Project Ex-Jay

[Stone Dragon]

Welcome to Project Ex-Jay. My name is Anthony Hamel (a.k.a. Stone Dragon) and this is my project. I have been searching for some time now for a strictly off road vehicle that I could fabricate so my son, Afroman, could have something to drive and we could wheel together. I ran across this one that belongs to Jon, the Kaszman, from CO. Check it out!
http://i90.photobucket.com/albums/k269/stonedragon223/Boatside_Profile.jpg
This is what I am working towards and I want to keep it under $1500. It started with this 1984 XJ (Freebie) in fair condition……. OK maybe a tad less then fair.
http://i90.photobucket.com/albums/k269/stonedragon223/HPIM0035.jpg
http://i90.photobucket.com/albums/k269/stonedragon223/HPIM0036.jpg
The ride home!
http://i90.photobucket.com/albums/k269/stonedragon223/HPIM0043.jpg
I started with the interior just to see if there was a lot of rust. I did find some under the driver seat, but this is defiantly fixable.
http://i90.photobucket.com/albums/k269/stonedragon223/30.jpg
http://i90.photobucket.com/albums/k269/stonedragon223/31.jpg
I then went to disassemble the front end and engine compartment. No surprises here, but what a pig!
http://i90.photobucket.com/albums/k269/stonedragon223/06.jpg
After lots of soap and bleach, it came clean.
http://i90.photobucket.com/albums/k269/stonedragon223/12.jpg
This was the point where I stood back and wondered if there is a point in a project when you STOP disassembling, and start reassembly…… I am still searching for that point.
http://i90.photobucket.com/albums/k269/stonedragon223/09.jpg
Finally got some paint on.
http://i90.photobucket.com/albums/k269/stonedragon223/16.jpg
I am 2 weeks and $60 into the project and I can go a long ways on the supplies I have. I am working on paint, undercoating, and reassembly of the front end next. To be cont…………..

[SHNIPE]

this is gonna be awesome! just dont let the kid drive it :D he might roll it... oh that would be ok with this one huh??

[JCSXJ]

Come on man don't hold out on us. Let's see the back end. I see the back of a blue XJ leaning against the wall in the 9th pic down:eek: Looks good!

[SHNIPE]

Come on man don't hold out on us. Let's see the back end. I see the back of a blue XJ leaning against the wall in the 9th pic down:eek: Looks good!

Yeah i saw that after my post! already back halved = WOOHOO!

[Stone Dragon]

I talked with Kascman and got an Idea as to where to cut, but I was kind of on my own. It ain't pretty. http://i90.photobucket.com/albums/k269/stonedragon223/34.jpg

[JCSXJ]

Do you plan on keeping the leafs? If not I would cut the back a little more and dove tail it. Looks awsome...keep up the good work!

[Stone Dragon]

The leafs are history. I have a 4" lift (4 springs and shocks) from a TJ that were donated. I kind of stopped working on the back for a while less't it tick me off.:D Every time I walked past it, I added more skin to the sheet metal.

[Triple-XJ]

Thats cool, Its great to see what people could do with an imagination, and some tools.

You have alot of work ahead of you, but please keep us posted.

And if you could meet the $15oo budget, your alot more concervative then most of us. :)

[Special K]

this is gonna be awesome! just dont let the kid drive it :D he might roll it... oh that would be ok with this one huh??

Whats wrong with rolling it? :eek:

Looks good so far, I'm sure it will be a blast to wheel in.

[SHNIPE]

if anyone should have the honor of rolling it, it should be him! Plus his son already almost rolled the GOOD xj in hackberry :D

[extreme96xj]

I would run the cage through the fire wall and the top side of the inner fenders to the bumper up front that way its tied front to back.

[joedokes28]

That's a neat project, but I predict that you are going to EXCEED the $1500 budget pretty quckly. What are you gonna use for the drive train? Looking good.

[Stone Dragon]

That's a neat project, but I predict that you are going to EXCEED the $1500 budget pretty quickly. What are you gonna use for the drive train? Looking good.
Dude.... You got to beleive.... You got to have faith brother. Things this week are slow. Lots of sanding and painting. Most of the plastic trim around the headlights is well, toast, so I am fab'in a way to lose the factory headlights and cover the holes with sheet metal. As far as a drivetrain????? Who knows what I will be blessed with. I know where there is a D44 and F9" in a '79 bronco....... But the guy won't leave his house long enough for me to get it.:eek:

[YJunk]

You can save a lot of money using those sticky Fred Flinstone brakes and accelerator... Just a little more fab work right here and you're good to go. You'll just need two people for true 4 Feet Drive.

http://i90.photobucket.com/albums/k269/stonedragon223/31.jpg

[Stone Dragon]

Things have been busy lately and I have not had much time to work on the project. The painting is coming along though. As you can see my wife sacaficed her parking spot for the good of the project, and as soon as I get out of the dog house, I will be able to put some more money into it. :D Check it out!
http://i90.photobucket.com/albums/k269/stonedragon223/072.jpg


I wanted to put some rally strips on the hood……. straight lines…. Sounds simple enough. Little did I know they would turn out to be a nightmare. I taped it off, I used newspaper to mask it for that lint cover look.
http://i90.photobucket.com/albums/k269/stonedragon223/075.jpg


http://i90.photobucket.com/albums/k269/stonedragon223/081.jpg



And then………. The dreaded ORANGE PEEL. Ruined the entire hood. Now I have to start over….. Needless to say it got put aside. They would have looked cool though!
http://i90.photobucket.com/albums/k269/stonedragon223/083.jpg


My replacements for the headlights came out nice though. Most of the fab time I have had has gone into finishing up my rear bumper project….. for the ’99 XJ…. But that’s another thread.
http://i90.photobucket.com/albums/k269/stonedragon223/087.jpg


To be continued........

[AZXJ]

Do you need some floor-board I have a tub I'll give you for free.. come get it out of my garage... PLEASE!!!!!

call me after 4pm on Sat or sun 480-720-1041
Dave

[vwkaferman]

This thread rules! Man, really makes me envious, wish I had some fab. skills.

James

[XJoshua]

Not that bad of a painter you are. How much did you spend for all your supplies?

[Stone Dragon]

This thread rules! Man, really makes me envious, wish I had some fab. skills.

James
8 months ago I knew nothing about working with metal. I bought a cheap HF welder and converted some of my wood saws with metal blades and the rest is history. One of the biggest, and most important reasons for all of these threads is to send the message that... Yes you CAN do it. I don't know that much able working on cars, but AM having a good time. Take your time, enjoy the fabrication experience, and just let it happen. And you too will find out yes you can do it yourself! Cost on paint is high.... about $70(@ $3.94 ea.) and will need more.

[XJoshua]

When I went to the auto paint store just for primer and paint Im looking at about $260, then the price off different sand papers would run me another $80. Sure I can paint computer cases and xbox's, but cars will be a new thing to me.

[afroman]

so yea i havnt been here in a long time...so about the jeep its coming out 2 b really cool cant wait 2 drive it :D oh its going 2 be LOUD:cool:

[Stone Dragon]

Well, it's been a month since my last update. I have continued work on the body, and although it is slow, there is progress being made. Here is a picture of the roof rack.

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM0500-1.jpg


The roll cage was very difficult to construct. One of the toughest choices was to spend the $300+ on the 1.75" jig for my friends tubing bender, or just go with the 1.5" tubing. I opted for the latter and tried to reinforce it as much as I could. I did a lot of research in this area and I think what helped me decide was the fact that most of the rail buggies are inch and a half...... So it will be fine. Oh, bending was a blast! Here is the front loop..... Check it out!

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM0527.jpg


Here is an in the works shot from the rear

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM0525.jpg


And here is the rear section of the cage. Its on its side, so you will have to visualize it.:D

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM0541.jpg


For the front bumper I used the 2x6 material again. I wanted to put some D-rings on, so I was going to have to make some mounts for them. I started with a scrap piece of 3.5"x.250 flat and ran them 14" up the sides of the unibody "frame". One of my friends recently got a plasma cutter, so I cut some 1/4" wide slots front and back of the 2x6 bumper and ran the mounts through and stuck out 3" in front. After drilling a big hole in the 1/4" mounts and a 1/2" piece to put next to it, I welded it all together. OK its half welded together

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM0578.jpg

To remain consistant, as soon as I got the bumper half finished, I started another project. These don't stick out this far, they are just staged on jack stands for the picture.... But you get the idea.

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM0581.jpg

I scored on a D35 out of a TJ, (so I won't have to weld on the spring perches) to use for now until I can afford to buy some real axles. I think the rear coil springs with the 4" lift are going to be too tall. I may have to use a set of stock springs.... Which I am looking for!:D
To be con't....con't....con't....con't....con't....con't ....con't....

[Triple-XJ]

Wow, you did make some progress. It looks good. :)

[AZXJ]

Lookin good !! :D

[GLEN REAMS]

WOW made some real progres it looks really nice!

[WalterD]

So how is the project going?
Walter

[Gordon]

OK, I will be the first to say it......

The Grill Is Upside Down!!

There, I got it off my chest! Who knows, maybe it will go faster. Ha ha, or get better mileage.

It is looking great by the way, I am jealous. I want to hack the back off of my '92 XJ and do the super short truck bed thing, but it's my daily driver and I don't want it to be down forever. Some day! You make me want to more and more though.

Keep up the good work and keep the pics coming.

[Stone Dragon]

The Grill Is Upside Down!!



I know! It is part of that go against the flow mantality that I have sometimes:D No..... I just thought it looked better that way.... Thanks for noticing. The project is kind of put on hold due to the holiday season. The family and I get pretty busy this time of year. I got a lot of the welding done, so I moved it from the garage so my wife could have her parking space back. I hope to be spending some more time on it after the 1st of the year. Later!!!!!!!!!!!!

[Stone Dragon]

Well….. It is with great regret that I must give up this POS.:eek: Well, not to much regret, because it is a rust bucket. When I went to fab the upper mount for the rear coil springs, I found that most of the rear uni-body “frame” was cancer’ed ….. and I mean bad. It was up inside where I didn’t look before. I would normally try and fix it, but with it back halved, I need as much support as possible there. Oh well, I can save the front and rear bumpers, rock sliders, roll cage and roof rack. I may be willing to part with this roof rack. It is too short for an XJ, unless you back half it,:D so I don’t have a use for it. Sometimes you just have to cut your loses. Its not all bad though..........
















Look what I found for $200………

http://i90.photobucket.com/albums/k269/stonedragon223/9.jpg


http://i90.photobucket.com/albums/k269/stonedragon223/5.jpg

And the adventure begins again!:D

[SHNIPE]

haha thats awesome! You dont mess around do you? You going to try and get the cage out and slide it in this one somehow?

That PURPLE has got to go! you going to go with white again?

[Stone Dragon]

I' m not too worried about the color for now. It doesn't have a driver side seat, but I have seats to put in it. Also, the guy I got it from said it had a bad knock in the engine, but the steering coluum is all broken up and you can't turn the key..... Which I have also:D . So I will see if it runs first, and go from there. I need to get tags on it before anything else...... And that means an emissions test.

[Wzzl13]

I LOVE it!. Keep us informed. Hope to see it on the trail...

[ArizonaJeeper]

Now this is a GREAT thread.

VERY nice work.
J

[SHNIPE]

hey do you havea spare front driveshaft? Im in need :D

[Stone Dragon]

hey do you havea spare front driveshaft? Im in need :D

Sorry man! I don't have an extra one.

[vwkaferman]

Aww man, so it ain't so! You had to give up on the other one? Bummer about the rust. Awesome, that's the (new) one from Craigslist isn't it? Haha, cool. No motor right? Plan on a small block? :D

James

[Stone Dragon]

Project Ex-Jay is still alive. I have been working on the motor. The guy I got it from said it had a knock in it...... which could be anything from a bad rod to pre ingnition from the bad gas that is in the tank. I started by trying to get it to run, and after no luck, decided to pull it. I pulled both driveshafts and the transfer case out.... which pee'd all over my driveway:eek: (remember to drain fuild from case before pulling:rolleyes: ) After having entirely too much fun under the hood, I finally pulled the engine and tranny out together and got it on the garage floor. The tranny seems to be in good shape, as is the intake and ex. manifolds. I got the the engine up on the stand last night, an did the disassembly. This engine is in good shape. Everything I have found up to this point, with the exception of the timing chain is in good shape. The timing chain has a full 1"+ of slop. A full rebuild kit is to follow. I hope to be getting the block and crank into the shop this week.

[Stone Dragon]

Well the motor is coming along nice. After grinding the crank and having the block bored .030" over and honed, I got the crank and pistons installed. I went with a Competition cam with a little less duration, and quite a bit more lift. The head was cracked in 7 places:eek: ..... Needless to say it was toast, but I got a line on a good head today. The timing set and oil pump went in last night, and I will be cleaning the bolts to the pan and sealing it up tonight.:D

[Jdemonto@Airpark Jeep Sales]

I like your project! Nice writeup..Can't wait to see it finished;)

Jason

[SHNIPE]

i cant wait to see you wheel it :D Can i drive :D

[Stone Dragon]

i cant wait to see you wheel it :D Can i drive :D

I can't wait to see it wheel either..... As far as driving it... You'll have to fight Afroman for that!:D

--------------

Thanks Jason!

[dragon51]

So how is it coming and lets see some pics, this new project XJ is worthless with out pics! :D

[Stone Dragon]

Things here have been pretty busy. I have not had much time to spend on the Project, so I have not posted any pics. The machine shop work came out great. Thanks to Steve at H & H Automotive Machine and Exhaust in Glendale for a great job. I have been focused mostly on the engine work lately, so the body has not had much done to it. I did clean and paint the engine compartment and rewrap the wiring harnesses, but that is about it. Here ya go….. Anyone got a shoe horn?

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1053.jpg


Here we go on our way to the machine shop.

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1076.jpg


Ahhhh! Old School Mopar Orange. (a.k.a. Chrysler industrial red)

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1088-1.jpg


The short block is complete!

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1097.jpg


Finally got the new head back and installed, and sealed up the top side.

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1110.jpg


And whoala! A completely rebuilt 246ci Jeep motor.

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1115.jpg

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1118.jpg

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1119.jpg

I have the intake manifold almost done, but the exhaust manifold, after a closer inspection, is toast. I’m at a stopping point now to save up for that high dollar header.:D

[GLEN REAMS]

that is nice! i know in the xj for sale section a while back there was a borla header forsale under one of the jeeps that were being parted out. dont know if it is still there but check it out
-Glen

[Stone Dragon]

Well…….. The project has been giving me somewhat of a fit these last couple of months, but I am still hangin’ in there. In my last post, I had the long block assembled and it was close to being ready to put in. I feel it is important to write this post to let all of those of us who don’t have a lot of experience rebuilding Jeeps, speaking of myself, to let you know of some of these little issues that come up with a rebuild such as this. Here are just some of the issues I ran into.
I got the engine finished up by welding up the cracks in the exhaust manifold. Which for an inexperienced welder like me; I had some trouble getting the heat settings correct. But after I got it dialed in, it went pretty quick. I see this as a temporary fix anyhow, so it will get me running. I mounted the intake and exhaust manifolds to the head together, and it was fairly easy to do. Next I needed to bolt the transmission to the engine. It seems that the torque converter did not want to go onto the input shaft of the tranny and had to be gently persuaded. I finally got the tranny bolted to the engine, but had a heck of a time getting the 4 bolts that hold the flywheel to the torque converter.
At this point I was ready to put this old bad boy into the Jeep. I borrowed an old school engine hoist from a friend that looked like it had been sitting outside in the rain for quite some time. The bolt that you use to open and close the valve to make it go up and down was broken off, so I had to weld another bolt onto what was left there, and put a “T” on the top to make it useable. I also cut a slot into an old bike seat post and made a handle. Finally it was all ready to go in and I found that they sold me the wrong motor mounts and the bolts didn’t line up. So I pulled it back out and got the correct parts and it went in……… I figured now is the correct time to put in the transmission cross member……. Right?…. No. The transmission mount has a plate that sits under it that holds the exhaust pipe and AFTER I got it all bolted together, I found that the exhaust pipe didn’t line up with it….. So back off it came, I fixed the issue with the exhaust, and figured now would be a good time to bolt in the cross member….. Right?...... No. I next went to put in the transfer case and found that there are bolts on the bottom of it…… And guess where they are?….. You got it. Right above the transmission cross member. So back off it came an I was able to install the transfer case, install the exhaust pipe and mount, and figure now would be a good time to install the transmission cross member…. Right? Right! I had fun that day.
One of the things I think most people forget is all the little stuff it takes to make an engine rebuild work. All the wiring, hoses, belts, sensors, fluids, etc. I went new with everything, so I found out first hand how much stuff there is. The wiring harness that runs across the top of the engine and down the front to the 3 sensors underneath was shot and the whole thing needed rebuilt. What a job that was, but I took my time and did it right, and it came of good.
The vacuum line network has a plastic line distribution piece that was missing half of the ports, and some of the others were plugged. I chose to bypass that completely and just run the lines where they needed to go. The service manual had a pretty good diagram of the system, so it wasn’t too bad.
I decided not to run the transmission through the radiator and went with an after market cooler from Perma-cool. I have this 3/8” 3000 psi steel braided aircraft hose that I have had around for a while, and I wanted to use it and replace the steel tranny lines. I found, through a lot of searching for a 3/8” barbed fitting to screw into the side of the transmission, that I actually have what is referred to a Toyota A340 transmission, which is what Chrysler bought and changed its name to the AW4. Anyway, long story short, I could not find a metric 3/8” barbed fitting, so I went with new quick disconnect connectors from NAPA for the stock lines on the one end, and took them to a transmission shop and ask them to put a double flare in the other where the rubber lines for the cooler fit. Done.
Now I am getting close. I went to fire it up last week and was getting backfires through the throttle body. This usually indicates a timing issue, so I removed the spark plug from the #1 slot, put my finger over the hole, and had a friend turn it over until it blew my finger off the hole (i.e. TDC of the compression stroke). Now I had a 50/50 shot of getting the distributor in correctly……. Of course….. 180* out. So I pulled the dist. out and got it set in correctly. I went to fire it up, and now it pee’s gas all over the garage floor due to a quick disconnect connector, on the fuel rail return line. After calling 10 different auto part stores trying to find these, I finally went and spent $20.86 at the dealership for the 2 o-ring and a piece of plastic. So I come back home all excited, install the part, and does it fire….. No, now the QD connector on the front of the rail is leaking…. Crap…. So I go back to the dealership, buy their last one for another $20.86 for 2 o-ring and a small piece of plastic. I come home all excited and install the part….. and….. Crap….. the fuel pump isn’t running.
Now it is at this point where I had to ask all the small children to leave the room…. :eek: If you’ all know what I mean. I gave this thing the boot out of the garage. Afroman and I pushed it outside and into the backyard. So after spending a week trying to find a good schematic for the fuel system to see if I have 12v at the tank, I finally get one and sure enough…. 12v is there. So I pull the pump assembly out of the tank, and it is a mess……$150 for a new assembly.
So……….After lots of time and lots of money this is where I am at. I would be content if I could get it to run…. Well, content for the moment. Till the next round of project I have planed for it. :D
More to come…..

[Stone Dragon]

IT'S ALIVE!!!!!!!!!!!!!!!!!! I stopped by Autozone after work and went ahead and picked up the parts and got them installed. After re-priming the oil pump, she fired right up. :D :D :D . I let it run for about 15-20 minutes at around 1500-2000 RPM to break in the cam, and it runs good. It has a few thing that I am not sure if are correct. It idles at about 1200. It is kicking a little black smoke.... Like it is running rich. It is parked on rocks,(it better get used to that:p ) and I noticed the rocks are now kind of black under the tailpipe, which again, would be consistent with it running rich. When I went to put it in gear, the back tires spin even with the brakes and em. brake on????? Thanks for everyones support, soon to come..... stage 2.

[twstdtj]

Good job. Yes the idle is high. Is this a computer controlled engine or not? If comp controlled it may kick down on its own after it breaks in. Mine usuall wont idle and then will after an hour or so after the computer gets straightened out. As for rich or lean with a computer controlled fuel injected rig this may be tough. If carbed rig adjust the fuel to air ratio and you should get it cleared up.

[Stone Dragon]

Yes! It is a computer controller Renix MFI 4.0L I6. I thought the computer controlled all the fuel mixture and the like. Maybe it will lean itself out as I drive it like you said I think the rear wheels are turning because it is at such a high idle and the torque converter is locking up. It will all work out as I continue to work on it. The most important thing is that is runs!!!!!!!! I got the rear hatch off and the side glass out and I am preparing it to be cut. Should be fun:D

[ROKBITR]

Well, this thread has definitely caught my interest. I will for sure be watching this one! You gotta love budget builds, and XJ's in general. Keep the pics coming!

[ORIGoodyear]

have you done anything with the rear brakes do they even work at all or just way out of adjustment

[TRobertsRN]

OK,

I am coming in on the end here so someone may have allready addressed this or I may be wrong.

I understand you are not running the auto tranny fluid through the radiator?

There are times of year that you will want your radiator to warm up your tranny fluid. Too hot is very bad but too cool is bad also. Would still want an addtional cooler.

Opinions vary on whether to put it before or after the radiator.

[TRobertsRN]

I know! It is part of that go against the flow mantality that I have sometimes:D No..... I just thought it looked better that way.... Thanks for noticing. The project is kind of put on hold due to the holiday season. The family and I get pretty busy this time of year. I got a lot of the welding done, so I moved it from the garage so my wife could have her parking space back. I hope to be spending some more time on it after the 1st of the year. Later!!!!!!!!!!!!

Upside down grills are a tradition with FJ40 Landcruisers that have V-8 Conversions.

[Stone Dragon]

Well it has been a while since I have posted, or for that matter even had time to log in. The garage is to darn hot, so I have switched to inside projects. The master bath is coming along nicely though. The cooler I chose was rated at 38,000 gvw, which is, I can be assured, the biggest cooler you will ever mount in the front of the radiator. It will give twice the cooling as the stock radiator and stock tranny cooler together. Shouldn't be a problem keeping the tranny cool, and will allow the radiator to cool only the engine..... It should work good. As far as too cool, does it get cold enough in AZ for this to be an issue? Remember, I'm an XJ guy, and this will be running without a heater or doors..... If its that cold.... I may stay home.... I'm spoiled like that. I'm not like you Wrangler guys. It takes a real man to drive without doors when its 30*:eek: and I had enough of that cold weather in Kansas City........ I still like the grill mounted that way, even without the V8 convertion:D

[Stone Dragon]

I finally found some time to work on the project. The boss at work is a slave driver, and the boss at home wants her master bath finished.:D A mans’ just got to spend some time with his Jeep and his dog though.:p I have been trying to bring closure to some of the projects on the old project and have the motor, tranny, transfer case and driveshafts' finished. She seems to be running good. The lift is a 4" for a TJ and was front coil springs, 4 shocks and adjustable lower control arms only........($40). I am in the process of fabricating a drop bracket for the track arm and the front lift will be done. I am waiting for steel prices to drop in the fall to buy some diamond plate to build a dash and enclose the gas tank between the roll bars in the cargo area. The front bumper and the right slider are almost ready for paint. The left slider, roof rack, rear axle, and rear bumper still need a lot of work. I also have a lot of work to do to the cage. I need to fab some seat mount and get them installed........ The list ya know....... It still isn’t much to look at, but at least it has tires on it and rolls.:D Check it out:


http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1619.jpg


http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1621.jpg

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1625.jpg

[BeaterXJ]

hey that looks good so far. i used tj parts to lift my xj too, works good dont it:D

[ORIGoodyear]

looking good:)

[Digger]

Do you need a radiator? I have 1 about 3-4 years old. nothing wrong with it. from my 96xj, auto trans. it's yours, just come and pick it up.

[GRUNT]

Looks good! I like the cut job you did on this one vs. the blue one... I like the look, kudos to you my friend. My son and I went to the coves with you and your family like 2 years ago, looking forward to going out with you and Afroman again when you get this thing done!!!!

[Stone Dragon]

Wow! Thanks everyone! I have not been pushing it real hard and it seems like the fabrication experience is a lot more enjoyable. Just to respond:

BeaterXJ- Ya the TJ stuff is a direct fit in the front and works good.

Digger- Thanks man! I went new with everything, But I do thank you for the offer.

Grunt YJ- I remember that! We had fun that day! I am shooting for that fall to wheel this one, but like I said..... It's a lot more fun when there isn't a deadline.

Thanks to everyone for the positive commits.:D

[tywilson88]

man i can't wait to see it later. that jeep is sick now.

[06TJWRANGLER]

This might not be a bad idea but I would sand blast the inside cab. Then go down to the nearest body shop and pick up about 6 quarts of this stuff called Body Schutlz 3M makes it very similar to spray in bed liner. You can get the gun from Harbor Freight for like 6 bucks. Set your air compressor to 20psi and spray the whole inside of that cab. Thats one thing im gonna do with my TJ.

[SHNIPE]

what a POS... scrap it (again) and start over :D

[Stone Dragon]

what a POS... scrap it (again) and start over :D

Oh....... ok!

[kjflowers]

wow it is looking nice

[Stone Dragon]

Well…….. Summertime is over and the cooler weather is here again, and that means its time to get back on the project. It’s been 2 months since my last post and the master bath came out nice. Here are just a few pics of what I have been up to for the summer.


http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1658.jpg


I now have a better understanding as to why people contract out the tile work, but I am happy with my first tile job. Check it out:

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1663.jpg

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1664.jpg

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1665.jpg

I have been a fair paint grade carpenter for a few years, but never been a furniture builder. I think the vanity came out good. The base cabinets are sanded smooth on both sides ¾” select maple plywood, and the stiles, rails, doors, and drawer fronts are North American select cherry.

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1679.jpg


It was a tough job, but I did have the support of my best friend……. I think he likes the rug best.

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1674.jpg


:D:D:D

[Stone Dragon]

As far as the project goes….. I got both rock sliders and the front bumper painted and installed. Here is one of the sliders:

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1706.jpg


And the front bumper:

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1713.jpg

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1715.jpg

The entire dash is gone, so I needed to fab a dash board for it. I started from the inside and worked outwards. Here is the inside ready to be welded:

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1698.jpg

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1699.jpg


I also have been working on the housing for the gas tank. Here is the finished dash and the tank housing:

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1703.jpg

And the seats installed:

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1704.jpg

If we refer to the first picture in the post, we will see that the rear is cut off and a new “tub” is fabricated in its place. Here is the start of the rear tailgate for that:

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1710.jpg

Seem like this project will never be done, but I keep working on it. I should be able to get some paint on the interior soon………. To be con’t

[SHNIPE]

UPDATES!!! SCORE!! Cant wait till that thing is done! Then you can dent something!! Dont let the kid drive :D

[GRUNT]

How heavy is it dragon?

[Stone Dragon]

That is a good question! When I started this project, the rear leaf springs were flat... or straight accross, and now they have a nice curve to them. So I figure I have taken off more weight then I have put on. The roll cage is about 300lbs, and the tank skin, and rear tub will add another 170lbs. The bumper I can lift by myself, and the sliders are not much.

[ROKBITR]

Looking good!

[azshtr]

Dude! This is cool. Still in the $1500 budget? Didn't think so... what are you up to?

[ArizonaSunshine]

Great work! Maybe I should leave my XJ @ your place for awhile :)

[Stone Dragon]

Hay all! I have been spending some time working on the new tub for the rear. Here are some pics of some of the progress. I built it in place to get the proper location of everything, and then removed it to work on some other stuff. I kind of like it….. Check it out:

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1728.jpg

I think it will look better once I get it skinned. I helped a friend move a couple of week ago, and he had this large barrel of tail and marker lights. He was nice enough to let me dig through it and I scored on 2-4" LED tail/stop, 2-4" white back-up, and 2 small lic. plate lights with all new rubber gaskets...... sweet. Here are a couple of pics with it on the Jeep:

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1732.jpg

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1737.jpg

I have to come up with some rear leaf spring somewhere, these are still the stock one and it is sitting pretty low. I have been spending quite a bit of time fixing a lot of little issues with the driveline and body. I finished up the roll cage and the inside is all taped off and it is ready for paint. Once I get the cage painted….. the dash, gages, and seats should go in quick. More to come later………


Oh! $1500.........:smilielol5:

[TwistedXJ]

I have a set of Rough Country add a leafs sitting in the garage it should give it 2.5" 30 bucks if you wanna go that route. PM me

[Stone Dragon]

PM sent!

[Andrew F]

Man, I always forget about this project and then you post something up and I have to step back and say, "dang, that is cool". Keep up the work. Throw those add-a-leafs in there until you decide to link the rear.

[SHNIPE]

Mad Max is proud right now.. well will be in the future.. wait if he was in the first one fromt he 70's what year was thunderdome? NM!! WAY OFF TOPIC.


Thats a BEAST!! I dig it! Definitely different than any other ive seen! Is that rear fender/tub setup pretty stout? Is it tied to the cage? Can i still drive it?? :D

[Stone Dragon]

The tub is 1x1 .120 wall steel.... and VERY stout!!!!! It will tie into the cage at several points, as well as the floor and rear bumper. Should be ok! And yes; you can still drive it. Its not like I am worried about scratching it or anything!

[ROKBITR]

HURRY!! Enough with the suspense. Just quit your job and finish the project already!!!! :D

I wish I still lived in Peoria, because I would be SOOO willing to lend a helping hand.

Keep the pics coming! :fashizzle:

[Stone Dragon]

Well I got the cage painted gloss black over the last couple of days... It came out ok. I also picked up the gallon kit herculiner for the floor and rear tub. I need to get the dash painted and installed (so all the wiring isn't hanging down) before I coat the pan. I am undecided as to what color to paint the dash. I can do just all black to match the cage, or royal blue, red, white, orange,green, or metallic silver....... for some reason I seem to have a lot of different colors in the paint cabinet. I will post pics once I get the dash in. Later!

[Jdemonto@Airpark Jeep Sales]

WOW...Looking good!

Jason

[Ted]

That thing is sweet looking cant wait to see it when you finish

[oldsmaxx]

is it painted yet? I want more pics!! come on, I check this post daily, I'm about to sell my Rubicon and build one of these

[Stone Dragon]

Well….. I got the cage painted, the herculiner installed on the front floorboard, and the dash and console put in…. Check it out:

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1803.jpg

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1802.jpg

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1806.jpg

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1807.jpg


I spent last weekend cleaning out the shop, so I can work on skinning the rear tub. I got it almost done..... It's getting close!:D

[GRUNT]

Right on. I feel like a turd watching you do all this work and your dedication and I can't even get out in the garage and finish my rock lights/corners/rockers... :(

Looks good

[SHNIPE]

NICE. Not a fan normally of Diamond Plate but that dash looks sweet!!! Cant wait to see afroman roll it!!

[WalterD]

NICE. Not a fan normally of Diamond Plate but that dash looks sweet!!! Cant wait to see afroman roll it!!
Aaaw man, what's wrong with aluminum diamand plate? As long as it's not polished. Ex-Jay project looking good.

[Papa Mo]

Looking good!! like the diamand plate dash!!

[yellow_X]

After looking at this thread, I am really considering getting a grocery go getter and firing up the ol die grinder

[ROKBITR]

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1806.jpg

The only problem I can see is that you didn't leave any spots for the tv monitors, stereo, and dvd and gaming system :confused: :laugh2:

Looking good!

[oldsmaxx]

That thing is awesome, I like everything about it

[Stone Dragon]

I have been making some progress on the rear tub. I got most of the skin on last week and it looks good. I decided to put the hitch back on for several reasons, one being I can build a cheap rear bumper. When I went to wire the tail lights, I found they used 2 separate light bulbs for the brake and turn signals, and rather then try and make this one LED tail light work for both, I decided to recess some smaller LED lights into the bumper. This is another rear bumper built from scrap and for under $20. I started with a piece of 2x6 .120 wall steel I got for $.40 a pound from Valley Steel in Glendale. I cut the ends at a 45 and holes for the tail lights. Check it out:

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1866.jpg

Here is the box I built to house the light:

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1868.jpg

I set it in place:

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1870.jpg

And welded it up:

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1872.jpg

With a lot of grinding, I got the lights to fit:

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1871.jpg

Next I fab’ed some basic mount to hold the bumper in place. I used .120 wall Flat steel for the plate and 2x2 .120 for the post (scrap):D

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1875.jpg

I centered it to the body and Tack welded it in place…… Then I ran out of gas for the welder and had it quit. What ya think…… Another $20 bumper!

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1880.jpg

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1879.jpg

[SHNIPE]

Nice work! love how you can pull crap metal and make it useful! That jeep sucks!

[Papa Mo]

You did a great job on that bumper :2thumbsup:

[brian lujan]

awsome

[Ted]

I love how this thing is turning out, very cool man

[ROKBITR]

It looks like you are giving up a good amount of departure angle with that hitch.

[SHNIPE]

It looks like you are giving up a good amount of departure angle with that hitch.
Just means he will have to go wider and stretch it later :D thatll clear up any clearance issues

[SHNIPE]

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1802.jpg

hey are you going to add any door bars? Looks pretty open and since i didnt see anywhere that the doors are going back on i would assume thatd be a good idea.

[Stone Dragon]

It looks like you are giving up a good amount of departure angle with that hitch.

I agree! But I gain a lot of structural support, I have a place for a receiver shackle without having to build it into the bumper, and it gives me a place to slam down off the rocks and not worry about bending something. I accepted the trade off.

As far as tube doors go, I left the hinges and latches just for that reason. I may add them later.

I got the outside of the tub painted and the bedliner on the inside. I'll post pics soon.

[ROKBITR]

I agree! But I gain a lot of structural support, I have a place for a receiver shackle without having to build it into the bumper, and it gives me a place to slam down off the rocks and not worry about bending something. I accepted the trade off.

As far as tube doors go, I left the hinges and latches just for that reason. I may add them later.

I got the outside of the tub painted and the bedliner on the inside. I'll post pics soon.

Nope didn't happen! :worthless: JK.

I definitely think you should add tube doors, because I want to add them later in my XJ's life when it gets retired from DD duty :laugh2:.

[BearWagon]

Loads of jealously on your XJ, very nice work. I'm just starting to acquire the parts/tools to start my own XJ budget (LOL) build and enjoy the insight you've given thus far. One question...on your cage, how have you been making your notches and cuts? And have you been getting all of your steel at Valley Steel in Glendale??? Anyone know of anyone good in the tempe/chandler area???


Notice to all...:laugh2:
To help fund my build I"m selling a '05 Honda TRX450r quad, like new!!!!


Thanks
Jason

[Stone Dragon]

I got the rear tub almost done. The rear bumper is installed and I have gotten a lot of issues taken care of. The transfer case linkage is fixed, the front driveshaft was completely rebuilt and installed, the rear suspension is all lock-tite’d and tightened up, the steering column and linkage is all repaired and tight, the horns are relocated and working, The power steering system was replaced including new pump, both hoses, and pulley, and of course rally stripes……. The list ya know. I still can’t seem to figure out why the turn signals won’t flash even though all the lights light up, and the back up lights don’t work. I have to finish wiring the lights up top and need to put on a mount for the spare….. And the list goes on…… It’s getting shorter though. Here are some pics:

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1927.jpg

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1928.jpg

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1929.jpg

I like the way the body work came out. I was concerned as to how I was going to interface the tub with the rest of the Jeep. Lots of cuttin' and welding.... And I did use just a tad bit of bondo to cover some of the small digs I put in it while shaping it with a hammer:

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1930.jpg

Chrome.... Yuck! But the horns work!:D

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1931.jpg

Here I am replacing the power steering pump:

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1917.jpg

Race Jeep..... The rally stripes makes it go faster.... oooh..... ahhh! :D

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1926.jpg

It's getting close to being street legal. Maybe a week or two. To answer your questions; I do buy all my steel at Valley and I cut with a 10" chop saw, and make the fish mouths with a notcher from Harbor Freight.

[SHNIPE]

SICK! thats sweet work you did for the rear section!

[Stone Dragon]

Thanks man! It's SO much work its nice to know everyone likes it! I do have a good time at it though!:D

[AZCA Jeeper]

Wow Dragon, you're an inspiration to all of us!!! That is some fantastic work you do. Top notch!!!

[Duality]

pretty sure the black one is the coolest thing I've ever seen.:fashizzle:

[06TJWRANGLER]

Nice Work That Has Turn Out Hella Sick!

[Andrew F]

Get some more pictures of that beast. I want that thing on the trail by the end of the month so we can all sit here and be jealous of it.

[Stone Dragon]

Get some more pictures of that beast. I want that thing on the trail by the end of the month so we can all sit here and be jealous of it.

The steering box has a screen door on the bottom of it and leeks all the fluid out. After removing it to install new seals, it seems everything has a nice blue tint to it, all the bearings are toasted, and all the seals are shot...... Toast!!! So I have a line on a boneyard box and I will have to take care of this. Just another issue.

[Stone Dragon]

I picked up the steering box late on Sat. and was able to get it cleaned up and installed. I had a lot of trouble getting the column to line up and ended up running out of daylight. Then, of course, Sunday was the SB, so I didn't have time to work on it then. Should be able to drive it soon. A bunch of us are headed to the dunes in a few weeks, and was hoping to have it ready for that trip. It would be a good shake down run for it.

[AZScooby]

Just checked out this thread for the first time. DAMN that is one awesome transformation. Great job!!!!

[ROKBITR]

:dots: :whistling: :sleeping2:

[Stone Dragon]

:dots: :whistling: :sleeping2:

Dude..... I have a life. Try working 60 hours a week, supporting a wife, 2 kids, 2 grandkids, 5 cars, 2 home improvement projects, and a dog.....(Dang... I don't have a life:aagh:) Anyway....It's dark when I go to work and dark when I get home, and since it doesn't fit in the garage anymore it hard to work on it at night. So after working all day Sat. and spending time with the family on Sun. This beast gets no time........... I'll get it all together soon. I can take more pics of it and post them if you'all want...... But it looks the same as before. Believe me when I say.... No one want to wheel this thing more then me. Can ya dig it?

[AZXJ]

are you gonna have it done for May ?? :D

[Stone Dragon]

are you gonna have it done for May ?? :D

Maybe! I wanted to have it done for March.......

[jporvaz]

That is an awesome looking project. I'm impressed with the work you've done to it. I hope you can have it done for Mar for the NAXJA event in FJ. (that is what your talking about isn't it?) I'm looking forward to seeing it.

[Stone Dragon]

That is an awesome looking project. I'm impressed with the work you've done to it. I hope you can have it done for Mar for the NAXJA event in FJ. (that is what your talking about isn't it?) I'm looking forward to seeing it.

Yep!

[Wounded XJ]

I like it!

[BaronVonRoot]

nice job!!

[GRNMachine]

I personally can't wait to see this thing done. I only wish I had the time and the patience to even attempt something like that.:smug:

[ROKBITR]

Dude..... I have a life. Try working 60 hours a week, supporting a wife, 2 kids, 2 grandkids, 5 cars, 2 home improvement projects, and a dog.....(Dang... I don't have a life:aagh:) Anyway....It's dark when I go to work and dark when I get home, and since it doesn't fit in the garage anymore it hard to work on it at night. So after working all day Sat. and spending time with the family on Sun. This beast gets no time........... I'll get it all together soon. I can take more pics of it and post them if you'all want...... But it looks the same as before. Believe me when I say.... No one want to wheel this thing more then me. Can ya dig it?

I'm just giving you a hard time :) I just don't have patience. I can't wait to see this thing done and out on the trail! :fashizzle:

[Stone Dragon]

I have insurance and a 30 day tag on it. I had a couple of opportunities to drive it around the hood and take care of some things. The engine is running great and I think I have seated the rings properly. I am still having problems with the top side of the lower hose, where it connects to the engine, leaking a tad bit. I also have something loose in the front suspension. It makes a loud noise, like something is loose, when you drive over curbs, and other peoples trash cans, and the like.:D The windshield wipers only work on low and the right turn signal doesn’t work at all, and neither of them flashes. The driver’s seat is WAY too far forward and on a solid mount with the B pillar of the cage directly behind it, so we won’t be fixing that….. A minor miscalculation. The horn is half and half. Half the time it works with the key on, and the other half it works with the key off. I will need another steering column soon. So as you can see, I have some minor issues to take care of, but overall it’s cool. It’s a BLAST to drive and is not lacking in the power department. I guess that high lift cam I selected did the trick…. Let's hope it doesn’t come back to bite me at the emissions test.......which is the next step. Later!

[UNLIMITLESS]

This Project is AWESOME!!!!
You are an inspiration to all driveway mechanics/fabricators everywhere!
Keep up the good work and keep us posted.

[ROKBITR]

:whistling: :lurk5: :D

[Ted]

Ya get back to work :whip: I want to see this thing done its a sick rig already :pimp2:

[Stone Dragon]

Updates???…………hmmm….. Don’t really know where to start. I am beginning to think this thing was a POS when I bought it. And I mean issues that go FAR beyond the engine being blown up. One of the biggest issues is it failed the emissions test last week. I was very concerned about taking the test because of the high lift cam I put in it…. And of course everyone you talk to has a story about how they had a car, or one of their friends had a car with a cam and all the trouble they had passing emissions….yada….yada …..yada….. you know the deal. So I go in there not really knowing what will happen, and was smilin’ from ear to ear when they told me the engine had passed…. Then I go to get the tank pressure tested and it fails….crap (that’s not the exact word I used, but you get the idea:D) So I replace the fuel send and return lines, the tank vent lines, resealed the fuel pump gasket, and got a new gas cap, and will see what happens. I am still fighting the top side of the lower hose, where it connects to the water pump, leaking anti-freeze. I tried 2 different clamps with zero improvement, so I decided to pull it for a closer inspection. The flange on the pump is machined and appears to be free from any type of burr or defect, and the hose still looked new. I had to sweet talk them at AutoZone and they exchanged it for another new hose. I got that installed with another set of new clamps…. And it still leaks…..same place.:confused: I am beginning to think that maybe the flange on the water pump is out of round or something. Keep in mind that everything in the system is new. While I was waiting in line at the emissions place, the engine seemed to start to get hot. I noticed the aux fan was not coming on and started to do some research on this. I guess the original radiator has a thermocouple on it to sense the temp and tell the computer to turn the fan on….. pretty basic stuff…. Well the late model open system I put in doesn’t have this so the fan will never come on. I decided it may be good to have manual control over this anyway and wired it to a switch on the dash. Works great. I am still fighting a bunch of issues surrounding the steering column and don’t think I can fix them without replacing the column itself, but none of these are critical and will deal with them later. The remanufactured steering pump I put in it seems to work about half the time, but has a warrantee…. So I will need to get that changed out. I have been fighting a klunking noise somewhere in the front suspension and have gone through it from top to bottom and found nothing. I don't know if it is because I have removed the front and rear anti-sway bars, but it gets really squirrelly when you hit bumps in the road at 40-45 MPH??? Sometimes it's a hand full.... more like a two hands full. I never had the short piece of speedo cable that runs from the cruise control sensor to the speedo itself, so I had to use some of that good old yankee engineering. I had the short piece from the '84, but it was too short and the threaded connectors were different. I found that if I flipped it end for end and made an adapter piece from some old plumbing fittings, and held it all in place with a couple of heavy duty structurally reinforced wire ties it worked great. I should get some sort of jury rig of the century award for that one..... but hay.... it works! I also have some other issues with the ol' project, but you get the idea…. What did we expect from a $200 car? So as you can see, I have not been sitting on my arsh doing nothing. This thing needs tags, and I need to feel it is reasonability safe to drive it before I will take it too far from home. I keep working on it and try not to let it tick me off……………………… And in all fairness……IT'S STILL A BLAST TO DRIVE:D:D:D……………..................... Thanks for your support!

[tywilson88]

i want pics:whip:

[Stone Dragon]

K

[brian lujan]

Pics Pics Pics Pics Pics Pics Pics Pics Pics Pics

[Stone Dragon]

Pics Pics Pics Pics Pics Pics Pics Pics Pics Pics

What are we saying here? Don't beat around the bush!:D

[Stone Dragon]

Any suggestions on that lower hose issue would be appreciated! And no, duct tape won't work! Thanks!

[SavageSun4x4]

... high lift cam I put in it….

Stone I have been following along and it really looks great. That said I am looking at cams and I would like to know what make and model of cam you used.

Give me enough info to dig out some stuff on their website please.

Thanks :)

[Stone Dragon]

Stone I have been following along and it really looks great. That said I am looking at cams and I would like to know what make and model of cam you used.

Give me enough info to dig out some stuff on their website please.

Thanks :)

I'll see what I can find. I know it is a Comp cam, but don't have the numbers with me here. I know it has a little less duration and quite a bit more lift, which should bring my max HP and torque numbers down to about 3200-3300 RPM's.(i.e. gas hog..... no wait "TORQUE MONSTER"..... no, no, I think I had it right the first time!:D)

[brian lujan]

What are we saying here? Don't beat around the bush!:D
my BAD, i seen the first pic and all the rest but i want to see the finshed pic or wheel with ya to see it on the trial.

[Stone Dragon]

I'll take some more pics of it tonight and get them posted over the weekend.

[Ted]

You should bring it to the Meet and Greet I want to see that rig in person

[SavageSun4x4]

I'll see what I can find. I know it is a Comp cam, but don't have the numbers with me here. I know it has a little less duration and quite a bit more lift, which should bring my max HP and torque numbers down to about 3200-3300 RPM's.(i.e. gas hog..... no wait "TORQUE MONSTER"..... no, no, I think I had it right the first time!:D)

I suspected it was a comp cam, but you would NEVER sort that out on their website...that is why I asked for a number or something so I can try and track it down...I would appreciate it.

How do you think it runs as compared to OEM?

[tywilson88]

You should bring it to the Meet and Greet I want to see that rig in person

yeah

[Stone Dragon]

She runs good. It's difficult to access a comparison as I have never driven a non-HO XJ. Its quick off the line, and has good acceleration while moving. I would say it is faster then my '99 with the HO motor, but it's also has a lot less weight. I tried to sort out their website as well and found it confusing. I gathered info off the web on what varying the duration and lift actually does and then had some knowledge of the numbers when I spoke with Steve at H&H automotive machine shop in Glendale. He was able to direct me to the cam I wanted to achieve the HP and torque ratings at the lower RPM. There are formulas you can use to calculate these. I just did a lot of web research.

[SavageSun4x4]

She runs good. ...I tried to sort out their website as well and found it confusing.

Great, that is enough for me to sort out. Glad you had problems with the website also and it just wasn't me...:)

[Stone Dragon]

Stone, I am looking at cams and I would like to know what make and model of cam you used.

Give me enough info to dig out some stuff on their website please.

Thanks :)

Hi Don! I am running a Comp Cam #68-232-4. Stock cam specs are .424/.424 lift, and 270/270 duration for the intake and exhaust respectively. My Comp Cam is running a .462/.478 lift, and a 250/256 duration for the intake and exhaust respectively. Hope this helps!

[SavageSun4x4]

Hi Don! I am running a Comp Cam #68-232-4. Stock cam specs are .424/.424 lift, and 270/270 duration for the intake and exhaust respectively. My Comp Cam is running a .462/.478 lift, and a 250/256 duration for the intake and exhaust respectively. Hope this helps!

Thanks I will try to track down a curve chart for this...Found it!

[FrenchChili]

Why use a cam that gives you less torque where you need it the most while crawling? This isn't a Jap 4cyl damn it!!! :D

[SavageSun4x4]

Why use a cam that gives you less torque where you need it the most while crawling? This isn't a Jap 4cyl damn it!!! :D
Not so fast grasshopper.

The answer is yes and no. The stock came has low grunt but start throwing some deep gearing like 6.14 and stay with a 37 in tire.

Most likely you will not be able to access that bottom grunt. So what you do is re cam and shift the torque curve up higher in order to get at it. Typically this will shift the entire torque band up and out.

I run 37's, 4.88s and my Jeep RARELY sees rpm beyond 3k. In addition as I go beyond 3k my Jeep starts to get tired real quick because of the early drop off in torque.

Shift that torque up and out and now those deep gears will not cause my engine to get as tired beyond 3k. I now pick up good usable rpm beyond the 3k mark.

I know that is the short answer, but I am running out of time to write much more. Let me know if you are not fully seeing what I am trying to convey.

[Stone Dragon]

Why use a cam that gives you less torque where you need it the most while crawling? This isn't a Jap 4cyl damn it!!! :D

How is it you came to this conclusion from reading this graph? Looks like there is more torque and HP throughout the entire band with this cam over a stock cam. More off the line, more in the midrange, and more on the top end. I am at somewhat of a loss as to what you are seeing??? If I am reading the graph incorrectly, please assist me in having a better understanding.

[SavageSun4x4]

How is it you came to this conclusion from reading this graph? Looks like there is more torque and HP throughout the entire band with this cam over a stock cam. More off the line, more in the midrange, and more on the top end. I am at somewhat of a loss as to what you are seeing??? If I am reading the graph incorrectly, please assist me in having a better understanding.

There is a small difference that equalizes at about 1800 rpm and after that its nothing but net for the Comp cam.

Albeit small this difference would raise its ugly head and crawling speeds under 1800 rpm, meaning the sweet spot that Jeep has between 800-1200 rpm would be degraded.

I often see a lot of discussion that wraps around your crawl ratio. With everyman trying to get it deeper. In reality this is foolhardy thinking as there is no reference point, no index on which to base your Jeeps ability. A low crawl ratio is no guarantee of better performance.

If you really want to rate your Jeep, then use the Rock Crawling Index which uses the Jeep Rubicon as the reference point. You could use any reference point but it needs to be something that is fixed.

check out this discussion on RCI: http://www.savagesun4x4.com/enter/viewpoints-technical_discus/

Click on the "Rock Crawling Index (RCI) Discussion

[Stone Dragon]

OK.... I was reading the chart wrong. Got my colors mixed up. I see it now. Thanks!

[ROKBITR]

AHHHHHHH!!!! I thought there were going to be pics! This thread is like my crack, and I can't get my fix until there are new pics! Hopefully I don't resort to stealing stuff to get my fix, because I don't think it will be very effective.

[Stone Dragon]

I been spending time trying to make this thing trail worthy and am getting real close. I got my plates....Finnally... so I won't have to worry about that for another 2 years. The on board air system is done and I can fill my 7 lb. tank from 0-105 psi in 19 seconds. I am very pleased. Here are some pictures of the compressor and tank. Check it out:

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1955.jpg

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1956.jpg

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1962.jpg

"Rock krawler"........ Or at least this is the closest I've come so far:

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1963.jpg

So, after working on it all day, I was left with the clean up, and my helper was well..........

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1954.jpg

Hope to get it out soon. I pulled the lower hose back off again and tried to seal it up. If it doesn't work this time, I am thinking there is some sort of defect with the water pump housing. We will see. Later!

[Antman]

What about lockers and gears?

[Stone Dragon]

I have a loc-rite in the front of the '99 and it seems to work pretty good, so I may go that route with this one.... If I decide to keep the D30. The turdy-five in the back....well..... no. I do have a 29 spline 8.25 with 4.10 gears waiting to be cleaned up and all the new stuff installed, but really want a ford 9" and a D44 full width combo and about 8" of lift and 37's. One step at a time. It's running 3.55's now.

[ROKBITR]

I have a loc-rite in the front of the '99 and it seems to work pretty good, so I may go that route with this one.... If I decide to keep the D30. The turdy-five in the back....well..... no. I do have a 29 spline 8.25 with 4.10 gears waiting to be cleaned up and all the new stuff installed, but really want a ford 9" and a D44 full width combo and about 8" of lift and 37's. One step at a time. It's running 3.55's now.

It sounds like you are heading in the same direction I want to with my rig. So close, yet so far.

What tire size are you running with the 3.55's?

[Tom Schenk]

Chrome.... Yuck! But the horns work!:D

http://i90.photobucket.com/albums/k269/stonedragon223/HPIM1931.jpg



I have that same steering wheel in non-chrome version from my old CJ. You're welcome to it for a 6pack of Guiness :)

[Stone Dragon]

This is the last entry for this project. I have had it out a few times and it does great. It is a BLAST to drive on the streets, and even more fun on the trails. I would post pics but the digital camera bit it. Overall, the ol' "Project Ex-Jay" has been fun. I learned a lot on what works and what does not. I would encourage anyone who want to take on a project like this to go for it. Just remember, it takes a lot of time and money. Thanks for everyones support and I hope you can see it wheel someday. Later!!!!!!!!!!:)

[Stone Dragon]

This is what I am working towards and I want to keep it under $1500.

$4762.24 not counting the 1000 hours of labor:aagh:

[FrenchChili]

Well get a camera and show us some action pics:D

[SamuraiAZ]

good job on the build, the jeep looks good

[brian lujan]

that is good to hear. mad props

[AZXJ]

You Gonna make the AZXJ Draw run this year ??

[familyxj]

Sweet ride!!!! I've been wanting to build stuff ever since I saw this post. My XJ has officially entered the operating room........My wife wanted to kill me when she came home and saw the XJ taken apart. All she could do was shake her head. Show us some action Pics soon!

Great job!

[azorr]

Very cool project! Thanks for the encouragement, maybe someday, when I have a garage and tools, I will get to do something as fun! Good luck with it!

[ROKBITR]

Any updates?

[brian lujan]

yes updated pics and wheelin pics.

[urbex]

$4762.24 not counting the 1000 hours of labor:aagh:

LOL...I just now started to read this thread, and I'm thinking "this guy is delusional if he thinks he's going to keep it under $1500 if he's planning on running anything bigger than a 31" tire, unless he gets a ton of freebies, a la Monster Garage" :D Still a really sweet build though.

Looking at the pics of the OBA, is that nipple on the air intake for an occasional manual squirt of compressor oil?

[Stone Dragon]

LOL...I just now started to read this thread, and I'm thinking "this guy is delusional if he thinks he's going to keep it under $1500 if he's planning on running anything bigger than a 31" tire, unless he gets a ton of freebies, a la Monster Garage" :D Still a really sweet build though.

Delusional, ah? Take away the $3233 I put into the motor and tranny. I've been remodeling the rest of the house and have not been out. I was at wally world a few weeks back and for no reason it blew the freeze plug out the back side of the head. I figured it was a blown head gasket, but after running a whole series of different test to determine why? I think it just wasn't install properly. So I am waiting till it gets REALLY hot before I pull the motor back out. I'll sell it for $2800!

[AZCA Jeeper]

Delusional, ah? Take away the $3233 I put into the motor and tranny. I've been remodeling the rest of the house and have not been out. I was at wally world a few weeks back and for no reason it blew the freeze plug out the back side of the head. I figured it was a blown head gasket, but after running a whole series of different test to determine why? I think it just wasn't install properly. So I am waiting till it gets REALLY hot before I pull the motor back out. I'll sell it for $2800!

Make it 5 bucks and you gotta deal.

[Stone Dragon]

Make it 5 bucks and you gotta deal.

I think I'll pass.

[AZCA Jeeper]

I think I'll pass.

OK 10 bucks, that's my final offer. :D

[ROKBITR]

So are you selling the project?!?!?!?

[AZCA Jeeper]

So are you selling the project?!?!?!?

I think he's just selling a motor (I hope!!). But $2800 is a bit much for a motor.

Please tell me you're not selling the project!!:aagh:

[ROKBITR]

I think he's just selling a motor (I hope!!). But $2800 is a bit much for a motor.

Please tell me you're not selling the project!!:aagh:

Eh...it is stroked if I remember correctly from the beginning of the project.

[Stone Dragon]

But $2800 is a bit much for a motor.


Who is this clueless person? And no....... I'm not selling it!

[Digger]

The talent to create a cool ride out of an doomed xj, and a sense of humor too! Your "closest to rock crawler" picture had me ROTF LMAO. And your helper sleeping on the job... to cute!!