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Mud_Pig · 08-05-2010, 07:29 AM

Well I guess I will post a build page of the current Jeep.
We started with a bone stock 97XJ 4door 5 spd with a HP D30 and 29spline 8.25 rear sproting good old 3.07 gears.
Here is a pic of the Jeep sitting next to our old Jeep (93 YJ on 35's)

The "original" purpose of this build was to do a small lift and use it as our guide jeep for the Penn's Woods Jambo in Bradford PA.

Mud_Pig · 08-05-2010, 07:37 AM

Well the parts started to arrive.

The list included:
15x8 Soft 8 wheels
32x11.5R15 BFG KM's
A/A SYE
Tom woods rear shaft
RE 4.5" Full Kit
Rusty's rock rail and t-case skid

Mud_Pig · 08-05-2010, 07:42 AM

Got everything on but the Rock rails and could not believe how well it road.

An of course I have to put a shot of the wife in with "her" Jeep.

Mud_Pig · 08-05-2010, 07:48 AM

Got the rock rails on (these things are tough!!!!!)

The idea behind this build was to make the XJ a capable wheeler while I took the YJ off the road to do some much needed repairs and build it back up from the ground up.

So it got wheeled a lot......

Mud_Pig · 08-05-2010, 07:58 AM

Well it's funny how plans change from what you thought you would do.

We were about to become parents and after a lot of thought I decided to sell off the YJ and put all the money from it into the XJ and make that our new full time Jeep.

Stage 2 of the Jeep was going to be simple (I thought)

2" spacers in the front and rear.
35" BFG KM2's
Throttle body spacer
4:10 Gears
and some RC drop brackets for the front control arms.

So in with the gears spacers and tires.

Mud_Pig · 08-05-2010, 08:22 AM

Well with the lift, tires and gears in, it ran great......On the road. But there was no way I could take it offroad as there was not enough clearance in the wheel well.
We contemplated what to do, do we just cut till they fit or go bushwackers?
Well we wanted to keep a clean look, so a set of bushwacker flares were ordered up.

Only shot I have of the install is of my brother in law working away.

Mud_Pig · 08-05-2010, 08:46 AM

Testing out the set up I was very impressed with how well it was working.

Now it was time for some little goodies.

First up was a set of seats.

The brackets that came with them were useless so I had a good friend custom mount them to the original seat brakets with a little fabbing and welding.

**CT99XJ** · 08-05-2010, 09:00 AM

Holy hell, I like this build.

Mud_Pig · 08-05-2010, 09:39 AM

Next it was time for something usefull. I had contemplated putting an OBA system in the Jeep for running tools (still am) but decided to go a different path for now.

1000w inverter mounted under the rear seat will allow me to run an electric impact gun, grinder, drill ect plus if i need to charge the laptop I have it all there.

Here is the location.

I did not want to lift the seat everytime I had to use the inverter though, so my brother inlaw and I came up with this.

Opened up the side to gain acess to the wire and extend them.

My brother in law made up these boxes for the outlet and power switch from robotic diag port covers.

We got a chance to use it when a friend slashed his tire out on the rocks.

**mcatald** · 08-05-2010, 09:56 AM

Your rig looks nice, great build thread.

Just one thing; you would think with all the money your spending on it you would get some lift supports and leave the broom at home.

Mud_Pig · 08-05-2010, 09:56 AM

So with the 35's I thought it was time for some beef under it.
After looking at my options I decided to build from scratch a 03-06 TJ rubicon D44 front axle for it.

The new Housing waiting for something inside!

A box of goodies!

And the main piece, a factory carrier with the air locker.

And all set ready to go!

All that is left is to put it in the truck.

Mud_Pig · 08-05-2010, 10:29 AM

After having the axle sit in the garage for a couple weeks (felt like longer) I had a free weekend to install the axle.

Out with the old.

And in with the new.

We decided to mount the Factory compressor on a pre existing bracket by the brake booster.

For the switch we decided to go with a ARB switch.

With the axle in I could only get under a liter of fluid in, so we had the fill plug moved up about an inch

I forgot just how much a locker in the front helps, it has got me out of a lot of "could be" ugly spots.

Mud_Pig · 08-05-2010, 10:31 AM

Quote:

Originally Posted by mcatald

Your rig looks nice, great build thread.

Just one thing; you would think with all the money your spending on it you would get some lift supports and leave the broom at home.

LOL I just can't be bothered with them yet, they still work when it's warm out though.

Mud_Pig · 08-05-2010, 10:55 AM

Well, while I had the Jeep in the air to replace the brakes, I found the the bottom leaf on the right side had split and was working its way apart.
It's hard to see but the split is right between the u-bolts.

So it was time for an upgrade!!!
I ordered a set of Rusty's 6.5 rear springs, to go with the Rusty's 9" front coils I had in the garage with a RE long arm kit that had been lengthened for the bigger coils.
I don't have many pics of this install though.

Goin up in the air.

New springs in the rear.

No turning back now.

And old lower from RE 4.5' kit vs RE long arm kit.

And one side in.

Mud_Pig · 08-05-2010, 11:11 AM

Next step in the saga....

After running this Jeep as a DD and trial rig for a couple years we decided it was time to clean up all the rust and put the Jeep off the road.
So into the shop it went for body and paint.

And the paint is almost done.

Just waiting for the floors to get done and then they have to re-do the clear coat. Once it sits for a week or so I will re-badge it and get some pics of the finished product.