My "Project Junk" Build

[JRW7072009]

I called it Project Junk because when I bought it thats what it looked like.

I am doing a build thread on what I have already done so far and any new progress when I can.

A little bit if history I bought my 94 XJ Sport off Craigslist in April 09. I had no unibody damage and a ton of maintenance records so I decided to buy it.

Here is what it looked like the day I bought it.




I bought some new/used JY parts and a header panel and grill from ebay along with some clear turns and markers.




Next was time do do something about the paint, I liked the color but could not stand the clear coat flaking off like it was. So I sanded all the clear off smooth.



Also got rid of the trim.



Masked it.

[mcatald]

I'm confused. Is this a thread on a new project or is it the one in your avatar in various stages of completion.

[JRW7072009]

After a few cans of Rustoleum Satin Black spray paint.




Then I threw on a front bumper from the JY. Installed a 1 3/4 budget boost, some Rubicon wheels, and trimmed the fenders.



Next was time to get rid of the D35 and get something better. I went to my local JY in search of a 8.8, and I happen to find a 87 XJ with a D44 so I said why not its almost as strong and it bolts right in. I gave it some new drums, wheel cylinders, and shoes the old ones where shot.

[JRW7072009]

Originally Posted by mcatald

I'm confused. Is this a thread on a new project or is it the one in your avatar in various stages of completion.

Yes the one in my avatar, this is what I have done so far.

I am getting ready to do some more stuff so I decided to do a build thread on what I have done and will be posting more of what I am about to do.

[mcatald]

Nice looks awesome so far I look forward to more, especially the lomg arms.

[ZackXJ]

awsome! you cleaned it up very well!

[JRW7072009]

Originally Posted by mcatald

Nice looks awesome so far I look forward to more, especially the long arms.

Thank you, and I cant wait either taxes are supposed to be in my account on the 5th.

Originally Posted by ZackXJ

awesome! you cleaned it up very well!

Thank you, its been fun so far.

[XJ Philly]

Great improvements so far Can't wait to see the long arms

[JRW7072009]

Next I rounded up some other parts like:
RE 7.5" coils
Dodge UCAs for my lowers
Pro Junk shocks
2" RC shackles
Pro Junk full size AAL
JK UCAs cut, shortened, and re welded
Stock JK sway bar end links
Some used 315/75/16 M/Ts
And I got this.



I don't have many pics of the my budget lift install cause (it sucked) I am planning to upgrade with 63" Chevy leaf springs and LA upgrade. So I will get detailed pics of those installs after I do them. I didnt have a SYE yet cause D44 pinion is longer so my D line angles where pretty good with a 3/4" T case drop.

Here is after the new 15x10 Pro Comp Steelies and 35" Xterrains





I do have some pics of my rear fender patch job and my bump stops. I will get some pics of those up soon.

Like most of us here my list of things to do to the XJ are never ending but here are the plans for what I want to do next when funds and time allow.

These should be done over the next few weeks...
Long Arm upgrade (RE possibly)
JCR OTK steering
Adjustable track bar
Sliders JCR stage 3
63" Chevy Leaf springs

These will be next on the list (in random order)
JCR front bumper with 2" receiver
XRC 10 Comp winch
Warn Demountable winch cradle
SYE
Gas tank skid
Rear bumper
Roll cage

For the rear axle:
Ox locker
4.56 Gears
Chromoly axle shafts

The front axle will be getting gears when I do the rear but that's it, I am looking to do the G2 D44 front with some Reid racing knuckles and possibly the Detroit locker. Then some 36 or 37" tires.

My goal for all this to be done is spring time 2011

[JRW7072009]

Here is my Ghetto Fab work on my rear fenders and my super ghetto bump stops.

I did the bump stops out of metal I had laying around the shop and some old full size truck bump stops. I plan to make some more sooner or later.

I started with a mess of metal.


I chose these over the stock XJ just cause there thicker and stronger.


Cut and drill 4 stips of metal and welded them on a square tube.


And bolted the bump stops on and bolted them to the Jeep.
I made them offset a little to clear the shocks, I plan to make a better set one day. These work for now.

[moab]

looking good! love the dull black

[JRW7072009]

I cut the rear fenders and water was getting up in the back and soaking the rear carpet. So I had to make a quick fix so here is my patch job I did last week.

I used 20g steel and had a 220 Miller welder, trying o to weld to the XJ body was a real test to my welding skills. If I held the trigger to long it would burn right through the XJ body.

I cut the inner fender or wheel well back a little till it flattened out and took the 20g x 4" x 4' piece of steel and put a self tapper screw in to hold it. Then tacked it in a couple places.



Then I used a body hammer and a ball peen hammer to bend and shape the metal closer to the body, and tack it all up.


Then when I got it all in place I started to stitch weld it in small sections.


It was a PITA but I got it done and I shot it with some under coat that apparently does not dry fast at all. Here it is after some grinding I still need to clean it up on the insides but grinding sucks and I ran out of time.




I am going to strip the cheesy under coat off and smooth it all out with a flap disc and prime and paint it but for now it stops the water and mud from soaking my rear carpet.

[JRW7072009]

Originally Posted by XJ Philly

Great improvements so far Can't wait to see the long arms

Thanks, yeah I cant wait I'm like a kid on Christmas Eve.

Originally Posted by moab

looking good! love the dull black

Thanks, it turned out better then I thought it was going to.

[Alexfm]

I really like where this is going. Im think I might paint my hood with a satin black strip on it, and maybe do that to my side trim as well. Did you buy the clear lenses or did they come with the header panel? Im thinking about getting some of those as well.

[CT99XJ]

looks good man. the carpet issue is why i kerfed and folded my rears instead of cutting it outright like that. it got me less of an opening, but it was a little safer on the cutting because of the pinch seam.