms, got the coilover mounts all tacked in and got it supporting it's self. Unbolted the rear end and flipped the springs
http://img199.imageshack.us/img199/7751/img3012y.jpg

Finished mounting the tranny cooler
http://img40.imageshack.us/img40/4702/img3013a.jpg

Nothced the hood to clear the fan and welded a patch back into the hood support.
http://img524.imageshack.us/img524/9863/img3007d.jpg
http://img403.imageshack.us/img403/643/img3010.jpg

Got some new Chrome H2 wheels. And the 40" LTB's are on their way from Interco!
http://img35.imageshack.us/img35/3914/img3011jyd.jpg

got everything buttoned up under the hood.

PCM mount
http://img297.imageshack.us/img297/4481/img3020a.jpg

http://img20.imageshack.us/img20/6483/img3019r.jpg

fues block
http://img196.imageshack.us/img196/5827/img3021x.jpg

http://img43.imageshack.us/img43/4148/img3022y.jpg

http://img197.imageshack.us/img197/4983/img3023m.jpg

I tapped the PS box, started the belly pan, installed the SYE, and built all the skid plate tabs.

http://img33.imageshack.us/img33/8643/img3033y.jpg

http://img267.imageshack.us/img267/2430/img3024.jpg

http://img44.imageshack.us/img44/2707/img3035e.jpg

http://img197.imageshack.us/img197/7938/img3037xxc.jpg

http://img24.imageshack.us/img24/1470/img3038z.jpg

http://img197.imageshack.us/img197/2646/img3039wnq.jpg

cross member just about done (need to add some ribs to the tranny mount)
http://img140.imageshack.us/img140/789/img3040g.jpg
http://img218.imageshack.us/img218/5858/img3042lcz.jpg
http://img15.imageshack.us/img15/1756/img3044ywo.jpg
http://img263.imageshack.us/img263/4766/img3045y.jpg
http://img140.imageshack.us/img140/3568/img3046j.jpg
http://img7.imageshack.us/img7/256/img3048i.jpg
http://img218.imageshack.us/img218/4994/img3050b.jpg

went and got the rearend, FF60 67" WMS-WMS. And got it torn down

Worked on the skid some more. I still need to counter sink the 1/2" bolts and drill four more holes, Along with all the bracing that needs to be added. But here is what it looks like.
http://img7.imageshack.us/img7/879/img3055a.jpg
http://img23.imageshack.us/img23/4091/img3057j.jpg
http://img207.imageshack.us/img207/4596/img3058o.jpg
http://img291.imageshack.us/img291/2585/img3056i.jpg
http://img207.imageshack.us/img207/9458/img3061o.jpg
http://img23.imageshack.us/img23/4452/img3063m.jpg
Some of the axle parts came in. 35spl. 4340 inner and outer, 5.38 gears, rear spool, front lock-rite. still waiting on diff covers, disk brake kit, Bobby long 300M u-joints and drive flanges.
http://img176.imageshack.us/img176/8035/img3059h.jpg

http://img268.imageshack.us/img268/3234/img3147j.jpg

http://img5.imageshack.us/img5/2655/img3150wpd.jpg

http://img34.imageshack.us/img34/6757/img3152b.jpg

http://img188.imageshack.us/img188/1883/img3153h.jpg

http://img514.imageshack.us/img514/674/img3155d.jpg

Finished the truss
http://img7.imageshack.us/img7/881/img3157i.jpg

Got the tires mounted up.
http://img12.imageshack.us/img12/4548/img3165nyj.jpg
http://img7.imageshack.us/img7/685/img3164yax.jpg

Built the drag link and started on the pitman arm. All the steering joints will be double shear.
http://img524.imageshack.us/img524/9281/img3161.jpg
http://img35.imageshack.us/img35/9114/img3166s.jpg
http://img199.imageshack.us/img199/7812/img3173h.jpg

here it is done
http://img215.imageshack.us/img215/1121/img3174x.jpg
http://img412.imageshack.us/img412/2536/img3178.jpg
http://img26.imageshack.us/img26/1621/img3179g.jpg

track bar and mounts ALSO NOT DONE
http://img215.imageshack.us/img215/498/img3183.jpg
http://img215.imageshack.us/img215/2527/img3187fkuexfaxdo.jpg
http://img29.imageshack.us/img29/6725/img3181f.jpg
http://img188.imageshack.us/img188/541/img3188r.jpg

STARTED the double shear tabs for the knuckles
http://img29.imageshack.us/img29/2029/img3189hoj.jpg

double sheared all the steering
http://img249.imageshack.us/img249/7362/img3194t.jpg
http://img269.imageshack.us/img269/673/img3195y.jpg

finished the track bar mounts (still need to weld the axle side, but I am going to pull the axle for that) and I forgot to get pics of the axle side
http://img38.imageshack.us/img38/1433/img3204j.jpg

braced the tranny mount and finished the belly pan... drilled the last few holes and counter sunk them.
http://img194.imageshack.us/img194/874/img3210u.jpg
http://img132.imageshack.us/img132/755/img3208k.jpg

And mounted the tires up to check for clearance. Which it all cleared, exept the lower link braces, so I will have to make a differand brace.
http://img21.imageshack.us/img21/6577/img3203nyq.jpg
http://img21.imageshack.us/img21/4584/img3197g.jpg
http://img38.imageshack.us/img38/3052/img3198i.jpg
http://img22.imageshack.us/img22/8554/img3199b.jpg
http://img194.imageshack.us/img194/7070/img3201k.jpg

http://img207.imageshack.us/img207/4984/img3218f.jpg

http://img197.imageshack.us/img197/2951/img3222fiy.jpg

http://img194.imageshack.us/img194/9987/img3221f.jpg

http://img14.imageshack.us/img14/9891/img3224t.jpg

http://img259.imageshack.us/img259/599/img3223l.jpg

Well the fun shit has started.

After I got the axle in the back...
http://img20.imageshack.us/img20/194/img3231x.jpg
http://img269.imageshack.us/img269/1267/img3234g.jpg
about 2.5" over ride hight
http://img175.imageshack.us/img175/6084/img3226.jpg
http://img20.imageshack.us/img20/4070/img3227k.jpg

I started cutting, but dont even ask whats going on. It's to hard to explain and its nothing ever done before so... Just sit back and watch.
http://img269.imageshack.us/img269/3936/img3228r.jpg
http://img175.imageshack.us/img175/9075/img3235.jpg
http://img222.imageshack.us/img222/4769/img3237w.jpg
http://img20.imageshack.us/img20/9681/img3239w.jpg
http://img222.imageshack.us/img222/2285/img3240w.jpg
http://img407.imageshack.us/img407/1271/img3241r.jpg

here is the passenger side rocker.
Befor
http://img18.imageshack.us/img18/1160/img2362x.jpg
After
http://img197.imageshack.us/img197/6827/img3246z.jpg
http://img31.imageshack.us/img31/4190/img3243f.jpg
Cut the body
http://img526.imageshack.us/img526/3086/img3248b.jpg
and bent some tube
http://img269.imageshack.us/img269/5018/img3249v.jpg

http://img35.imageshack.us/img35/8295/img3251n.jpg
http://img29.imageshack.us/img29/2011/img3260o.jpg
http://img502.imageshack.us/img502/7537/img3262.jpg
http://img35.imageshack.us/img35/7361/img3265t.jpg
http://img402.imageshack.us/img402/5391/img3264z.jpg

cut the front fender and A pillar and the front of the tube that is bent out will be tied into the front bumper.
http://img402.imageshack.us/img402/222/img3269.jpg
http://img141.imageshack.us/img141/5025/img3270.jpg

top rail
http://img141.imageshack.us/img141/6567/img3272e.jpg

D-piller
http://img405.imageshack.us/img405/9513/img3273.jpg

Cut the C-piller, and moved the rear wendow frame back to clear the top bend
http://img141.imageshack.us/img141/3594/img3279.jpg
http://img56.imageshack.us/img56/6995/img3283.jpg
http://img194.imageshack.us/img194/5825/img3286g.jpg
http://img33.imageshack.us/img33/6058/img3285l.jpg

a still need to tweek on the back C-piller tube
http://img194.imageshack.us/img194/5629/img3289y.jpg

all the scrap tube so far... I think I am doing pretty good about keeping waist low.
http://img405.imageshack.us/img405/3129/img3287.jpg

second A-piller bar tied in, second B-piller bar tweeked and paint sanded off.

http://img220.imageshack.us/img220/3535/img3292.jpg

http://img441.imageshack.us/img441/6089/img3291a.jpg

http://img441.imageshack.us/img441/876/img3293.jpg

http://img213.imageshack.us/img213/9638/img3295j.jpg

Got almost all the passenger side tubes bent, now I just got to cut them down and fit them into the body.

http://img215.imageshack.us/img215/9279/img3299.jpg

put the driver side back on after welding all the seams
http://img199.imageshack.us/img199/174/img3363a.jpg

then startedthe passenger side.
http://img33.imageshack.us/img33/4254/img3367s.jpg
http://img178.imageshack.us/img178/279/img3366t.jpg
http://img34.imageshack.us/img34/7589/img3369ax.jpg
http://img142.imageshack.us/img142/770/img3371k.jpg
http://img178.imageshack.us/img178/4584/img3372s.jpg

finished mocking up the passenger side and pulled it apart to weld and sand away the paint.
http://img15.imageshack.us/img15/536/img3375s.jpg
http://img29.imageshack.us/img29/6672/img3377y.jpg
http://img29.imageshack.us/img29/3967/img3378u.jpg
http://img12.imageshack.us/img12/4380/img3379x.jpg

Got the passenger side all put together
http://img182.imageshack.us/img182/3824/img3381.jpg

front leaf springs hangers plated
http://img182.imageshack.us/img182/7691/img3391.jpg

Boat sides started. Driver side almost done.
http://img156.imageshack.us/img156/3558/img3396o.jpg

OH AND I HATE HOLE SAWS AND DIMPLE DIES. :mad3: I spent 4 hours cutting holes and dimpling this one plate... it will be getting black 1/4" UHMW over it
http://img34.imageshack.us/img34/5681/img3402j.jpg
http://img14.imageshack.us/img14/7410/img3404h.jpg
http://img156.imageshack.us/img156/8271/img3406h.jpg

had to build this because my press wasn't wide enough.
http://img30.imageshack.us/img30/9978/img3405y.jpg

got to work on it a little this afternoon.

welded up the supports, and tacked the 1/8" backer into place
http://img338.imageshack.us/img338/5313/img3411.jpg

then made a few cuts
http://img245.imageshack.us/img245/9012/img3413n.jpg
http://img443.imageshack.us/img443/9351/img3416b.jpg

welded it up
http://img199.imageshack.us/img199/9236/img3417d.jpg
http://img42.imageshack.us/img42/7338/img3418i.jpg

Then Work stopped again on 9/17/09

Then I broght the jeep over to my new shop last week and started doing stuff in my free time. So work resumes.

http://a.imageshack.us/img198/4224/img5118q.jpg
http://a.imageshack.us/img717/3843/img5122c.jpg
http://a.imageshack.us/img826/351/img5119b.jpg
http://a.imageshack.us/img718/8539/img5124r.jpg

If you have an questions I will be happy to answer them again. If you dont want to wait for my reply, read through the first thread. It probably in there.
http://www.pirate4x4.com/forum/showthread.php?t=764951

Glad to see you are back in action.

Good luck with the business and the rest of the build.

Nice Work Mister.:smokin:

this is one sick ass build. good work man

That jeep has some dimples! Dang man lots o' work. Looks great tho.

are you working with full width axles? Just wondering if i'm going to have tire interference with control arms if i don't bend them. I'm doing similar 3 link in front with 42's on full width ford dana 60.

oh, and great idea, reposting this up without having 14 pages :) Nothin but quick descriptions and pictures galor! Wonderful, great work man. Can't wait to see how your tubed bodywork turns out.

are you working with full width axles? Just wondering if i'm going to have tire interference with control arms if i don't bend them. I'm doing similar 3 link in front with 42's on full width ford dana 60.

oh, and great idea, reposting this up without having 14 pages :) Nothin but quick descriptions and pictures galor! Wonderful, great work man. Can't wait to see how your tubed bodywork turns out.

Yes they are full width, but we are using H2 wheels that have 5.5" BS (If I remember right). So if you have a pre 1980 ford axle you can leave them straigh if you keep the axle mount close to the diff. If it's 1980+ then you will need to put some kind of bend in them or mount them further inward. On my ZJ I have the lowers centered under the tranny since I am running a nerrowed 04 ford 60 with straight lowers.
http://a.imageshack.us/img12/9067/img2231cx1.jpg
and yah the other thread was pretty cayotic

what is the clearance of that rear 60 vs a stock 44?

1/8" more clearance than a 44! I will also be shaving the front axle the same way.

1/8" more clearance than a 44! I will also be shaving the front axle the same way.

Good stuff there. 42s wi

th better clearance than a 44, I like it.

Nice build man. Quick qestion about the tube crosmemeber. How did you modify the plate to fit the cut out section of the tubing for the front output of the transfer case?

Nice build man. Quick qestion about the tube crosmemeber. How did you modify the plate to fit the cut out section of the tubing for the front output of the transfer case?

I'm pretty sure he just flipped the section he cut out and welded it back in upside down.

This is nothing short of a work of art....:eek:

Nice build man. Quick qestion about the tube crosmemeber. How did you modify the plate to fit the cut out section of the tubing for the front output of the transfer case?

I'm pretty sure he just flipped the section he cut out and welded it back in upside down.

No fliping the piece I cut out wouldn't work. It would actualy make the tube be even more in the way.

What I did was... take a piece of paper lay it into the '"hole". then take your fingers and crease the edges. then cut out the shape that is left in the paper. Transfer the shape to some plate, cut out the oval shape, then bend it to fit into the hole. Weld it in and grind it smooth.

To bend the plat to fit... this works for bending any plate. I put it in my vice, then start taping it with a dead blow. I move it in 1/4"-1/2" increments every time I hit it. I go back and forth till it's the perfect chape.

The filler plate.
http://a.imageshack.us/img140/789/img3040g.jpg

that tube frame looks really really cool! but why the double tubing? seems like overkill or would be better to go with something stronger if your really needed two tubes instead of one.

not criticizing, just wondering why you did it that way.

http://img29.imageshack.us/img29/3967/img3378u.jpg

It's differant, no one has ever done it this way, and that is how I invisioned it. When it is all done it will all look like one piece. And once the doors are on you will see how they flow and how just one wouldn't have worked. I am going to fill in between the tube and weld it all into the body then mold it all so that it's perfectly smooth and flows together.

Edit: and its not very heavy, I can lift each side pretty easly. There is only 100-125lbs of tube total in the cage so far.

The tube work is phenominal. I've seen an S10 done like that and it's always looked pimp:smokin:

Fucking rad tube-work!

No fliping the piece I cut out wouldn't work. It would actualy make the tube be even more in the way.

What I did was... take a piece of paper lay it into the '"hole". then take your fingers and crease the edges. then cut out the shape that is left in the paper. Transfer the shape to some plate, cut out the oval shape, then bend it to fit into the hole. Weld it in and grind it smooth.

To bend the plat to fit... this works for bending any plate. I put it in my vice, then start taping it with a dead blow. I move it in 1/4"-1/2" increments every time I hit it. I go back and forth till it's the perfect chape.

The filler plate.
http://a.imageshack.us/img140/789/img3040g.jpg

Cool man, thanks for the info. I thought it was a bit too flat to be the piece that you had cut out.

fuck yeah man, this build turned me on to pirate in the first place, glad to see its back on the go

I bought a bender today along with 1.75, 1.5 and 1" dies. The metal will be here tomarrow to build my press for the dimple dies. So maybe by next week I will have my tools together do I can move forward.

Damnit Action Fab, the masses demand more updates!

so glad ur back to building this beast... i would check everyday on the last build up for my daily dose of xj porn so i could drool allday at work over it. but i agree the build up was getting cluttered way to clean it up and get back on the ball... best of luck with ur new shop man.

One of my favorite builds on here. Like everyone else said, glad to see updates!

I will be checking it on a regular basis :smokin:

killer fab work!
can you explain the process of welding to the cast sections of the axles?
special wire? pre or post heat needed? or do you just mig it the same as the tubes?

I used .035 wire with my welder set on 21.2 volts, and buned it in then wraped it in a welding blanked and let it cool slow. I also did all of that in the summer when it was over 100*. It is cast steel and welds easly but it is pooris so the cooling slowly is what is key to the weld being strong. The cast steel will cool much faster than the weld and will "pull away" causing a crack. So you have to let them cool at the same rate. Another good way to do it is to stick them on the grill after welding. Then with the cover closed let the grill cool slowly on it own and it will thus let the cast parts cool slowly too.

Hey it may have been mentioned in the other 14 pages, but what kind of tube and wall thinkness are you using? Thanks

1.75 .120 hrew.

Any updates, Chris?

X2 ^^^

here is the passenger side rocker.
Befor
http://img18.imageshack.us/img18/1160/img2362x.jpg
After
http://img197.imageshack.us/img197/6827/img3246z.jpg
http://img31.imageshack.us/img31/4190/img3243f.jpg
Cut the body
http://img526.imageshack.us/img526/3086/img3248b.jpg
and bent some tube
http://img269.imageshack.us/img269/5018/img3249v.jpg

http://img35.imageshack.us/img35/8295/img3251n.jpg
http://img29.imageshack.us/img29/2011/img3260o.jpg
http://img502.imageshack.us/img502/7537/img3262.jpg
http://img35.imageshack.us/img35/7361/img3265t.jpg
http://img402.imageshack.us/img402/5391/img3264z.jpg


One of these things doesn't belong here.
One of these things is not the same...

LOL!
Billy

Some of the best fab I've ever seen. No Joke.

Great build so far. You do awsome Fab work.

amazing work. its like everything that you fab is WOW!

great work cant wait to see it finished.
great skills and good luck on new venture sure you wont be sure of work with them fab skills

subscribed, nice build so far

Well I am glad ou guys like it. I just wish I could finish it some time soon. But paying jobs come first, and those are really startng to mound up on me.

I'm sure that pretty dress has been bringing in all the customers^^^^^:flipoff2:

I dont really know why thats there?

But paying jobs come first, and those are really startng to mound up on me.


good situation to be in ;) if anyone spends money on stuff they dont have to i always thank em, it helps everyone out these days when the $$$ get movin

Ok guys, Donnie asked me to post this... As much as I hate to.

He is considering selling the Stage two XJ... :eek:

It will come as is with the parts listed in this thread. The only things that will not be included are the 40" tires, H2 wheels or suspension seats. Those are all on his new TJ that I am wrapping up now. He is tired of seeing it rot and dosn't feel he needs another rig on tons and 40's since he has the TJ and just bought a 4 door JK to serve as the 4 door wheeler. He is also getting married in a week, trying to remodel his second house so he get get it put on the market along few other money pits he has in his life this just isn't a priorety.

I am going to offer this a few ways...

First:Turn Key... I can put it together, finish the cage mount the factory seats in it, plub all the flued systems, finish the suspension, finish the bumper, put the axles together. For this price you will get a running driving, ready to wheel Stage two XJ that will only need wheels, tires and paint. I can have it done May 1st of 2012.

$18,000 (We can discuss plans to finish it baced on your specs and wishes and that may leave the turn key price subject to change)

Second:Complete but unfinished. Baisicly you will have to finish what I listed above along with buying coilovers, tires, wheels, drive shafts, along with any other needed parts to finish the build. Donnie has about $10,000 in parts and would like to recoupe the money he has put into those parts. If I were to have charged Donnie labor there would have been somewere in the neighborhood of $12K in labor thus far... You can come get it right now as it was last sceen in the photos above sitting on rollers with the windshield and all the new parts still packed in there new boxes, for...

$8000

Third:
part out...

The chassis minus the axles and steering (I'll include a set of roller axles and stock steering box) with clean title. $4500

Front and Rear axles with the knuckles (no steering arms) all the new bling parts and link mounts as they sit. $4000 (I will shave the front to match the rear for an extra $500)

Steering system with double sheer high steer arms, double sheer pitman arm, 3/4 heims, 1.5x.250 DOM tie rod/drag link, tube clamp for ram, PSC ram with hoses, and fresh taped box. $1000

This is your chance to own on of the most well known and well built XJ's to come across the pages of Pirate4x4. This Jeep is a work of art and at the prices above you are getting it for less than half the build cost. If you are seriouse feel free to call the number listed below in my signature, or PM me or Donnie (Hillclimber227).

-Chris

Hahahaha.... You only thought this was a dead project... I worked out a deal with Donnie and now I am the proud owner of the stage two XJ! :flipoff2:

Some time this spring I will bring her to life. :grinpimp:

The tube work looks great. Are you using 1.75 x .120 tube?

1.75 .120 hrew.

The tube work looks great. Are you using 1.75 x .120 tube?

Got it for ya:flipoff2:

Hahahaha.... You only thought this was a dead project... I worked out a deal with Donnie and now I am the proud owner of the stage two XJ! :flipoff2:

Some time this spring I will bring her to life. :grinpimp:

I have two things to say to you.

1) Thats great news, its good to hear this thing will be finished.

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2) HURRY UP ALREADY!!!!!!!!! :flipoff2:

2) HURRY UP ALREADY!!!!!!!!! :flipoff2:

Yah yah... it's time is coming... I'm thinking April/May.

Got it for ya:flipoff2:

oh hey thaks that's real nice of you! :flipoff2:

back to work.

nice Dress :grinpimp:


anyhow... love your fabwork.

I am interested to see how the fawk you got that case flat. did you clock it? what did you do about the bend in the unibody? I see when you plated it you just went flat, did you put a spacer piece in there, or did you just leave a gap?

I built a flat crossmember for my transmission and that still didn't make my t-case flat to the frame rails. unless you did some floor cutting and did not post piktars?!?

interesed in how you are gonna do your upper front shock mounts too.

nice Dress :grinpimp:


anyhow... love your fabwork.

I am interested to see how the fawk you got that case flat. did you clock it? what did you do about the bend in the unibody? I see when you plated it you just went flat, did you put a spacer piece in there, or did you just leave a gap?

I built a flat crossmember for my transmission and that still didn't make my t-case flat to the frame rails. unless you did some floor cutting and did not post piktars?!?

interesed in how you are gonna do your upper front shock mounts too.

I can't remember what t-case he's running, and you didn't mention what t-case you're running, but check out my write-up on clocking a 231... on the cheap no less. Mine is above my frame rails. The link is in my sig.
Billy

I did not clock it. My frame plates add about 3/4" to the bottom of the frame rail.

The Jeep changed hands again. My buddy silent bob is the new owner and he's paying me to finish it! So; the build lives on. It's undergoing some changes. The body is going bye bye... we chopped the top tonight and I'm working to get it ready for sandblasting next week. Then I can get started on fab work again.

http://img163.imageshack.us/img163/3113/img949s.jpg

http://img217.imageshack.us/img217/8188/img947.jpg

I did not clock it. My frame plates add about 3/4" to the bottom of the frame rail.

The Jeep changed hands again. My buddy silent bob is the new owner and he's paying me to finish it! So; the build lives on. It's undergoing some changes. The body is going bye bye... we chopped the top tonight and I'm working to get it ready for sandblasting next week. Then I can get started on fab work again.


Wait...What? The body still being there was the sweetest part of the cage. I know you will still make it look great, but i'm a little sad the body went bye bye.
:(

It does look like Silent Bob.

It does look like Silent Bob.[/QUOcan

You have no clue. The dudes legit.

[QUOTE=Jeepinkid83;14167668]Wait...What? The body still being there was the sweetest part of the cage. I know you will still make it look great, but i'm a little sad the body went bye bye.
:(

Yeah well money is a concern now, so we're cutting labor hours where we can.

Action Fab are you ever going to finish a project of your own? :flipoff2::flipoff2::flipoff2:

Action Fab are you ever going to finish a project of your own? :flipoff2::flipoff2::flipoff2:


Shit I wish! I'm gathering parts to build a shop buggy. Enough of this full body rig shit. Plus it's hard to work on my own stuff when people are begging me to work on their projects. It's hard to justify turning paying jobs away for my own crap.

Shit I wish! I'm gathering parts to build a shop buggy. Enough of this full body rig shit. Plus it's hard to work on my own stuff when people are begging me to work on their projects. It's hard to justify turning paying jobs away for my own crap.

Just giving you shit :D Between "rock solid revival" and this rig I wanted to see what other tricks you had up you sleeves. When xo_jeep and I picked up the "rock solid revival" I was hoping this rig would be at the shop. Glad to hear business is good.

Just giving you shit :D Between "rock solid revival" and this rig I wanted to see what other tricks you had up you sleeves. When xo_jeep and I picked up the "rock solid revival" I was hoping this rig would be at the shop. Glad to hear business is good.

It was out there at my lake house under the other car port... LOL

As for tricks, well I've got a TON of hair brain ideas. But finding someone willing to pay me to create them... well that's hard to find. Part of the reason business is doing so well is I've quite giving all my buddies the hookup. Well because lets face it all my buddies are into rock crawling and all my customers are buddies. Now that I'm actually charging for my work like I should I'm making money.

Imagine that. :laughing:

It was out there at my lake house under the other car port... LOL

As for tricks, well I've got a TON of hair brain ideas. But finding someone willing to pay me to create them... well that's hard to find. Part of the reason business is doing so well is I've quite giving all my buddies the hookup. Well because lets face it all my buddies are into rock crawling and all my customers are buddies. Now that I'm actually charging for my work like I should I'm making money.

Imagine that. :laughing:

I'll keep an eye out in gen4x4 for an ORS shop buggy build:smokin:

Back from sand blasting. Word is shocks are bought/being bought. 1 guess its getting 2.5 air shocks. Work is slammed still... its 11:00pm and I'm still here working. But this thing is going to receive attension ASAP.

http://img135.imageshack.us/img135/6828/img1161ci.jpg

Kick ass, glad to see this project rolling again, even if it doesn't have a "full" body!