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Old 11-11-2016, 10:14 AM   #1 (permalink)
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Honky Lips builds a bigger xj costing much more money than the last one

Built this xj to have fun with. got tired of breaking axles real fast. had about 2000 invested. parted it out for about 3500. Been kicking around the idea of going full retard for a few years now. decided its time to pull the trigger and get this build out of the way so i can concentrate future finances on other stuff. like my model t thats been neglected for almost 2 years. we dont have any wheeling closer than 2.5 hours from me. so my goal is to build something hard to break so i dont drive 3 or more hours and break in a few hours. I promised myself this build would have excellent steering. because my last two have had shit steering. homebrew hydraulic on my k5, stock on the xj. both sucked and made wheeling a bummer. and the brakes are going to be good, for the same reasons as the steering.

plans for build are as follows.
3 link front 4 link rear
d60/14ff
atlas 4 speed xfer case
4.0 auto transmission
psc steering
aluminum beadlocks
trep 40-42" stickies. (this depends on how much snow i get this winter, if not much just gonna go tsl's in a 40is flavor.)

bought this. 4 speed atlas with 5.45 ratio. sexy beef.

Pic of the starter Cherokee. It was a good time.
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Old 11-11-2016, 10:17 AM   #2 (permalink)
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picked up 4x4 outpost drive slugs for 35 spline d60 used.
and ruffstuff showed up today. this is all the smaller stuff. still waiting on frame stiffiners and whatnot.
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Old 11-11-2016, 10:24 AM   #3 (permalink)
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psc 2.75" dual ended ram with p pump steering setup. makes me wanna touch myself.

roll control i found laying around. be good for an e brake.

and warn 9.5 winch.
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Old 11-11-2016, 10:36 AM   #4 (permalink)
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d60 balljoint axle is wating for solid inner c's and outer knuckles and hi steer arms. 4.10 gears in the axles since i can gear down using the atlas case. (This idea was abandoned in favor of 5.38 gears because reasons.)
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That guy can go fuck himself with whatever power tools he has left.
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Old 11-11-2016, 10:39 AM   #5 (permalink)
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2001 xj 4 door. girl rolled it on a soft gravel road after a hard rain. very little damage. and best of all its from california so no rust!!!! 4 door will allow room for the two kiddos to ride with.

i also got a tv tuner, headrest screens and dvd player for the jeep. so the kiddos can stay entertained longer.

kept my racequip harnesses to re use.
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Old 11-11-2016, 12:16 PM   #6 (permalink)
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Was this one posted for sale on GT4W?
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Old 11-11-2016, 01:46 PM   #7 (permalink)
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yeah
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Old 12-02-2016, 08:48 AM   #8 (permalink)
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More neat things showed up today.
Solid inner c's
D60 spool is on the way. Ordering the knuckles next week
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Old 12-09-2016, 06:52 AM   #9 (permalink)
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Solid knuckles in the house! Got the d60 spool from Lugnut4x4
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Old 01-03-2017, 04:09 AM   #10 (permalink)
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Started grinding the inner c welds off last night. Cutting perches off until I ran out of oxygen. I can tell getting the c off is going to be a fun time.
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Old 01-04-2017, 03:40 PM   #11 (permalink)
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Well this was fun. Beating off the ball joint inner c's to replace with solid king pin is a lot of work
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Old 01-06-2017, 05:58 PM   #12 (permalink)
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Artec forgot to ship my truss. My guess is cause I ordered on a holiday weekend. They sent it out today. Be here Wednesday. Got the other side inner c off. Everything ground smooth. Gears will be here Wednesday . Got the master rebuild kit from ecgs in today.
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Old 01-07-2017, 09:56 AM   #13 (permalink)
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Sounds like next week will be busy for you getting that axle put together. Build looks good so far
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Old 01-11-2017, 07:49 PM   #14 (permalink)
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Friday afternoon I'm pulling the jeep in the shop and the plasma cutter is coming out to cut off any unnecessary brackets and Saturday will be spent putting on the center frame plates maybe fronts and rears too we'll see how it goes. I'm really not looking forward to this. I still haven't found anybody that's enjoyed doing it. Once I get the frame Stephanie is on then I'm going to try to slide the atlas in to see if I'm going to need the spacer or not.

Ordered the atlas rear mount kit and 15 Bolt shave kit from TMR customs.

Axel trust and Gear's will be here next Wednesday and I will get that done. I have the kids that weekend so the following weekend will be three link mock up start. oh, btw. anyone need some standard rotation non thick cut 5.38's for a d60 i have a set. because thats what i get for driving and ordering parts. fucked up.
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That guy can go fuck himself with whatever power tools he has left.
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Old 01-13-2017, 11:05 AM   #15 (permalink)
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high steer arms from four wheel offroad.net showed up today. spacer ring for the atlas4 shows up monday with the yoke i need.

15 bolt shave kit from tmr and atlas rear support from tmr show up next week sometime.

got the front suspension and steering cut off last night. frame washed, going to start stiffiners tonight. hopefully by saturday night the main front and rear stiffeners are all on.

pics to come.
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Old 01-13-2017, 06:54 PM   #16 (permalink)
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Got the driver side center and front frame Stiffeners tacked on. Wasn't too terrible. The rough stuff stiffeners are pure beef. ruff stuff front Stiffeners are not quite as thick, they dont need to be. but still nicely built. I'm going to wait to do the rear stiffeners until after I have the rear axle pulled out and leaf spring perches cut off.

got the pass side all on. working on welding everything up. millermatic 180 can only go so long, then it needs a cooldown.
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Old 01-14-2017, 01:55 PM   #17 (permalink)
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Hey when you're welding those on, and you're setting up the welder, do you set the voltage and line speed to the thicker metal or to the thinner metal? And then start the weld on the stiffener due to heavier gauge and then drag the weld to the unibody?

Learning to weld. I have a Hobart 140.
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Old 01-14-2017, 02:10 PM   #18 (permalink)
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I set it up for the thicker material start your weld on the stiffener itself and then drag the puddle to the frame of the Cherokee and circle back.

Just finished up welding the front and center Stiffeners are all done. Depending on the ice storm coming in and if I have to salt or not tomorrow I'm going to take off the rear receiver hitch sway bar shocks and bump stops. Also taking out the seats carpet and headliner.
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Old 01-14-2017, 02:35 PM   #19 (permalink)
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awesome! Thank you for the help!
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Old 01-15-2017, 04:34 PM   #20 (permalink)
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Today's progress was gutting the interior. Cutting the front inner fender wells off to narrow it. Removed rear sway bar gas filler hitch and bumper.
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Old 01-18-2017, 02:24 PM   #21 (permalink)
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made the transmission and transfer case crossmembers today. going to add a couple front to back bars and make a skidplate that covers everything. pretty much a flat belly so im happy about that. clocking the atlas was a bastard. the studs they send were nearly impossible to get into the clocking ring without a 2 foot pipe wrench. i tossed them and used bolts where i could fit them.

got the 5.38 gears set up in the 60. again, nightmare. had to adjust and shim and check and take apart and repeat for about 3 hours. but its done. the ruff stuff cover is on.

the xj is on jackstands now in my flat bay. going to position the front axle under it and get the pinion angle figured out, then weld on the SOLID inner C's, then the ARTEC truss, and then were making the 3 link.

I've decided to run my lower links to the frame rails instead of the transmission crossmember. both to get better link seperation at the body side and its pretty cramped real estate under this thing. running the upper link on the pass side i think.

pics in the following post.
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Old 01-18-2017, 02:45 PM   #22 (permalink)
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I've decided to run my lower links to the frame rails instead of the transmission crossmember. both to get better link seperation at the body side and its pretty cramped real estate under this thing. running the upper link on the pass side i think.
This is my plan for my next XJ build. My last one had the links on the tranny crossmember, and while it was nice having everything tucked up tight and I loved the geometry with the angled lowers, servicing the thing just flat out sucked.
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Old 01-18-2017, 03:44 PM   #23 (permalink)
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Trans and transfer case crossmembers.
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Old 01-19-2017, 05:35 PM   #24 (permalink)
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Didn't get much done today. Got jeep in the flat bay and set at ride height. Tomorrow's goal is adding bushings to xmember mount instead of solid mounted. Then set axle at ride height and mark inner c positions and maybe install inner c's. Once that's done I can weld the truss on and start with the Lower links.
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Old 02-14-2017, 09:04 PM   #25 (permalink)
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Got the rear quarters cut out. Tried putting knuckles on and it wasn't even close. Dropped them off at machine shop today. Got the 14 bolt torn down. Going to Costa Rica for a week Thursday. Ordered these today. The wallet felt than one.
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