Matt's XJ

[Hadfield4WD]

I haven't done this here yet so I figured I would let you know what I drave and how it came about.

Well this is how it started several years ago. I bought it for $500 with 232k miles everything worked but the tape deck (I don?t own any tapes anyway). AC power windows, 5 speed AX-15, 3.73 gears open/open, D30, D35.

http://i85.photobucket.com/albums/k51/hadfield4wd/Early%20Progression/kidsandjeepbeforelift2.jpg

Wheeled it for 3 years that way. Then bought a Rock Krawler 4.5 lift and put it on.

http://i85.photobucket.com/albums/k51/hadfield4wd/Early%20Progression/jeepsprings3.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Early%20Progression/jeepsprings2.jpg

Some parts I took off.

http://i85.photobucket.com/albums/k51/hadfield4wd/Early%20Progression/Jeepparts1.jpg

Ended up like this.

http://i85.photobucket.com/albums/k51/hadfield4wd/Early%20Progression/Jeepafterlift2.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Early%20Progression/Jeepfrontafterlift1.jpg

On 33?s

Did some trimming and made a front bumper.

http://i85.photobucket.com/albums/k51/hadfield4wd/Bumper3.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Bumper1.jpg

Here you can see the rockers as well.

http://i85.photobucket.com/albums/k51/hadfield4wd/Bumper2.jpg

[Hadfield4WD]

Did a bunch of wheeling still 3.73?s and open/open.

My dad built an awesome toolbox. I carry a spare everything.

http://i85.photobucket.com/albums/k51/hadfield4wd/Box4.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Box3.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Box1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Box2.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Box6.jpg

Made a rear bumper and skid combo.

http://i85.photobucket.com/albums/k51/hadfield4wd/skid1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/skid2.jpg

Put a locker in the rear at Crawfords at Tellico. Still do a bunch of wheeling.

http://i85.photobucket.com/albums/k51/hadfield4wd/jeep1tellico.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/jeep2tellico.jpg

[Hadfield4WD]

I massed parts in the garage for the axle swap for 2 years. How it sits today.

255k miles
AX-15
NP231 with sye
Custom drive shafts

Front HPD44 with:
? 5.13
? Lockright
? Alloy USA shafts
? Yukon Super Joints
? Warn Premium Hubs
? Modified Ford Radius Arms

OTK Steering using Chevy 1 ton TRE?s and 1.25 solid stock

Rear 9?
? 5.13
? Spool
? Alloy USA Shafts

2x4 rocker
36? TSL Radials Bead balanced

Still using Rock Krawler 4.5 front springs on top of the Ford mounts. Gets about 6? ? 7? of lift

Rear is a hybrid Rock Krawler/S-10 pack using all the long and no overload and Deaver spring liner. All for good flex. 1.5 blocks to go in to level it out. (I?ll be building a traction bar soon)

http://i85.photobucket.com/albums/k51/hadfield4wd/finalassembly009.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/finalassembly010.jpg

Flexes nice and level

http://i85.photobucket.com/albums/k51/hadfield4wd/Shakedown/frontshotfullflex1.jpg

Some clearance needed.

http://i85.photobucket.com/albums/k51/hadfield4wd/Shakedown/rearstuffed1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Shakedown/clearance11.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Shakedown/rearstuffed3.jpg

[Hadfield4WD]

Future plans

Install CO2 (it's in the garage)
Make traction bar I have all the parts.

[Hadfield4WD]

Here are some pics of the spring perches.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/axlewrap002.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/axlewrap001.jpg

I cut and straightened them out.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/axlewrap003.jpg

Just need to weld them up. Should be tomorrow.

I'll get the bump stops done and bolt it back in. I'm waiting on my brackets for the traction bar. That's all I need for that. I have all the bushings and links.

Wow thos welds suck. I may clean those up while it's out.

[Hadfield4WD]

Took the tool box out of the back for my dad to modify for the CO2. Fixed the perches, added the 1 1/4 blocks and finished the bump stop extensions. They needed a 1" spacer under the bump and an extension on the spring plate so they would hit. Also cut off the too long u bolts. Won't drive it until the traction bar is in. I should have the brackets when I get back from vacation.

Welded on the shock mount that I busted off at potts as well.

Also fixed my brake drum issue. They were on so tight I couldn't get them off. I borrowed an 8 inch gear puller and got them off that way. Then I used a dremel to grind the drum so they would slip on and off.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/blocksandbumpstops001.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/blocksandbumpstops003.jpg

[Want2Wheel]

That is looking good.

[TiredIronGRB]

That's a well documented build thread, well done 2ts

[Gordon]

:smokin: :smokin:

[Hadfield4WD]

Thanks. I actually have a buildup of the axle swap as well and all the parts.

[BroncoMike]

Good looking Jeep and nice work!!!

[Hadfield4WD]

The rear crossmember is done. Mounts for the shackle of the traction bar done. Welded up the shackle. tacked on the axle mounts. Bought all the hardware for the bushining I'm using. Cut the first peice of DOM an inch too short (idiot). Cut it again and got it tacked on. I have a cardboard roll I stole from the closet to make the template for the top tube. Unfortunalty the shackle is too long and I had to clearance the floor. I will get some sheet metal to cover it up.

[Hadfield4WD]

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

[Want2Wheel]

Nice job. Keep up the pictures.

[Hadfield4WD]

Nice job. Keep up the pictures.

My wife gets home tonight with the camera. So I'll get some more in the next couple of days.

[Hadfield4WD]

finally went and got pics
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar3.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar4.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar2.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar5.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar6.jpg

Still need to do the top piece and the cross supports and weld up.

[Hadfield4WD]

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/newseat001.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/newseat002.jpg

Fully adjustable and reclinable. just put them in the attic to install this winter.

[Hadfield4WD]

Finished welding the traction bar. Just need to paint it. I don't like the welds on the axle bracket. I don't think my little welder has enough juice to weld it. I will take it to a welder I know to fix it. And I am going to use a loaf pan to fill the hole. I will cut, trim and rivet it in and cover it with bed liner. Should get it on in a couple of days. Need to take my drive shaft off and compare to the spare and have the spare modified an fixed so it is straight.

[Hadfield4WD]

CO2 and modified box

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/CO21.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/CO22.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/CO23.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/CO24.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/CO25.jpg

by popular demand the modified loaf pan to fix hte hole in the floor.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/loafpan1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/loafpan2.jpg

[Andy's01]

Man you are doing a great job and I love the use of hosehold cooking utensils. LOL

[Bluegill]

Looking good, Matt! ;-)

[Hadfield4WD]

Man you are doing a great job and I love the use of hosehold cooking utensils. LOL

atfer I finish riveting it and bed liner it you'll never know. I was bent perfect. wonder when my wife will notice. :smokin:

Anybody smell banana bread?

[Hadfield4WD]

Here it is done. With Duplicolor bedliner.

Seat all the way forward.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar7.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar8.jpg

Seat back.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar9.jpg

[Hadfield4WD]

Here is the traction bar.

Tightsqueeze.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar10.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar11.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar12.jpg

Shackle side.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar13.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar14.jpg

From the rear you can see nothing hangs down to get caught on.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar15.jpg

Offering a little protection for the drive shaft.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tractionbar16.jpg

[Bluegill]

Nice work Matt! 8) I'd be a little concerned that the upper bolt might get into the shock body when flexed though. May want to flip the bolt to the opposite direction.

[Want2Wheel]

I do not understand the upper link. Is it designed to drop down further kind of like revolvers or double shackles? That thing looks great.

[Hokie_YJ]

The upper link with the shackle lets the bar follow the arc of the spring and not bind when it flexes.

[Hadfield4WD]

Nice work Matt! 8) I'd be a little concerned that the upper bolt might get into the shock body when flexed though. May want to flip the bolt to the opposite direction.

I tested this. Full extension and compression it does not hit, but comes close. I just need a lock nut and cut off the rest to be sure. It can't go the other way because I will have to take the shock off to take the bar out.

[Want2Wheel]

Duh! It has a leaf spring. I did not look good enough once again. I thought that it was for coil springs. I like that setup.

[RamAford]

The XJ looks awesome!!! just wish i had the time and place to do this with mine!!

[Hadfield4WD]

The XJ looks awesome!!! just wish i had the time and place to do this with mine!!

Thanks for the props guys. I was supposed to head to tellico this week but my daughter has had pneumonia and is this is her first day back in school and my wife starts her new job on thursday. So that won't happen.


Most of that work gets done in the driveway. Sometimes in the garage. I do a little at a time.

[Hadfield4WD]

Since I was supposed to be in Tellico and wasn't I still had thursday and friday off. Did a bunch of things around the house and Saturday ended up working on the tire carrier. I started by reinforcing the end of the bumper as the spare weighs 96lbs.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/reinforce2.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/reinforce1.jpg

Then finished the hinge side and welding it on the bumper.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/Hinge3.jpg

Then put the stop on the other side.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/Stop1.jpg

Had to clearance the hatch button.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/Openbutton.jpg

I still have a bunch of finish grinding for the fit-n-finish. I primed it because I won't get to work on it for several weeks and didn't want it to rust.

I'm also taking the bushing and swing to a machine shop to have him make a bronze bushing, because the poly one will flex to much, I think. It will be a partial, and I will have him machine down the poly bushing. to a 1/4" thickness, that way it shouldn't squeak or rattle. And still use it inside the bronze one he will make.

[Hadfield4WD]

Had to get a new battery today.

Optima Yellow Top from Advance. Optima is proud of their batteries. NAPA has an Exide gel battery, for about $40 less, but I went with the name known.

[Hadfield4WD]

Measured for front bump stops.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/forkliftflex1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/forkliftflex2.jpg

Rear's look good.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/forkliftflex4.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/forkliftflex3.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/forkliftflex5.jpg

[Hadfield4WD]

Did some grinding and used a flapper wheel on the hinge.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/Hinge4.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/Hinge5.jpg

[R.E.C.O.N.45]

Looks real good does not look ghetto at all. Nice taking time to do it right. good job.

[Hadfield4WD]

Well it came today. Freaking huge. 1/2" steel. Next to a 5 gal bucket. I think this will do the job.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/yokeguard2.jpg

[Hokie_YJ]

:shock:

Sweet!

[Hadfield4WD]

I don't think the springs are supposed to be wavy like this.

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

sooooo..............

[Hadfield4WD]

......I bought BDS springs today from DC. I'll take them apart and put the spring liner in. They have a lifetime warranty so we'll see.

[BillM]

Sounds good man.

[Jeep07]

gonna remove that lift block too?

[Hadfield4WD]

gonna remove that lift block too?

Most likely. We'll see how it levels out. I'm not worried about it as I have a traction bar.

[Hadfield4WD]

Well got the tire carrier 99%. Just need a hotter welder for the mounting plate. Will do that on Monday. Here are the pics.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/latchside2.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/latchside3.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/supports1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/supports2.jpg

[Hadfield4WD]

And more.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/Hinge6.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/latchside4.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/newpics005.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/99.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/992.jpg

[Bluegill]

Looks VERY sharp, Matt! ;-)

[Hadfield4WD]

Here it is.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/final4.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/final2.jpg

Here is how I mounted the high lift. 1/2" ss wingnut to allthread.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/highliftmount.jpg

If you don't like it I'm going to send my ninja over to put a hurting on you.

http://i85.photobucket.com/albums/k51/hadfield4wd/Misc%20goofy%20stuff/Ninja.jpg

[BlueCrawler]

Thats a good looking tire carrier! :!:

[C-Man]

8)

[TiredIronGRB]

Awesome detail but why did you make the tire so high?

[Hadfield4WD]

Awesome detail but why did you make the tire so high?

Thanks for the props guys.

I didn't want the tire to hit on stuff. Crozet where I wheel mostly has a lot of drops and don't want to drag tire. Plus I need the workout.

It moves way to much with that bushing and needs some bracing at the hinge and latch on the bumper so a little more welding. For the bushing I think I'll have a bronze one made and not worry about it.

[Simo]

be careful about it above your roofline and low hanging tree limbs... thats also alot of weight really high up it can rip your whole tire carrier off the hinge. then again, where else are you gonna put a tire that size in a cherok and maintain cargo space and backseat. Can you see anything directly behind you? I dunno what size youre running but it is possible to lay a 37" tire behind the upright back seat and still see out the back window by cutting out a portion of the hatch's interior wall. But then ya cant have a cool storage toolbox like u do back there.
Nice fabwork ... and now youve got an excuse not to back up... just floor it n take it to the top!

[Derrickalda]

be careful about it above your roofline and low hanging tree limbs... thats also alot of weight really high up it can rip your whole tire carrier off the hinge. then again, where else are you gonna put a tire that size in a cherok and maintain cargo space and backseat. Can you see anything directly behind you? I dunno what size youre running but it is possible to lay a 37" tire behind the upright back seat and still see out the back window by cutting out a portion of the hatch's interior wall. But then ya cant have a cool storage toolbox like u do back there.
Nice fabwork ... and now youve got an excuse not to back up... just floor it n take it to the top!

he needs the extra room in the back to haul NINJAS!!....i think it looks great. nice fab work. i do agree with the height issues.....i wonder what a stinger rear would look like on a cherokee??...hmm

[Hadfield4WD]

be careful about it above your roofline and low hanging tree limbs... thats also alot of weight really high up it can rip your whole tire carrier off the hinge. then again, where else are you gonna put a tire that size in a cherok and maintain cargo space and backseat. Can you see anything directly behind you? I dunno what size youre running but it is possible to lay a 37" tire behind the upright back seat and still see out the back window by cutting out a portion of the hatch's interior wall. But then ya cant have a cool storage toolbox like u do back there.
Nice fabwork ... and now youve got an excuse not to back up... just floor it n take it to the top!

It's a 36". All I can see out the back window is a tire. I thought about totally redoing the toolbox, but didn't. It would fit inside standing up.

I am adding support to the hinge and a bigger bolt. I will rip the bumpber off instead of the hinge.

I usually don't back up. :smokin:

[Hadfield4WD]

Gotta tell ya. Had a crappy day on the Jeep today. Took the new spring packs apart and put in the Deaver spring liner. Got the passenger leaf in no problem. The driver bolt stripped off inside the "frame". Only way to get is out is cut then weld it all back up. I'll use this opportunity to switch from the 4.75 dealer bolts to 9/16" grade 8's. What a pain.

[Hadfield4WD]

9/16 grade 8 won't fit. Got the bolt and nut at the stealership. Cut the unibody up, welded my new $5 nut to the inside, welded the unibody back together and put my $7 bolt through the bushing. I should have it back on tires soon.

Getting rid of the poly bushing on the tire carrier (way too much give) and i ordered a bronze bushing from McMaster. I just need to make some pieces to strengthen the bumper.

[Hadfield4WD]

Picking up the machined bronze from Clay this afternoon. All done the springs etc. Got the yoke guard on. And put the fixed drive shaft on and put the spare in the tool box. Had a missing problem and found it to be a bad injector. As I have a spare intake I just took one off of it. I gave it a tune up as well. Plugs, cap, rotor etc.

Pic of the yoke guard. Hangs down a little low, but I will hae access to the nuts for the drive shaft. This thing will laugh at rocks.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/yokeguard3.jpg

Well I'm loaded on the trailer so I'll be going wheeling tomorrow.

[Hadfield4WD]

Well haven't posted complete pictures so here you go. I cut the 60" jack down to 54", because with it being 60" when you open the carrier it apparently breaks the tail light. :evil: It doesn't rattle or move on the street or trail so I am happy with it.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/final6.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/final7.jpg

How it sits. Back is still low. I may put the lift blocks back in, as I have a traction bar I am not worried about wrap. The BDS springs are much more stable than my old bastard ones. I will wait on the blocks until I have the winch on the front. The shackle angle is pretty good as well.

The Grace sticker is going on the horizontal swingout.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/Jeeptotalshot.jpg

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

[TiredIronGRB]

Very nice :grin:

[Hadfield4WD]

Well got the winch installed. Here is the story. Got a killer deal on it from DC. It was not working. I knew that when I got it. I assumed it was at least 2 solenoids, as it didn?t operate in either direction. Turns out it was a bad motor. Warn wanted $250 for a new motor plus shipping. This would bring the cost close to $300. Warn recommended I go to a local starter/alternater repair facility to see if it could be repaired.

Enter PAR, Porters Automotive Rebuilders. I took the motor to them and they said there is a history of these motors have history of poor longevity. Here are a couple of issues with the Warn motors. One is the plastic brush holders (Mine was broken). Loosely would field coil windings (I had a bad one as well). Plastic end cap. Low quality bearings and a reputation of armature problems. He said he had a bolt in replacement made in the USA with a full metal case, metal brush holders and larger brushes. He also said to bring the body in and he would put install the motor and remove the existing pressed in armature bearing. This motor is more powerful and should draw less amps. I?ll report on load testing. The motor is physically longer as well.

Anyway here are the pics.


http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/winch3.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/winch4.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/winch1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/winch2.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/winch5.jpg

[SamuraiGuyTN]

I have alwyas like the sports over the four doors, yours is a good example.

[Hadfield4WD]

I have alwyas like the sports over the four doors, yours is a good example.

:oops:

I like the way it looks, but I wish I had a 4 door. Would make the cage and access for the kids easier. Maybe I'll just cut the roof off.

[zj4life]

I have alwyas like the sports over the four doors, yours is a good example.

:oops:

I like the way it looks, but I wish I had a 4 door. Would make the cage and access for the kids easier. Maybe I'll just cut the roof off.

I'll trade ya for my 4 door!

[4Xthelord]

Alton Brown would be proud! ver'nice!

[Hadfield4WD]

I have alwyas like the sports over the four doors, yours is a good example.

:oops:

I like the way it looks, but I wish I had a 4 door. Would make the cage and access for the kids easier. Maybe I'll just cut the roof off.

I'll trade ya for my 4 door!

Sorry I think I'll keep mine. 8)

[Hadfield4WD]

Well many people know that the charging/electrical system on the XJ is subpar at best. When you add things like a winch it is really lacking. With the headlights, AC, radio and CB on I was down around 10 volts. The first time I kicked the winch on the Jeep stalled. I knew it was time to fix this. I got my info from here:

http://www.geocities.com/JeepI6Power/ (http://www.geocities.com/JeepI6Power/)

Jon is very knowledgable and ready to help. I made all my own wires out of #1 welding wire. It is braided and makes for easier bending. All of my ends are soldered, crimped and have heat shrink. I tested my first one by putting a hook in either end and used it as a pull-up bar. It held so I think the connections are fine.

I replaced/added the following wires:



Battery Positive to Starter
Battery Positive to the distribution block
Alternator output to battery positive (stock has this connected to the distribution block I skipped that and went right to the battery – ANL Isolates the alternator from the rest of system should it surge, when you bypass the distribution block it bypasses the factory protection mine is 150A because my new alternator is a 140A) [Added parts]
Battery Negative to engine block
Battery Negative to fenderwell [Added]
Battery Negative to alternator case (Case bonding) [Added]
Engine block to firewall

With the stock alternator I lose very little voltage with everything on. Maintains around 13 and I don’t have to rev the engine in order to winch. The HO alternator should also help and will be installed shortly.

Anyway here are the pics.

The first 2 are comparisons of old to new. From left to right – New wire, alternator output to distribution block, engine block to battery negative, battery positive to starter, battery positive to distribution block and Engine block to firewall.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/compare1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/compare2.jpg

Here it is next to my thumb for a size comparison

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/compare3.jpg

Here is the battery. You’ll notice I only had black wire so the positive I put red tape on the ends. The one red wire is for the winch.

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

Here is the 150A ANL fuse.

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

[Hadfield4WD]

I took out the existing pickup and sending unit. It looked like this.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/Pickup1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/Pickup2.jpg

I then got a piece of 3/8? tubing. I could only find chrome, so in this case ?chrome will get me home?.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/Pickup3.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/Pickup4.jpg

With the 3/8? tubing it was difficult to get it in the bottom grommet. That was the one left from the pump. When I pushed it in, it expanded it enough that I couldn?t get the pickup screen on. I then put the pickup screen on then inserted the tube. The screen will not fall off.

This done I switched to the wiring and cut the orange wire (Fuel Pump Hot) and soldered a longer pig tail on and used heat shrink to seal it. The ground wire I had to splice into because the fuel gauge sending unit needs the ground as well. I soldered a pig tail on to it as well.

I then installed the pickup. This is a pain in the neck and part of the reason for me going to external on my Jeep. I used Vaseline on the new gasket to hold it in place. Then installed the locking ring with a bronze drift. No sparks are wanted in this area.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/Pickupinstalled1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/pickupinstalled2.jpg

I made a bracket out of 2 x 4 3/16? angle that I had around. Cut it down to 3/4? by 4 for mounting on the skid plate. The skid plate is really beef and secure. It is 1/4? plate with 1 x 1 1/8? angle welded around for rigidity. This is then got 2 frame brackets on the front and is bolted to the bumper via tapped tabs I welded on.

I then mounted the pump (Summit Racing Part #SUM-G3138) on my bracket and installed it on my skid plate. According to the directions the pump should not be mounted below the bottom of the tank. I also installed a pre-filter (Summit Racing Part # RUS-645080). I may be changing this as it has 5/16? barbs at both ends. I had a hard time getting the 5/16? line on the 3/8? end on the pickup. The pump was supposed to have a 3/8? intake and 5/16? discharge. But it didn?t. It seems to work fine, I?ll keep an eye on the lines and change them if need be. I could also put reducers in the line. We?ll see how it does. The pre-filter has a replaceable element so I?ll be getting an extra as well as a spare pump. I installed a new factory fuel filter as well.

I then plumbed everything and wired it up. I used zip ties to make sure nothing rubbed.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/pumpmounted1.jpg

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

[Hadfield4WD]

So here are the weights of the Jeep. Done by a race shop with individual scales.


LF ? 1147lbs RF ? 1121lbs Front total - 2268lbs 48.3%

LR ? 1212lbs RR ? 1214lbs Rear total ? 2425lbs 51.7%


Total weight ? 4694lbs

All that to say the Jeep is just too heavy. And the fact that 51.7% of the weight is on the rear is not to my liking. No wonder it doesn?t climb well. With the tire carrier and the tire up high and out back as soon as the nose points up the front tires have very little weight on the so the are not pulling at all. For now it stays, because it is convenient but when the cage goes in, I will remove the tire carrier and the tire will stand up behind the rear seat. I will only carry it when required for specific rides, other than that I won?t carry it at all.

Here is what I started with.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/fatty001.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/fatty002.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/fatty003.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/fatty004.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/fatty005.jpg

Ah. A clean slate. The box has served it purpose. When I designed it, I didn?t trailer the Jeep. I drove it everywhere. It was designed to fit 2 coolers and the Rubbermaid bin with the camping gear in it. It kept everything secure and was easy to pack. Could fit the family in it with all the gear, it was a little tight, but worked.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/fatty006.jpg

It?s just too hot to do anything else right now.

The plans are to move as much of the weight forward and low. I will put as much as I can under the seats. The parts and small tools fit in small bags. I will eliminate some items as well. Everything will be secured and the rear seat needs to remain usable. When I am done I will reweigh it on the same scales to see the difference.

[Hadfield4WD]

As you may remember I broke out all my rear glass at Crozet a couple of months ago. Well I got tired of tarping the Jeep in the driveway and gettin wet while raining on the trail. So now I have the best of both worlds. Snap in side curtains.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/sidecurtains1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/sidecurtains2.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/sidecurtains3.jpg

[HANO]

Looks good Matt!

[Jeep07]

looks awesome. Did you have somebody build them? Do you know what type of plastic used for the windows or where to buy it? Same Q for the vinyl? I wanna build a top etc for the Ftoy for the spring/fall when weather is so unpredictable.

[Hadfield4WD]

looks awesome. Did you have somebody build them? Do you know what type of plastic used for the windows or where to buy it? Same Q for the vinyl? I wanna build a top etc for the Ftoy for the spring/fall when weather is so unpredictable.

Thanks. I had a boat canvas place do it for me. She took templates a while ago and I picked them up last week. I have no idea as to the material that was used. I just know I'm happy with it. She'll be doing my half doors as well.:icon_mrgreen:

[96 coutry cherokee]

Can you post some more detailed pics of the tire carrier? Im wanting to build something similar

[Hadfield4WD]

There are more pictures on page 3 in this thread. I assume you have seen them. Tell me what specifically you want pictures of and I'll go take them. Also mine is coming off this winter and will be available.

You do know you would need a very strong back bumper right.

[96 coutry cherokee]

Ive got one :icon_mrgreen: Im just going to add to it. I would like to see/hear how you installed the jsck mount bolts, the back of the piece that hold the wheel, and does is swing all the way open or do you have a way for it to open just so far. If so then I would like to see that as well. Thank you very much for helping me with my visiual needs/wants :kewl: Also why are you taking it off?

"Now Im just being needy" lol

[R.E.C.O.N.45]

Nice soft glass swap. The sides looks kinda odd with it having straight edges for me, but as long as it works. What would be cool is it was set up so you can roll up the sides and the back. goot pics of how it mounts. I might do sometihng similar to my K5 side glass since the AC does not work. :kewl:

[Hadfield4WD]

Ive got one :icon_mrgreen: Im just going to add to it. I would like to see/hear how you installed the jsck mount bolts, the back of the piece that hold the wheel, and does is swing all the way open or do you have a way for it to open just so far. If so then I would like to see that as well. Thank you very much for helping me with my visiual needs/wants :kewl: Also why are you taking it off?

"Now Im just being needy" lol

I'll answer all your questions. Just had some distractions this week to put the time into it that would answer your questions.

[96 coutry cherokee]

take your time and thank you for your time its really nice of you

[Hadfield4WD]

take your time and thank you for your time its really nice of you

No big deal, but my wife was wondering why there were a tone of pictures of it on the camera.:icon_mrgreen:

Ive got one :icon_mrgreen: Im just going to add to it. I would like to see/hear how you installed the jsck mount bolts, the back of the piece that hold the wheel, and does is swing all the way open or do you have a way for it to open just so far. If so then I would like to see that as well. Thank you very much for helping me with my visiual needs/wants :kewl: Also why are you taking it off?


The jack mount bolts are 1/2". I used all thread theaded into a coupler like this one only bigger.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/tirecarriermore016.jpg

I then welded the coupler onto the carrier then alternated grinding and welding until it was smooth. To get the placement right I put bolted everything to the high lift then tacked it onto the bumper in the right location. Then welded it up strong. The rubber stopper just keeps it from rattling loose. Yes that's a 1/2" stainless wingnut.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/tirecarriermore010.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/tirecarriermore005.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/tirecarriermore006.jpg

The hinge is just a piece of heavy angle standing up straight with a top and bottom welded on. Its there is a piece of bronze that was machined with a 3/4" hole for the 3/4" grade 8 bolt. It doesn't rattle. It opens all the way until it hits the steel to stop it. Here are the pics fully open, bracing on the hinge side to the unibody and the latch.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/tirecarriermore001.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/tirecarriermore002.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/tirecarriermore004.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/tirecarriermore015.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/tirecarriermore014.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/tirecarriermore003.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/tirecarriermore008.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/tirecarriermore009.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/tirecarriermore007.jpg

Finally the plate for the tire mounting is just a stock 9" shaft that I cut the plate off and welded on. The 2" x 2" that it is welded to is not flush mounted to the main "A", but the top of the "A" is cut open and the piece slid in then welded up and tons of grinding for fit and finish.

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/tirecarriermore011.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/tirecarriermore012.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Tire%20Carrier/tirecarriermore013.jpg

Why am I taking it off? Well I don't ever use it. I have had it on a year and had a tire on it for 2 trail rides and only because it is required my the local club. I do drive around with it sometimes just because it looks naked but it is not a dd. I will no longer be a member there and I have CO2, patches, plugs and am working on a tube to carry as a spare. I have not seen any tire issues in the last 3 years of wheeling. Plus my spare is heavy. 100lbs and I have lightened up the rig and I don't want that weight all the way back. I really can notice the difference in wheeling with and without all the weight. My 36" spare will fit standing up directly behind the back seat which is where it will go if I need it once I put the cage in. When I get new/bigger tires I won't even buy a spare (I got sucha good deal on these and I had to get all 5)

[96 coutry cherokee]

wow it looks really thought out and looks like you put alot of time into it but it looks really good!! when you say that its coming off is that as in the whole bumper or just the 5th wheel carrier itself? but thank you very much for the detailed pics they look really good along with your carrrier (even though you dont like it lol) I hope you do well with your rig

[Hadfield4WD]

wow it looks really thought out and looks like you put alot of time into it but it looks really good!! when you say that its coming off is that as in the whole bumper or just the 5th wheel carrier itself? but thank you very much for the detailed pics they look really good along with your carrrier (even though you dont like it lol) I hope you do well with your rig

Thanks. Yes I've put a ton of time in it. It's probably got 5 -6 hours of grinding alone in it. It was a really good fabrication exercise and I learned a bunch building it and am glad I did.

Just the carrier is coming off. The gas tank skid is also tied into the bumper and if I took the bumper off I'd have to redo the skid. If I end up selling the carrier I'll carefully cut off the hinge and latch and fix the bumper.

Quite frankly I like the way it looks and if it was a dd I'd leave it on.

[96 coutry cherokee]

I like the way it looks too thats why I having a guy build me one but its a little different I wanted to see how you did yours (my jeep is a DD)

[Hadfield4WD]

OK all. Some of you know I have been working on my hydro assist. I’ll get to that. Also many people have asked me about my OTK (Over The Knuckle) steering. It is not a true high steer, but a less expensive alternative. This will net you approximately 3” of clearance at the tie rod. First off this is on a HPD44. I ran 2 years with no assist. I had a DOM Drag link and a solid stock tie rod. The solid stock tie rod took a beating and did end up bending. I have had zero failures. Here is a pic.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tierod001.jpg

I used the typical 1 Ton steering parts. I got the TRW ones from Advance Auto and these numbers can be cross referenced at any parts store.

Here are the part numbers for the steering ends.

ES2234R (you need 2 of these) - 28.99 ea
ES2027L (one needed) - 27.99
ES2233L (one needed) - 33.99

Just so you know there is a difference between the drag link end and a tie rod end. ES2027L is a drag link end. It allows for a larger angle to be achieved.

ES2027L is the passenger tie rod end. This is originally designed for a chevy under the knuckle and the hole is drilled to a smaller taper for the wrong direction. The hole is for the steering stabilizer on a chevy. So this needs reamed from the opposite direction to accept the tie rod end. There is plenty of material to support this.

Here is what the rod ends look like. Yes I know there are no cotter pins on the castle nuts and the jam nuts need tightened, I still need to do an alignment.

Passenger side knuckle

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/rodends002.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/rodends001.jpg

Driver side knuckle

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/rodends003.jpg

Pitman arm

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/rodends004.jpg

Me new tie rod is 1.25 .335 4130 DOM. Drilled and tapped to accept the 7/8” x 18 thread of the tie rod ends. This way there are no welds to fail.

You can go to regular DOM and weld in bungs if you want something less expensive.

The knuckles and pitman arm will also have to the reamed. The knuckles from the top down to go OTK and the pitman arm to accept the larger drag link end.

Due to me using a D44 I had to go to a longer pitman arm to match the length of the knuckle. I chose a ford drop pitman arm. Rough Country part number RC6602. It provides a 1” drop over the stock xj.

All in all I am very happy with this set up.

[Hadfield4WD]

Next comes in the hydro assist.


I ordered this cooler from Summit

http://store.summitracing.com/partdetail.asp?autofilter=1&part=FLX%2D3818&N=700+4294924500+400226+115&autoview=sku

I have a yj box drilled and tapped for 3/8" NPT

I have the inner frame plated.

I have this Tie Rod Bracket.

http://www.ballisticfabrication.com/OD-Tube-Clamp_p_21-1474.html

I did the West Texas Pump Mod.

http://westtexasoffroad.homestead.com/powersteering.html

I have this cylinder.

http://www.surpluscenter.com/item.asp?UID=2007040810283306&item=9-4410-08&catname=hydraulic

SPECIFICATIONS
Double Acting
Bore/Stroke 1 1/2" x 8"
2,000 PSI max
Rod dia 3/4"

Ports 3/8" NPT
Retracted Length 13 1/2"
Shpg. 10 lbs.

END MOUNTINGS
Rod End Crosstube
Pin hole 3/4"
1-1/4" cross-tube width

Base End Crosstube
Pin hole 3/4"
2" cross-tube width

I will also need to do an internal stop on the cylinder for 7 1/8" travel. Some say this isn’t necessary due to the box having an internal relief when it hits the internal stops. However I have my knuckle stops hitting before the box reaches the internal stops, so if I kept turning with the assist I’d push my knuckles right off the inner-c’s eventually as the ball joints can only take so much. So I took the cylinder apart and added this metal sleeve.

Before

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cylinderinternalstop1.jpg

After

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cylinderinternalstop3.jpg

Also why we are on the cylinder as this axle is very tight I needed to rotate the fixed end 90 deg so I could have the hoses coming out of the top of the cylinder. I had to cut it off and re-weld it on.

Started like this.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cylinderbefore1.jpg

90 deg rotated

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cylinderafter1.jpg

Lastly on the cylinder I didn’t want to use a ¾” bolt so I sleeved the ends with bronze down to ½”

Here is a pic of the frame plating ¼”.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/steeringboxbrace3.jpg

New box bolted in.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/steeringbox1.jpg

Axle brackets welded on.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/bracket003.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/bracket002.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/bracket001.jpg

[Hadfield4WD]

Cooler installed. I put it on the passenger side as it is the side with the mechanical fan and will be pulling air constantly.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cylindercooler2.jpg

The cooler is plumbed off the return line from the box to the top fitting on the cooler. The lower fitting goes to the reservoir on the pump.

I went to the local Parker store for the hose and ends. I may have gone a little overkill on these, but the hose is 4700lb hose reinforced with 3 layers of wire mesh. I had to cut it with a chop saw. I also used reusable ends. As a result if I have a broken line on the trail I can take out my spare line and put the ends on and call it good.

I prefilled everything I could with fluid. This would make bleeding much easier. As for fluid I have heard many things work well, but all agree that Amsoil Synthetic Power Steering Fluid works the best. Some problems are that most people go through growing pains when they first install the hydro assist and have to replace the fluid a couple times and that you can’t get it on the trail or at a part store. Well I bit the bullet and bought a case of it. This way I’ll carry my own and have enough to redo it a couple of times.

Bleeding procedure taken from here.

http://www.pirate4x4.com/tech/billavista/PR-Hydro_Steering/index3.html

Once you have everything installed and plumbed, it's time to fill and bleed. The procedure I discovered works well is:
Fill reservoir to just over tip of column
Raise front tires off ground to remove resistance
Turn steering wheel lock-to-lock while constantly checking the reservoir for air bubbles and level drop. Top us as necessary - be careful not to over-fill. When no more air appears to bubble out and the level remains constant, go to step 4
Check fluid level in reservoir, disconnect coil wire, and crank engine over to operate pump and flow fluid through entire circuit. Crank in short bursts. When no more air appears to bubble out and the level remains constant, go to step 5
Re-connect coil wire.
Check fluid level in reservoir and start engine. Operate at low rpm's at first, do not turn steering wheel. After a few seconds shut down engine and check reservoir. It will likely look like the pic at left, frothy and full of air bubbles. Allow bubbles to dissipate (can take upwards of an hour) and repeat this step until frothing does not occur.
Check fluid level in reservoir and start engine. Operate steering lock-to-lock while constantly checking the reservoir for air bubbles and level drop. Top us as necessary - be careful not to over-fill. When no more air appears to bubble out and the level remains constant, go to step 8
Top up reservoir, install reservoir cap, lower front tires to ground.
Here you can see everything installed. You can see how tight the clearances are.


Turned right

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/complete006.jpg

Turned left

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/complete001.jpg

Front shots

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/complete005.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/complete002.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/complete004.jpg

I just need to go through and tighten everything, align it and zip tie the lines.

Road test and trail test info to follow.

[RamAford]

Looks great! I really like the steering. I am going outside now to see about making something similar for my tiny dana 30 lol

[Hokie_YJ]

Looks great Matt. That's gonna be my next project on my junk.

[BroncoMike]

Look'n good man!

[Hadfield4WD]

Just finished the alignment. Went down the road great. No issues. Seamed to go straight. :mrgreen:
No leaks. Overall I'm satisfied we'll see how it does in some rocks.

[96 coutry cherokee]

all in all about how much money and time did you put into this??? and can you rate how hard it was also please

[Hadfield4WD]

all in all about how much money and time did you put into this??? and can you rate how hard it was also please


In the assist I have about 20 man hours total. That includes making all my own brackets and the alignment I do myself.

I had 2 major brain drains while doing this. The first was I measured what seemed like 400 times on the axle then went to the work bench and cut everything out. Unfortunatly I measured on the axle with a tape measure, when I do this I instinctivley start at 1 instead of the end because of the play in the end. Then I went to the work bench and used my machinists ruler and forgot to subtract 1. So all my brackets were off by an inch. And to make matters worse I didn't test fit everything because I had been so meticulous with my measuring and I fully welded the brackets on. I then had to cut them off and start over.:tongue3: Wasted about 4 hours.

I also had some kind of cerebral blockage while doing my alignment and it took about an hour longer than usual.

Cost wise I have about $430 into it. There are less expensive ways to go about it. I spent alot on overkill hoses and ends. You can just get 36" lines that are premade that will work. Also the Amsoil was really expensive and I bought an entire case that way I'll have enough for issues. I also bought enough hose for spare as well.

[96 coutry cherokee]

If I ever get to do this to mine I think I like the way you did it so I will modal mine around yours :) looks good and strong

[pplblazerdude]

One thing I have heard mention of from other people is when they use the clamps on the tie rod like you did they said that sometimes the clamp would move a bit when you really got it bound up. Most of the guys ended up putting a tack weld on both sides so the clamp could not slide.

[Hadfield4WD]

If it does move I'll do that, however the reason I did the clamp was so I could change to my spare tierod without major work. I'll see how it goes.

[Hadfield4WD]

My Jeep eats trees for lunch.

http://i85.photobucket.com/albums/k51/hadfield4wd/Crozet%20MOR%20comp%206-27-09/DSCN0160.jpg

[99NCXJ]

ouch!. I don't think that was the best line to take.

[BillM]

No Kiddin.

[HANO]

:eusa_sick:... Matt you've gone crazy.

You may have to change the price now in your for-sale ad.

[Hadfield4WD]

:eusa_sick:... Matt you've gone crazy.

You may have to change the price now in your for-sale ad.

I'm thinking since it's proven to not break the price should go up.:icon_mrgreen:


Anyway I wasn't driving. Infact I was 100 miles away. My buddy was running it in the members only competition at Crozet.

Its basically a Rock Race.

From what I hear the line actually wasn't bad, it was the wide open in 2nd gear lo that got him. He hit the rock, pulled a wheelie and landed right where you see him.

He did fix it wheel the rest of the day and drove it 100 miles home.

Maybe I shouldn't have said "Have fun and don't do anything I wouldn't do"

[99NCXJ]

Ok, so now thats 2 people to not give my keys to... You and whoever it was driving yours that day ;)

[Hadfield4WD]

Started on my boatsides. I decided to cut out my rocker to the sill. I’m never putting the doors back on so I’m not concerned what it will do to them.

Here is the starter picture. I have already cut off the rockers at this point. The rockers were down to 24”

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/boatsides007.jpg

The main piece is 2” x 4” 3/16” wall box. It was my old rockers that I cut off and removed the legs.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/boatsides004.jpg

The legs to the frame are 1 1/4” x 1 1/4” 1/8” wall square tube.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/boatsides005.jpg

There are floor penetrations and the legs are welded at these points. I don’t have pictures of this.

Here is the final picture at this point.

I gained 3 ¾” at the rocker.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/boatsides011.jpg

I still need to plate these. I’ll get that done this week.

To answer a previous question keep in mind that my rockers are plated with 3/16" angle. The legs are welded to that.

[99NCXJ]

You mean your frame is plated with angle right?

Is there anyway to do this and still keep the area for the doors to seal against?

[Hadfield4WD]

You mean your frame is plated with angle right?


Yes


Is there anyway to do this and still keep the area for the doors to seal against?

Yes. You see in the last picture the seal is still on. I left it there so it didn't cut me getting in and out. You'd have to cut the bottom of the doors off and weld up the seam. It's not that hard to do and the windows and everything still work. But my doors were in really bad shape. The passenger we had to kick open and closed and the gap was big enough to put my finger through, both door handles were broken off, glass broken in passenger door and the speakers didn't work. So not point in keeping them, not even for half doors.

[Hadfield4WD]

Well since I had problems last trip out with valve stems getting mangled I decided to make some changes. So I unmounted all the tires, removed the valvestems. An filled in welded closed the holes. I then redrilled holes so they would stick towards the center and not out towards the face.

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

[Hadfield4WD]

It’s nekid. Tube arrives on Tuesday. 1.5 x .120 HREW

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep001.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep003.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep004.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep006.jpg

Cut line for the comp cut

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep002.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep009.jpg

[HANO]

You've got alot of work and a short amount of time! Get to it!

[Hadfield4WD]

You've got alot of work and a short amount of time! Get to it!

yeesh I still have to figure out how to use the bender.:eusa_think:

I have a friend coming over this Saturday to hook me up though.

He is a custom bike builder. Here is his sight.

http://atombombcustom.com/home.html

he certainly has the skills.


As this is a 2 door xj and I need access to the back seat made design a little tough. I need the access to the back seat so in the event something happens I can go back and get the kids. I understand some compromises will have to me made. As a result this is being build to withstand a rollover and protect the occupants, but very well may be unusable after the fact. I believe this will withstand many flops and easy rolls.

Design criteria:
Protect myself and the kids
Access to the back seat
Protect A pillar and rain gutter area
Incorporate the front fender area
Be able to mount front airshocks (eventually) to the front

What I will be doing is an external roof halo and A pillar. Internal B, C and D pillars. V behind the front seats and X behind the rear seats. Downbars on the windshield.

[99NCXJ]

Silly 2 door owner... You don't have a D pillar.

[Hadfield4WD]

Silly 2 door owner... You don't have a D pillar.

Actually I'm adding a C pillar so that means the factory C becomes a D, or maybe a C.5?:icon_mrgreen:

[Hadfield4WD]

Got the skins cut out and mocked up. Still need to cut some sort of access hole for the spring bolt. And drill some holes to plug weld it to the legs.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/boatsideskin013.jpg

[Hadfield4WD]

Well I’ve been travelling a bunch and haven’t had time to pick up the tube. But I cut a bunch out of the back end.

The inside is where I want it. I’m still playing with the outside before I do a final cut. I still have to figure out what to do about the gas fill tube as well.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep011.jpg

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

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep015.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep012.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep016.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep014.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cageprep017.jpg

[dmoore714]

I was going to ask about that filler tube. Would it be possible to shorten the plumbing, turn it 180 degrees and put it here...
http://i212.photobucket.com/albums/cc201/elrojogrande/cageprep016b.jpg

I like that fuel tank skid you have. I need something like that. My stock plastic one had a huge chunk of tree limb stuck in it when I got it.

[Hadfield4WD]

Well I want the filler outside the body. We'll see how high I cut up for the rear tube. I think I have the space to lengthen the hose and move it higher. I'll mess with that later.

If you look on the other side I have cut out way more of the floor, and the driver side will mirror that. But I am going to cut that with a hand hacksaw as its so close to the gasoline. Then I will add some kind of protection.

[96 coutry cherokee]

where do you plan to put the tank? I think that would detremine where the filler would go

[Hadfield4WD]

Right now the tank stays where it is.

[MikeL1346]

Silly question I may have missed it somewhere but are you running tail lights? If so make some brackets to mount the lights to the lift gate (may or may not be easier said than done I don't have alot of experience with XJ's) turn your filler neck 45 degrees to the rear and let the tail light hide it. Sure you have to lift the lift gate to fill up but it's not a DD.

[Hadfield4WD]

Silly question I may have missed it somewhere but are you running tail lights? If so make some brackets to mount the lights to the lift gate (may or may not be easier said than done I don't have alot of experience with XJ's)

Yes I was. I took them off for the cutting and welding. I'll be either running military lights, Gen-right integral lights with back up light or cheap trailer LED's. Haven't decided yet.

I'm most likely not going to put them in the hatch as it is fiberglass and already is cracked. Plus I'd have to run an extra ground wire. Just gonna skin the rear and make some lights fit.

turn your filler neck 45 degrees to the rear and let the tail light hide it. Sure you have to lift the lift gate to fill up but it's not a DD.

That's a great idea. I'll have to look into that.

[Want2Wheel]

Man those are big holes to fill.

[96 coutry cherokee]

I have a set of red trailer LEDs and white some circle lights for backup if you want we could work something out I dont need them

[Hadfield4WD]

I have a set of red trailer LEDs and white some circle lights for backup if you want we could work something out I dont need them

Let me get further down the road but that is a distinct possibility. Don't hesitate to remind me later as I can be forgetfull.:tongue3:

[96 coutry cherokee]

ok will do lol

[Hadfield4WD]

Here are the tires tsl's in the front boggers that will go in the rear.
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tirestslandboggers001.jpg
I'll be cutting out the little lug totally to allow them to flex and grooving the big lug for more lateral stability. You can see the little nubbins on these.
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tirestslandboggers004.jpg
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tirestslandboggers003.jpg
The TSL's will get some kind of grooving, not totally a TN cut.
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/tirestslandboggers002.jpg

[Jeremy1977]

you should just cut the little ones in half , goes faster :icon_lol:

[Hadfield4WD]

I goofed up on my first piece of tube.
I can use some of it though.
I did get my mini stinger bent up as this is where my front will tie in. Plus it is the only small, single plane bend on the jeep so you gotta start somewhere.
I do like the 54" handle. Makes bending easy, although I can't see the degree wheel while bending. So I gotta move around some and take it slow at the end of the bend.

[Hadfield4WD]

Got it tacked on. I have to clean everything up before final welding.
Yes it's straight it's the camera angle. There is not enough room to get in front of it for a picture.
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/stinger1.jpg
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/stinger2.jpg

[Hadfield4WD]

Next I wanted to tackle the comp cut area with the symmetric compound bends. I pretty happy with the results. I still need to trim the ends and tack them on. And do some final cuts to one side, bumper and hatch.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/compcut1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/compcut2.jpg

[Hadfield4WD]

Well I’ve got a bunch of projects started, but I needed to further along the boatsides. I had to do some finish fitting, drill for plug welds and tack on. I am almost out of both wire and gas so I just tacked it on. Here are the pics. I’ll get the driver side done shortly then its back on the cage.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/boatsideskin14.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/boatsideskin15.jpg

[Horton]

bends look great dude!

[Hadfield4WD]

bends look great dude!

Thanks. I was sweating while doing those. I measured about 10 times. Then set it up in the bender. Then went to bed. Came out the next morning and rechecked everything then bent it. 3 angle finders later they came out fine. I'm pretty happy about those. Now i have my front wheel hoop which is 3 bends on one plane.:help:

[Hadfield4WD]

Now that it's torn apart I may have a buyer.:help:

[Hadfield4WD]

Well I have a deal for it, but I'm gonna pass. Somebody wanted to trade. It is an even trade, but his rig needed more work and money. Just didn't want to commit to another 4 - 5k in parts.

All the access holes for the front spring are cut. Plug welds for along the legs are done. All tacked on.
Just need to finish weld and paint. I’ll do that when I’m welding the cage.
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/boatsideskin16.jpg
Calling these done.

[Tiny]

Man that thing looks great.

[Jeremy1977]

Man that thing looks great.


Yeah , I need to do that real bad . Looks real good .

[96 coutry cherokee]

how are the fenders coming?? ;)

[Hadfield4WD]

They look exactly the same.

Plus this weekend is my wifes birthday, district band tryouts for my daughter, basketball tryouts for my daughter and Pro Championship motorcycle and quad ice racing, so nothing will get done this weekend.

[96 coutry cherokee]

WOW lots of stuff going on!!!! I know how you feel!!

[bignugly]

that thing looks great, a lot of hard work is paying off

[HANO]

Matt, PM me with a good time to call this weekend. I need to adjust the internal bumpstops on my DE ram. I need some pointers!

[Hadfield4WD]

Completely cut 1 entire bogger.

I got the rear comp cut fender bars tacked in. The passenger side was a little short so I cut, sleeved and added a small piece. Also had to cut my hatch.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/compcut3.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/compcut4.jpg

Also I got the front fender lower bar in place. There is still a lot to add here and it’s just tacked, but I was pretty happy with how they turned out. 3 bends on 1 plane to identical pieces.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/frontfender1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/frontfender3.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/frontfender2.jpg

[96 coutry cherokee]

Nice cant wait to see this thing finished!!!!

[99NCXJ]

Nice. looks like you are starting to get the hang of the bender.

I'm still trying to figure out if i'm going to do the same kind of comp cut on mine as you are or just do it the way i've cut it already. What are your plans for the tail lights?

[HANO]

Looking good Matt!

[HANO]

Looking good Matt!

The jeep, not you :icon_mrgreen:

[Hadfield4WD]

The jeep, not you :icon_mrgreen:

Thanks for clarifying, with my new beard I wasn't sure.:cool:

[Hadfield4WD]

What are your plans for the tail lights?

I've got a couple ideas. I may do some military lights or just do Northern LED trailer lights.

[Hadfield4WD]

Got the roof halo, A pillar and B pillar’s tacked on. Notching owns me. Other than that pretty happy so far. I have a bunch more to add in the front fender area. Then gonna work my way back.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage002.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage005.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage004.jpg

[HANO]

Little late for an EXO lol!


BTW That thing is going to be tough to wax

[99NCXJ]

looks like its coming along. What part of the notching is giving you a hard time?

[Hadfield4WD]

Little late for an EXO lol!


BTW That thing is going to be tough to wax

It's not an exo in the traditional sense. It's a hybrid. Also I've got a cool idea for the front fenders. The b pillar is actually inside the door. I'll get a picture that shows it better.

What part of the notching is giving you a hard time?

Since I don't have a notcher I'm doing it with a chop saw. I just am having a hard time with all the compound bends getting everything to line up. Just a lot of time with a grinder so I dont' ruin too much money in steel.

[Hadfield4WD]

Still making progress. I have a good feel for the notching. Finished up the roof pieces and cross ties. Got the fender bars complete. I still have one piece to add, a diagonal from the front of the lower fender bar to the node where the upper bar meets the tube. Also the piece with blue tape is a piece I need to insert into the A pillar tube with a slug, I just didn’t want to lose track of it.

Also I checked for clearance the hood does open and the windshield wipers have plenty of room.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage010.jpg

This picture shows the B pillar in the door jamb, not outside like a true exo.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage009.jpg

The windshield bars are 1” sch 40. I wanted something smaller that would be in the line of site.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage006.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage007.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage008.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage015.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage011.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage013.jpg

[HANO]

Lookin' good. I May actually ride with you now as a passenger!

[96 coutry cherokee]

wow looks great!!!

[Hadfield4WD]

Lookin' good. I May actually ride with you now as a passenger!


Good because the gloves come off now. No more driving gingerly.:icon_mrgreen:

[BroncoMike]

Nice job, everything looks nice and snug.

[Tiny]

Good because the gloves come off now. No more driving gingerly.:icon_mrgreen:
Oh I cant wait to se the new driving methods:icon_mrgreen: It will be like skiping rocks on water

[99NCXJ]

Looking good. I know the two bars that follow the hood line, wrap around the front and hit the stinger at an angle were tricky. It might look like one simple bend to someone who hasn't had any bending time but when you have done them before, you know that those notches are a pain to get to match.

[Roverintherockies]

Man you have been working hard on this project... I think it is looking very good... Keep it up...

[Hadfield4WD]

I’ve been working on it just wanted up update the thread.

Got all the fab done. The cut the halo of so I could weld the underside of everything.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage020.jpg

I also fixed the front fender I wasn’t happy with. I determined the wheel would hit the front part of the fender bar at stuff. So I cut it off, flipped the bar and welded it back together with a slug and plug welds.

Before

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/frontfender3.jpg

After

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage019.jpg

Then Jon (xjtrailrider) came over to help me get the halo back on. Thanks Jon. Then proceded to weld everything. I’m about 40% done welding. Everything is tacked in.

I also fixed the area at the a pillar with a new piece welded on with a slug.

I’m pretty happy with it.

Here are the pics.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage024.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage025.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage026.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage027.jpg

[99NCXJ]

Very nice. I have to say, I think i like the look of the front of yours better than I do mine. Looking straight at the front It has a real mean look.

[ParadisePWoffrD]

I really like how you inlayed the B pillar... I have thought about channeling the A pillar to inlay the tube before... also, I think it would look slick to skin the front fenders, give it that "factory" look....

Also, are you planning to put the doors and hatch back on? It would be some work, but, IMO, worth it on those winter days...

[Hadfield4WD]

The hatch is on, just up. The threw the doors in the garbage a couple months ago. There is no way the would go back on. The tube that come donw off the a pillar is welded to where the hinges were. I do have some ideas however, I jsut don't know if I want to do it. It will be getting some door bars though.

[Horton]

are any of the bars tying into the frame or are they just going to sheet metal?

[Hadfield4WD]

It is tied in and reinforced. None of it actually goes to the body portion of the unibody only. The a Pillars and b pillars tie into the boatsides that are 3/16 which is tied into the frame portion that is plated with 3/16 angle. The a pillar bar will also be stitch welded to the a pillar next to the windshield. The c pillar that I added is on 1/4" plate that is welded over the frame rail portion of the unibody. Also the d pillar is also welded onto 1/4" plate that is welded overtop to the rear spring hanger. the roof halo will be stitch welded to the rain gutter. The front portion is tied to the bumper and eventually the inner fender as it will support the new suspension if I ever get around to doing it.

So it is tied in at the strongest portions of the unibody.

[96 coutry cherokee]

to you just welded yourself a tank is what it sounds like every other word is "welded to" lol

[Hadfield4WD]

BA Baracus was my inspiration.:icon_mrgreen:

[Hadfield4WD]

Here are my cut tires. I opened up the gap between the lugs in the TSL's and made the obvious ones on the Boggers.
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cuttires003.jpg
I have a heater in the garage to try to heat it up so I can paint it. I also picke up my wheel wells. I'll try to get them in tomorrow.

[yoder519]

now im not a jeep guy, but ive alwasy had a soft spot for 2 door cheerokees. i enjoyed readin your build up. keep it comin!

[Hadfield4WD]

Well the plastic battery box cracked the last time out and put my battery into the fan.
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/batterybox4.jpg
So I whipped this up.
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/batterybox3.jpg
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/batterybox1.jpg
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/batterybox005.jpg
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/batterybox006.jpg

[Derrickalda]

simple fab jobs are always fun. looks great, should be bulletproof too!

[BroncoMike]

You should weld you some nuts on the sides then build another one for the top and then you would be able to clamp the battery in place.

[Hadfield4WD]

You should weld you some nuts on the sides then build another one for the top and then you would be able to clamp the battery in place.

It gets clamped using the factory metal top piece. Thats what the tabs on the sides are for. I would never have a battery that wasn't hooked down.

[Tiny]

Looking good. I cant wait to see that ride back at Mt. City. When do you think you and Gabe are going to come back?

[BroncoMike]

It gets clamped using the factory metal top piece. Thats what the tabs on the sides are for. I would never have a battery that wasn't hooked down.

OIC I didn't know you still retained the stock clamps.

[ParadisePWoffrD]

box looks simple and good.... but have you thought about relocating the battery?

the last XJ I wheeled, i wanted to install a bigger & dual batteries... so I made an L bracket and used one of these (installed in the stock battery location):

http://static.summitracing.com/global/images/prod/large/sum-g1431.jpg


I hooked the battery terminal stuff to one side, and a 2ga wire to the otherside that ran back to the battery...

[Hadfield4WD]

Looking good. I cant wait to see that ride back at Mt. City. When do you think you and Gabe are going to come back?

Don't know. I'm coaching my daughters softball team so I will be kinda limited. Also next week my Jeep goes up to crozet and willb e staying there for about a month. Has to do with tow rig logistics. And Gabe is racing it in April.

And I want to do the southern shine so I would say it will have to be in the summer.

Which gives us time to do Gabes SAS.

box looks simple and good.... but have you thought about relocating the battery?

I hooked the battery terminal stuff to one side, and a 2ga wire to the otherside that ran back to the battery...

I have thought about relocating it. I have the wire to do it, however there is no need for me to do it. Shorter wires are always better. Also anywhere I put it, it will be in the way. The wire will have to run tot he back and I don't have carpet so it'll see alot of abrasion. And I don't run any accesories except a winch so I just don't need dual battery's.

[Hadfield4WD]

Here you go Mike.:icon_mrgreen:

Battery is in

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/batterybox007.jpg

[ParadisePWoffrD]

cool, I can understand that... when I did mine, I ran it in 3/4" plastic pipe on the inside of the frame rails, and never had any issues...

I am really diggin the cage, I like how its all tight to the body...

[BroncoMike]

Ah yeah! Nice work!!

Man I wish I had me a welder!!!!

[Hadfield4WD]

Man I wish I had me a welder!!!!

Unfortunatly it then becomes I wish I had a press, lathe, mill, bigger welder, better chop saw, etc.

Never an end to it.:icon_cry:

[Jeep07]

Unfortunatly it then becomes I wish I had a press, lathe, mill, bigger welder, better chop saw, etc.

Never an end to it.:icon_cry:

No truer words have been spoken...

[Hadfield4WD]

http://www.4x4grace.com/vBulletin/showthread.php?t=10430

Based on the good constructive conversation in this thread I wanted to make sure all was good. I found 1 area that needed attention. The C Pillar sits on 1/4” plate that is over the frame rail portion. However I realized the area that supports the bars was just hanging out there. So I added this piece. I did this on both sides.
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage035.jpg
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage031.jpg
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage037.jpg
Got my wheel wells done as well. Not perfect but will keep the rocks out.
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage033.jpg
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage034.jpg
The only thing that I’m not all that happy with is the fuel filler. I have some ideas for it but they’ll come later. I’m just going to use a bungee cord now because I want to go wheeling.

[96 coutry cherokee]

what do your wheel wells look like from the outside?

[96 coutry cherokee]

Hey as far as the front wheel area is going what if you welded in something similar to a blamer and then skinned the outside something like this?

http://i709.photobucket.com/albums/ww100/96TNXJ/MattsXJPhotoshopped.jpg

Bad idea?? any other reason why not other then the added weight?

[Hadfield4WD]

I was thinking something along those lines. However I decided to go wheeling instead at this point. I have some thin sheet steel that I will most likely put on. Not weld. I put some tabs on the cage and bolt them on. I think I am going to try and stretch the rear some with out removing my tank.

Thanks for posting the pic. My photobucket should be back up the first of the month.

[96 coutry cherokee]

Oh no prob I barely use mine so if you ever want me to post something for you let me know Ill be happy too

[Hadfield4WD]

YouTube- Matt Flop Lower Sphincter

[Hadfield4WD]

Final pics completed.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage049.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage047.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage046.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage039.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage042.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage043.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage044.jpg


That rock landed on the weakest part. I know how to strengthen it without losing too much access. I’ll be making changes stay tuned.

[HANO]

Stretch the rear, and throw some tons and 40s on it and call it day!

Exo looks good man. Skin the front tube fenders, and move the rear back a little, I think it's coming around well.

[Hadfield4WD]

Stretch the rear, and throw some tons and 40s on it and call it day!

Exo looks good man. Skin the front tube fenders, and move the rear back a little, I think it's coming around well.

I know. Right now I want to go wheeling. So no more work except repairs.

I need to build the boys buggy. I did pick up their tranny today.

[Derrickalda]

are you going to use green seat covers in their buggy too...haha

the tube work looks great.

I think I am going to try and stretch the rear some with out removing my tank.

why do you not want to put a fuel cell in the back when you eventually stretch it?

[Hadfield4WD]

:icon_mrgreen:are you going to use green seat covers in their buggy too...haha


Nope they are mine. They can't have them.


the tube work looks great.


Thanks

why do you not want to put a fuel cell in the back when you eventually stretch it?

The main reason is my spare won't fit in the back. Right now it fits standing up against the X behind the passenger seat. A stretch is a ways away. I promised the boys no more upgrades to mine until I finish theirs.

[fivetreoh]

...well get to work on their buggy and post some pics of it! :icon_mrgreen:

[Hadfield4WD]

I whipped these for cheap. I just used $8 trailer lights. I wanted them flush mounted so I sandwiched the steel between the lens and the housing. I had to add a ground wire to the main mounting pieces.

The whole thing cost me less than $20. I had the steel laying around.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/taillightboxes002.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/taillightboxes004.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/taillightboxes006.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/taillightboxes005.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/taillightboxes008.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/taillightboxes007.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/taillightboxes012.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/taillightboxes011.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/taillightboxes013.jpg

[dmoore714]

Nice!

[ParadisePWoffrD]

I like this thing more and more every time I see it... I think linking/stretching the rear should be in the near future...

oh yeah, that and a 609 front

[96 coutry cherokee]

Looks good!!!!

[marko]

Sweet rig! Cool idea on your lights. I think ideas like that are awesome. Can't wait to see some of these rides in person.

[Derrickalda]

great fab work!!

[GasHouseWranglerDood]

thats awesome man, and sweet green seats! lol

[Hadfield4WD]

oh yeah, that and a 609 front

Isn't that the truth. Especially since Gabe raced it last weekend and brought home the broken front shafts.:eusa_think:

[Jeep07]

Great job on the lights.

[Hadfield4WD]

http://i418.photobucket.com/albums/pp266/xjtrailrider/hadefield/P1020307.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/hadefield/P1020308.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/hadefield/P1020309.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/hadefield/P1020310.jpg

[Hadfield4WD]

Oh and yes I know if the strap on the snatch block would have let go it would have taken my head off. I realized this and moved.

[Rtaylor]

Oh and yes I know if the strap on the snatch block would have let go it would have taken my head off. I realized this and moved.

I'm just glad that nobody took pictures of me when I installed the 4Mogger body onto the frame all by myself. "Darwin Awards Nominee" comes to mind...

[ParadisePWoffrD]

did you already tweak the tubes?

[96 coutry cherokee]

lol what did the people next door say? just wow by the way

[Hadfield4WD]

did you already tweak the tubes?

I'm not sure tweak is the right word. More like bent the crap out of them. It was that roll off the rock that did it.

lol what did the people next door say? just wow by the way

They're pretty used to my by now. Except Crazy Phil across the street. He keeps watching me with a wary eye.

[99NCXJ]

I wish we lived in the same neighborhood. Then I wouldn't be the only one doing strange things. You should have seen the looks on peoples faces when I torched the Comanche in half a while back.

[Hadfield4WD]

Well crazy Phil is not amused. The rest of the neighborhood thinks I'm a little off balance. But they come to me when they need stuff fixed.

Well here is the damage.
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage054.jpg
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage052-1.jpg
Like a said earlier I still want access to the back seat. And the rock landed at an area that had very little support. So Chris (jeepnchris) gave me this idea. This way if I did land like that again it would have the support to withstand it as the bar comes off at a node and transfers the force to the rest of the cage.
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/cage057.jpg
While I was at it I added some door bars. And yes I can still get in the back seat.
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/doorbars008.jpg
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/doorbars007.jpg

[HANO]

Matt "B.A. Baracus" Hadfield. All it needs is the patented steel plated windows with the viewing slits.

haha

Well at least I know you wheel it.

-H

[Hadfield4WD]

Matt "B.A. Baracus" Hadfield. All it needs is the patented steel plated windows with the viewing slits.

haha

Well at least I know you wheel it.

-H

Can't say I've ever been called that before:tongue3:

I've always been a Murdock kinda guy.

http://i85.photobucket.com/albums/k51/hadfield4wd/a-team_edition.jpg

[Hadfield4WD]

I had some gussets made before Harlan and welded them in.
http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/100_5320.jpg
Had some damage and issues with the Jeep. I ripped off the rear hatch. I saved the lifts for a cool project though. Anybody have the little mounts that they attach to? I threw out the hatch at the campground and had my brainstorm half way home.:rolleyes-1: I blew a coolant hose and it shot coolant all over my dist and wires etc. It didn't run right after this. So it's gonna get a tune up, which hasn't been done in years. It also has a manifold gasket leak and a valve cover leak. In addition the power steering was screaming and leaking my "more expensive than gold" Amsoil, I think the pump is shot. I'll need to investigate this. So it'll get some TLC. When we towed the Jeep off the trail I knew it would bash my light boxes so I took them off. The mounting area is pretty wasted so I won't be putting them back on. I'll do something different as well and clean up the wiring to the rear, as the only thing I need is the tail lights.
Harlan Sept 2010 :: DSCN3305.mp4 video by hadfield4wd - Photobucket
The stinger is bent from using it as a winch point to get the other xj up so I'll need to change that and well as a fragged winch cable. I have new winch rope already, however not the hawse fairlead.

[Hadfield4WD]

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/100_5427.jpg

[99NCXJ]

Number of holes don't match

[Hadfield4WD]

Number of holes don't match

I know. They are aero race wheels. They make stuff for circle track cars. The idea i believe is the ability to turn the ring. I could be wrong I'll call them on monday to make sure. They were really inexpensive comparatively. No need for a coning ring and are about 7lbs lighter than A typical 1/4" DIY kit. I plan on doing a full review after I get them welded on.

[96 coutry cherokee]

are you keepin the yellow?

[Hadfield4WD]

are you keepin the yellow?

Yeah. I am demoing and doing a write up for them. I got a major deal on them, this is what they sent me. They also have black, chrome and an aluminum ring. I'll eventually get the aluminum ones.

[96 coutry cherokee]

go chrome just for fun lol :D

[ParadisePWoffrD]

are these the kits that speedway motors sells? I have seen their kits and wondered how well they would hold up...

I really like how thin the lip is vs. DIY beadlocks

[Hadfield4WD]

I don't know if Speedway sells them or not. I got mine from Josh at Trailhead customs.

Here is the manufacturer. Aero Race wheels. They do circle track race stuff. They only have 13" and 15"

http://www.aeroracewheels.com/accessorie_pgs/beadlock_kits.html

They also have inexpensive complete wheels with these bolt patterns. 5x4.5 and 5.5. That is most jeeps and the new JK's however I don't know if 15's will fit on a JK.

I haven't pulled the trigger on any DIY kits for basically 2 reasons.

1) Weight - I want to keep my rotational mass to a minimum. I am already breaking axles. Typical DIY 1/4" beadlocks add around 14 - 16 lbs per wheel. These are half that. I have a chart about weight on beadlock wheels. I was looking to go aluminum with an insert like staun or inner airlock or diy steel. My weight will be around 28lbs per wheel. The alum with double locks are the same. Which surprised me. Yes I know I only have an outer lock but so do thousands of other people.

2) Coning - these don't need a coning ring or anything of the sort.



Also these were less expensive than standard diy bl's. They do only have 16 bolts so we'll see how they work. They came with all the hardware. I'm pretty sure I have the ability to see how well they hold up under a beating. Plus I'd like to go to the aluminum rings they have.

So once I get them welded on and tested we'll know more.

[Hadfield4WD]

So I called Aero they said I will have no problems with the 16 bolts versus 32. Also they said they are drilled for weight removal and so the ring can be truned incase there is a problem.

[Hadfield4WD]

The beadlocks are welded up and the rims are completely painted. 3 coats. They are drying in my office where its warm. Also got all my tires unmounted on from the old rims. Should have these done next week

[Hadfield4WD]

Well I have needed beadlocks for a long time. Just about every trip I lose a bead or bend a rim or both. I have had an extra set of rims around the house in order to get a weld-on kit. However I have a problem with the weld-on kits. They all are very heavy. Anywhere from 20-28 lbs. Added to a rim and you’re talking about a close to 40lb rim. I already break shafts so that much added rotational mass would only add to the situation.

So I have spent a lot of time looking into the different options. I thought about going to aluminum rims and internal beadlocks like the Inner Air locks. But I felt I’d need a strengthening ring to weld to the outer lip so I didn’t break a rim. That is when I stumbled on Aero Race Wheels (www.aeroracewheels.com (http://www.aeroracewheels.com)). I purchased mine through www.trailheadcustoms.com (http://www.trailheadcustoms.com/). They build wheels for dirt track cars. They only come in 15”. They have a DIY kit that is relatively inexpensive and is very light comparatively. The DIY kit they sell is only 7.2lbs with hardware, which is amazing. Also because the outer ring has a shape to it, you don’t need to worry about coning or centering the tire. Also if you want to go even lighter they have an aluminum outer ring that will save you another 1.5lbs. Anyway here is a chart that I did to compare the weights.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/Beadlock-1.jpg

You can see that buy going aluminum I wouldn’t save any weight. I weighed my rims after I welded the beadlocks with the hardware and they are right at 28lbs. Now keep in mind there is a lot of variation in rim weights. The unbeadlocked steelies I took off were considerably heavier than what I started with. They weighed in at 26lbs. So I had a net gain of 2.5lbs per wheel. I’m pretty happy with this.

Ok back to Aero. I was very pleased with the quality. The inner ring holes all had nutserts installed so no need to use a box wrench on a nut on the back side when torqueing down the bolts.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/100_5427.jpg

One thing I was surprised by was that the inner ring only had 16 nutserts and holes and the outer ring had 32 holes. If I had read their webpage better I would have seen this. The other thing I was surprised about was that the bolts were 5/16’s and not 3/8’s like most other manufacturers recommend. In addition the bolts were just case hardened and not grade 8. So I went to the local Fastenal and bought 64, grade 8 5/16’s flange bolts. I spoke with tech support at Aero and they don’t think the number or size of the bolts will make a huge difference for my application. The bolt heads are protected from rocks by the ring and they use this setup on 800hp sprint cars. They did suggest checking the torque regularly as most of their users change tires every week. Only time would tell.

The powder coating on the outer rings is very good. These are 1/8” but with the pressed outer, that adds a lot of strength over a flat piece of steel like most DIY kits. There is also a mounting flange for a mud cover that I’m not using and was tempted to cut off. Maybe I’ll do that at a later date. In addition all my valve stems had to be relocated. With the beadlocks on they pointed directly at the inner ring. It would make it virtually impossible to fill with air. So I used a solid rod to fill the gap and welded the holes closed. Then I redrilled holes out of the way.

The welding was pretty easy. I took my time and prepped everything well. Ground the rim and the inner ring then wiped them down with acetone. Due to the fact that these are not ¼” thick they sit further down in the rim than other DIY kits so I tacked them in then very carefully cut 3/16” off of the rim. This way the weld surface was flush. Here are the pictures completed and mounted on the Jeep.

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


http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/100_5486.jpg


http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/100_5487.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/100_5485.jpg

If you’re interested in Aero Race Wheels they don’t sell directly you have to go through a vender. You can e-mail Josh at Trailhead Customs for pricing.

josh@trailheadcustoms.com (josh@trailheadcustoms.com)

Also on a side note they have complete beadlock rims in 5 x 4.5 and 5 x 5. The 2 most popular Jeep bolt patterns. They have various backspacing and colors. They are also really light at 23lbs each.

[Bluegill]

Very nice! :kewl:

[Hadfield4WD]

Thanks.

[96 coutry cherokee]

I like the yellow it gives your xj a little BLING lol :)

[ParadisePWoffrD]

looks good Matt... if I hadnt found the aluminum beadlocks, I would have done these...

[Hadfield4WD]

Here is the damage form towing the other xj off Harlan.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/100_5327.jpg


http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/100_5512.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/100_5514.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/100_5515.jpg

[96 coutry cherokee]

It seems that your bandwidth has been exceeded again lol