Stumptaco's has gone over to the darkside..XJ style.

[StumpXJ]

The time has come for me to start the new thread showing my buildup of my recently acquired 1996 XJ. This is the vehicle I decided to replace my 98 Taco with since Toyota is buying it back.

I decided to BUY an XJ here instead of shipping ours over from the states (we have an identical one at my in-laws in Georgia) It was going to cost about $2,600 bucks just to get it shipped from my inlaws to Germany, so I couldnt really justify spending the money on a perfectly good daily driver jeep that is barely worth the cost to ship it over. So, we will keep the XJ we have in the states as it is much easier when we visit family and friends since we dont need to rent a car. I stumbled on a 1996 XJ sport at the local Auto Recycling Center here on the military base last week and put in a bid. Well, I found out Monday I had the high bid, so I went to check out the XJ a little more thoroughly. It has about 50,000 less miles than ours, and everything works perfectly.

The reason it was up for bid/didnt pass inspection?...... Right rear wheel cylinder was blown out and leaking, and the right front signal doesnt work. 15 dollars in parts, and she will be as good as new.

I took delivery of/paid for it on Monday, and had to wait until today (Friday) before I could register it with temps tags and until I get the wheel cylinder fixed. I thought it was a HECK of a deal, so I jumped on it. It was driving me crazy trying to decide what I wanted to do and which vehicle to buy. With the XJ, I had almost $9,000 bucks left over from the toyota buy back, so I am getting ready to order a huge amount of goodies to make it as close to the ultimate expedition/trail XJ as I can.

Mods will start very soon, firstly with my roof rack, lights and RTT on top as we have a camping trip to Finland on July 4th weekend.

Specs:
1996 Cherokee Sport
4.0Liter High Output
Automatic Tranny
NP 231 Transfer
Chrysler 29 spline 8.25 rear axle
Dana 30 in front
127,000 miles.

This is as stock as it will ever be. Took a little time today and cleaned it up.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0376.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0375.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0374.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0373.jpg


Took about 2 hours in the engine area. I am anal about engine compartment cleanliness, probably from being a mechanic for about 10 years. This one was filthy, I should have done a before and after shot.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0378.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0377.jpg

The truck it is replacing.

http://i114.photobucket.com/albums/n257/topfuel443/Truck%20pics/SS100280.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Truck%20pics/DSCN0217.jpg



Thanks, ~James

[adrenaline503]

I hope part of your buget is for paint! ;) I had a 96Xj and it was pretty cool. I can't wait to see the build, 8k would go a loooong way. Do you plan to ship it back to the states at some point?

[StumpXJ]

Yeah dude... not sure what they were thinking with the teal. The color isnt exactly expo white, but it will get a re-vamp soon enough. Yep, if all goes well it will be coming home with us, and will be our trail/camping/expedition vehicle. I will daily drive the jeep we have in the states.

~James

[adrenaline503]

I am seriously jealous, for that price you couldnt go wrong. I would reinforce the "frame" above the rear wheels sooner than later though. Is that a US spec one or a Euro one?

[OverlandZJ]

James, nice platform! Best of luck with it.

Whats the plan for mods?

[StumpXJ]

I am seriously jealous, for that price you couldnt go wrong. I would reinforce the "frame" above the rear wheels sooner than later though. Is that a US spec one or a Euro one?

Its a US spec. It was owned by a Senior Master Seargent in the Air Force here, and I assume he is the one who brought it over. I will do a carfax report on it just to find the history later on.

Yeah, I have been reading for weeks over on the NAXJA site (just became a member), and have gotten familiar with the trouble areas. I will definitely be plating the unibody rails. I Put about 50 miles on it today just doing some around town stuff, and it didnt skip a beat, drove nice and straight, shifts good, has plenty of power, and no rattling or clunking. I think it was a good deal, and aside from the color, I am extremely happy with it.

~James

[JPFreek1]

Nice catch on the XJ; however, that Taco was freaking awesome!

[StumpXJ]

James, nice platform! Best of luck with it.

Whats the plan for mods?

hmm.... I always get into trouble when I list things I "want" to do to vehicles, but I will give it a go:

Many of the items will be coming over from the Taco.

Full length roof rack, HID hellas on front, just like the taco, space behind the lights for a few items, probably the size of Jerry Cans. Then at the very rear of the rack will be the RTT. I have the rack, but I will have to extend it and do some modifications to it, especially the mounting.

Front bumper and winch will be first, I am pretty sure it will be a tube/plate hybrid, and will have a stinger, about the size of the taco.

The rear bumper will be next, and will include a tire gate, Jerry can mounts, and possibly high lift mount, but it may go somewhere else.

Kick out sliders like the taco, once the unibody gets beefed up.

all my elecronice gizmos, fridge, cameras, TV monitors, DVD, Navgation, stereo (this thing still has the factory tape deck!), etc will come over.

I will be going with the Rubicon Express 5.5" Longarm kit, unless I can be talked into something different. I want longarm, but not a rediculous amout of lift (8 inches etc.) I will run the Cooper STT's in probably 33 inch size. I would run the 285/55's, but we have too much mud around here for an AT tire. I need the full mud terrains.

probably some soft 8 wheels, or I may just paint what I have.

I want to re-gear to 4.56's, and an ARB in the rear.

The interior will get a revamp as well, I will be building a custom dash area to house my switches, Scan Guage, and anything else out of machined Delrin plate. Also, the mud around here does not bode well with carpet, so that will most likely come out and get rhino lined on the inside, or atleast in the cargo area. Not sure if I am going to use a drawer system or just keep it open, but that will come once I get it all figured out.

Thats a pretty substantial list, and will most likely EAT most of my budget. I will be doing all of the wleding and fabricating myself, but steel over here in Europe is rediculously expensive, as well as most anything else. I will have to pay for the lift kit in euros and buy it from here as its too heavy to ship from the states, so that will eat about 3000 bucks, not to mention the ARB, Gears, SYE, Tires/wheels, and I am MAKING myself get a new Engel out of the deal :victory: Budget will non-existant after all that!

Cant wait to start on it!!!!!!!!!!!!!!!!!!

~James

[StumpXJ]

Nice catch on the XJ; however, that Taco was freaking awesome!

Thanks man, it is in my driveway getting torn apart slowly. Its a painful process to say the least. Still dont know when Toyota is going to come pick it up.


~James

[Purple People Eater]

Did I miss the thread that explained why Toyota is buying your truck?:confused:

[OverlandZJ]

hmm.... I always get into trouble when I list things I "want" to do to vehicles, but I will give it a go:

Many of the items will be coming over from the Taco.

Full length roof rack, HID hellas on front, just like the taco, space behind the lights for a few items, probably the size of Jerry Cans. Then at the very rear of the rack will be the RTT. I have the rack, but I will have to extend it and do some modifications to it, especially the mounting.

Front bumper and winch will be first, I am pretty sure it will be a tube/plate hybrid, and will have a stinger, about the size of the taco.

The rear bumper will be next, and will include a tire gate, Jerry can mounts, and possibly high lift mount, but it may go somewhere else.

Kick out sliders like the taco, once the unibody gets beefed up.

all my elecronice gizmos, fridge, cameras, TV monitors, DVD, Navgation, stereo (this thing still has the factory tape deck!), etc will come over.

I will be going with the Rubicon Express 5.5" Longarm kit, unless I can be talked into something different. I want longarm, but not a rediculous amout of lift (8 inches etc.) I will run the Cooper STT's in probably 33 inch size. I would run the 285/55's, but we have too much mud around here for an AT tire. I need the full mud terrains.

probably some soft 8 wheels, or I may just paint what I have.

I want to re-gear to 4.56's, and an ARB in the rear.

The interior will get a revamp as well, I will be building a custom dash area to house my switches, Scan Guage, and anything else out of machined Delrin plate. Also, the mud around here does not bode well with carpet, so that will most likely come out and get rhino lined on the inside, or atleast in the cargo area. Not sure if I am going to use a drawer system or just keep it open, but that will come once I get it all figured out.

Thats a pretty substantial list, and will most likely EAT most of my budget. I will be doing all of the wleding and fabricating myself, but steel over here in Europe is rediculously expensive, as well as most anything else. I will have to pay for the lift kit in euros and buy it from here as its too heavy to ship from the states, so that will eat about 3000 bucks, not to mention the ARB, Gears, SYE, Tires/wheels, and I am MAKING myself get a new Engel out of the deal :victory: Budget will non-existant after all that!

Cant wait to start on it!!!!!!!!!!!!!!!!!!

~James


This will be a killer XJ! I look fwd to your progress.

You'll love the LongArm ride. I'v been through several suspensions on my XJ looking for one that wasnt a pita to drive distance on interstate.

What width are the Cooper 33's? The stock wheels could work with some minor rubbing on the lower arms with a narrow tire... or some spacers. But if your gonna invest... wheels would be a better option.

With 4:56's and the Automatic (AW-4) running a 33 you should see RPM's in the 2200 range at 65MPH. I get about 20 MPG on Interstate with this combo, some others have reported less.

I dont know the width of your RTT, but mine is 72" wide and takes ALL the roof area on my XJ. No way i could mount fuel/water in front.

Take a good look at the floor in your XJ, they are prone to rust when used in areas that salt the roads. If it spent time there you may need some minor repairs.

[StumpXJ]

Did I miss the thread that explained why Toyota is buying your truck?:confused:

My Toyota buildup thread is here, and I talked about it, but I often forget how big the board is now, and not everyone will have known about it.

http://expeditionportal.com/forum/showthread.php?t=5416

Here is a thread talking about why Toyota is buying them back. Its due to premature Frame rust resulting in large chunks of the frame caving in or falling off.

http://expeditionportal.com/forum/showthread.php?t=12850

~James

[StumpXJ]

This will be a killer XJ! I look fwd to your progress.

You'll love the LongArm ride. I'v been through several suspensions on my XJ looking for one that wasnt a pita to drive distance on interstate.

What width are the Cooper 33's? The stock wheels could work with some minor rubbing on the lower arms with a narrow tire... or some spacers. But if your gonna invest... wheels would be a better option.

With 4:56's and the Automatic (AW-4) running a 33 you should see RPM's in the 2200 range at 65MPH. I get about 20 MPG on Interstate with this combo, some others have reported less.

I dont know the width of your RTT, but mine is 72" wide and takes ALL the roof area on my XJ. No way i could mount fuel/water in front.

Take a good look at the floor in your XJ, they are prone to rust when used in areas that salt the roads. If it spent time there you may need some minor repairs.


Yeah, I have read nothing but mostly positive things about the long arm set-up. Hopefully it works out, it sure is pricey enough.

The Coopers.... well I am not sure what size I am going with exactly, I want a tall narrow tire, but not sure if I can find something in the STT to fit the bill.

Glad to hear you like the gear set-up, its what I think I will go with. I noticed today with the stockish size tires it turns about 2250 RPM at 75mph (just with the speedo/tacho, not a scan guage). I am not sure what gears I have currently, as I *THINK* this Jeep has the factory "tow package" and I read somewhere that it may have slightly lower gearing than the standard sport model with the auto/4.0L. Aside from actually looking at the gears, is there a code on the door jam somewhere that tells me what gearing it came with? The Toyota has this, but not sure about the Jeep. I know its one or the other ratios.

My RTT is a little smaller than yours, its ~ 60 inches wide. Its the two person model (maybe could squeeze in a small third, in pinch). I actually spent all day today building/modifying my old rack to how I wanted it to work on the Jeep. It is 82 inches long, and runs the entire length (literally) of the roof. I have it set-up to allow the RTT to be on the rear, and easily have enough room to zip on the cover, I have a basket area (raised sides) in front of that which will allow four Jerry cans, two on each side, and in front of that is my original light cage/mounting area for the Hella 4000's. I was lazy and didnt have the camera, but will have pics in a few days once it gets finalized. I didnt really want to hack up the old rack and extend it, but it was the cheapest/easiest solution. I just have to come up with a gutter mount system. I may build the mounts myself, as the gutter mounts I have seen are not cheap.

I havent figured out where the Jeep came from in the states yet, or how long its been here (we use salt here), but I did spend a few hours under it while it was on the lift. I noticed only very slight surface rust in the floor pan areas, both front rear, and I will be fixing that VERY soon, as I dont want a rust problem again. It should be an easy fix as it is, since its seems to be very light at least I hope! The rest of the underbody looks suprisingly well for a 12 year old truck.

Lots of work to do, so little time.

I am listening to any other areas to look for, keep it coming!

~James

[Jackel18]

4.0 with an auto (AW4) you should have 3.55's, unless the PO changed them.
you can comfirm the gear ratio by looking at your rear axel. on the left side of your diff cover there should be a metal tag that will tell you your ratio. the tag will also tell you if you have a LSD.

I loved your toyota and can't wait to see what you do to the XJ.

[StumpXJ]

Thanks for that info Jackel, I will have to look at that area again. I dont remember seeing anything, but I could have missed it.

~James

[OverlandZJ]

James, take a look at Clayton's LongArm system. I believe it's a bit cheaper than RE while not sacrificing quality. http://www.claytonoffroad.com/ I met Clayton yesterday at NAXJA-NAC's annual event, the bushings he uses are MASSIVE. You could still use your choice of spring. I have the RE upper and lower arms with Claytons crossmember (RE was still a prototype) when i put the suspenion on my rig.


Take a close look on the pass side floorboard along the trans tunnel above the downpipe and where the catalytic convertor sits, prime area for rust through. I would also suggest a long weekend pulling the carpet and inspecting it from the inside, maybe Herculine/Durabak it while your at it. My rig has a few spots that need attention after 8 years in Pa.

I realize you have alot of reading to catch up on @ NAXJA to familiarize yourself but i'm betting two concerns you'll need to address shortly will be a cracked header at the collector and the oil filter adaptor o-rings. Very common issues as well.

Again.. welcome to the XJ world!

:safari-rig:

[StumpXJ]

LOL... yeah, it has the typical exhaust leak sound that we are used to from the one we have in the states, I am assumiung this is at the collector area you are refering to? And..... there was oil spooge all around the oil filter area. Maybe the oring problem you speak of? I will do a search for this problem on NAXJA.

Thanks for the info on the suspension stuff, I have seen more an more guys making the lifts out of peices instead of buying the one whole kit. That may be my best bet, and will look into it when the time comes, thanks for the link.

I did read about the area above the cat, and mine appears to be ok from the underside, but the carpet is coming out this week, so I will be able to tell more pretty soon.

Thanks for the help! I will be picking your brain soon enough, hope thats ok! :)

~James

[gabe]

I've run that same set up for over a year now including the STT's Which I liked but get louder as they ware(most do). I did have a little problem though with highway speeds. When my speedo said 70 my gps would say 60 (stock speedo gear)and I was running closer to 2500 rpm's and when trying to get speed for a big hill I would turn 3k. So I just moved up to 34's a true 34 and it's a lot better on the highway. I'm still going about 5mph slower then speedo but it seems to be working the motor less. Oh and as for the LA If your going to wheel hard I would agree with Overland look at Clayton's I've seen them in action and Clayton is a great guy.

[IXNAYXJ]

James, take a look at Clayton's LongArm system.Haha, beat me to it. What I would do is buy the springs from RE and the Clayton LA kit seperately. It does require some welding but it's not too bad.

http://www.naxja.org/forum/showthread.php?t=955537

http://i79.photobucket.com/albums/j160/ixnayxj/Elbe%20Memorial%20day%2008/CIMG5805.jpg

Also, check out the Interco Trxus M/T for a tire; they're very well behaved on the road, last a long time, magical in snow and rule in the sloppy conditions you describe.

-----Matt-----

[FshTaco99]

Clayton has THE best customer support of any XJ affiliated long arm kit. Like T&T their product(s) are overbuilt and can take the abuse. I ran their LA kit on my ZJ. But, with Clayton, you break it, they will replace it no questions asked. With T&T though, you could buy the stiffeners, LA kit, belly skid, and bumpers and they will give you a wonderful deal in the long run.

[boknows]

Stumptaco,

Where do you over there. I used to live in Spesbach(near landstuhl) and would drive into kleber kaserne. I miss some of it, beer and schnitzel. Looking forward to your build, do you guys do much camping over there, it was hard for me to find anyplace in Germany where we could drive offroad

[IXNAYXJ]

With T&T though, you could buy the stiffeners, LA kit, belly skid, and bumpers and they will give you a wonderful deal in the long run.I bent my TnT stuff too many times. I was glad to sell it and move to the Claytons kit.

-----Matt-----

[OverlandZJ]

Haha, beat me to it. What I would do is buy the springs from RE and the Clayton LA kit seperately. It does require some welding but it's not too bad.



-----Matt-----

Yep, if i had it to do over again i think i would opt for Claytons arms as well.

[XXXpedition]

It does require some welding but it's not too bad.
if it's welding at the frame...
he's in germany. welding at the frame renders your road worthyness worthless.
damn TUV in europe...

[StumpXJ]

I've run that same set up for over a year now including the STT's Which I liked but get louder as they ware(most do). I did have a little problem though with highway speeds. When my speedo said 70 my gps would say 60 (stock speedo gear)and I was running closer to 2500 rpm's and when trying to get speed for a big hill I would turn 3k. So I just moved up to 34's a true 34 and it's a lot better on the highway. I'm still going about 5mph slower then speedo but it seems to be working the motor less. Oh and as for the LA If your going to wheel hard I would agree with Overland look at Clayton's I've seen them in action and Clayton is a great guy.

I like the STT, I have them on my Taco, and they do get loud as they wear, but most do. I was contemplating going with the 35 X 12.50 15's, (actual dia is about 34.?), but I think I will be happier with the 33 inch tire. Both for gearing, and mileage. Thanks!


Also, check out the Interco Trxus M/T for a tire; they're very well behaved on the road, last a long time, magical in snow and rule in the sloppy conditions you describe.

-----Matt-----

Matt, what kind of mileage do you get out of the Truxs? I am very limited on which brand tire I get if I get them on the base (MUCH CHEAPER), Mickey Thompson, and Cooper is about the extent of my selection. Thanks for the link, I will look in the Clayton arms.



Clayton has THE best customer support of any XJ affiliated long arm kit. Like T&T their product(s) are overbuilt and can take the abuse. I ran their LA kit on my ZJ. But, with Clayton, you break it, they will replace it no questions asked. With T&T though, you could buy the stiffeners, LA kit, belly skid, and bumpers and they will give you a wonderful deal in the long run.

Thanks for the info, I always build my own armor and skids, so that is taken care of. I just prefer to have the suspension components made by professionals, and it sounds like Clayton's is the way to go.



Stumptaco,

Where do you over there. I used to live in Spesbach(near landstuhl) and would drive into kleber kaserne. I miss some of it, beer and schnitzel. Looking forward to your build, do you guys do much camping over there, it was hard for me to find anyplace in Germany where we could drive offroad

We are over here with my wifes job. We are both civilians, but she (GS-13) works for the Army Corps of Engineers as a project manager on Ramstein air base. I am finishing up my college degree, and working at the local Se3rvice Credit Union as a teller on the base. I also run my own internet business as a side job/hobby.

We do quite a bit of camping over here, but not much in Germany. I do a lot of traveling with my side business to different countries to attend races, and that is usually when we camp. There are quite a few off road parks in Germany, but no real trails per se. We normally go to France for offroading trips. I recently took a 2,200 mile trip to Sweden and back, and camped for 5 nights. My wife and I are driving to Finland and back over the July 4th weekend. It will be a 4,800 kilometer round trip. We are going through the old eastern block countries (Czech, Lithuania, Estonia, Latvia, Poland etc) on the way up, and back down through sweden and Denmark on the return trip. Unfortunately, the Jeep is no where near ready, so we are mounting the RTT on the top of my wifes little suzuki wagon. It gets 36 Mpg, so that will be better in the long run.

Beer and Schnitzel. Yes. I love the beer and Schnitzel. I am having a Scoeffehofer Heffe Weisen right now :)


Yep, if i had it to do over again i think i would opt for Claytons arms as well.


I bent my TnT stuff too many times. I was glad to sell it and move to the Claytons kit.

-----Matt-----

Sound like the general consensus is for the Clayton arms! I will be looking into them.


if it's welding at the frame...
he's in germany. welding at the frame renders your road worthyness worthless.
damn TUV in europe...

Not true for us. One of the benefits of being over here with the US military is not having to have our vehicles TUV compliant. We have our own vehicle registration/inspection department, and TUV rules do not apply. I have tons of stuff welded to my Taco frame, and have no issues. The German guys I wheel with are very jealous of our situation, they hate the fact that I can drive around with everything on my truck, and not have to deal with TUV.

You US guys should know just how good you have it, even in Cali. The TUV SUCKS!!

~James

[Bongo Boy]

I'm pretty much a jeep guy, and I'm really scratching my head. I've kinda sorta gotta know, WTF were you thinking at the time this went down?

[IllianaXJ]

Looks like a great platform for a build. I have the TNT LA setup with Rubicon Express 5.5" coils/4.5" leafs, if I had it to do again I would have gone with the Clayton's. The front driveshaft becomes the low point with the way the TNT arms tuck.

For tires, I run tall & skinny 33x10.50 BFG MTs, and couldn't ask for better. Great on road and off. Only issue is they can be hard to find in stock, I ordered mine from Tire Rack.

FWIW, here's my setup, sounds similar to what you are shooting for. I have trimmed the snot out of the fenders though.

http://i61.photobucket.com/albums/h76/bfourman/01XJ/HPIM1176.jpg

http://i61.photobucket.com/albums/h76/bfourman/01XJ/HPIM1238.jpg

[StumpXJ]

I'm pretty much a jeep guy, and I'm really scratching my head. I've kinda sorta gotta know, WTF were you thinking at the time this went down?


what do you mean WTF was I thinking? Did you even read my posts?

Toyota had to buy back my old truck due to a major frame rust issue (ie swiss cheese on my frame). I made a HUGE profit, and it has allowed me to build pretty much whatever I want. Where is the confusion in that?

~James

[gabe]

Yep no complaints about the STT's plus I get a family discount when I get them from my cousins shop. I come from a rock crawling background so the only thing that worried me was the sidewall is only 3 ply I never got a flat but it still worried me, I just moved to the truxes M/T's (34x12.50) in part of that fear even if it's imaginary, the Truxes are 6 ply. Haven’t got enough miles on it yet but it’s sipped more then the STT which in theory is suppose to help wear, we’ll see.

[IXNAYXJ]

Sorry, I've been out wheeling and just saw the question about the TrXus. I rotate mine through for a new set about every 15k miles; they're at about 60% tread at that point and still very usable. I know guys getting 30k miles out of a set, but I drive hard and expect optimium performance.

-----Matt-----

[StumpXJ]

Ok, finally got some time today and finished up the roof rack. Its not 100% finished, but close enough that I could go ahead and mount it and the RTT. This is mostly the same rack I had on my taco, except I lengthened it so it could accomodate my RTT, 6 jerry cans (or whatever), and my lights on the front. Needless to say, it takes up my ENTIRE roof length. I was able to put the rack up on the roof by myself, so I would guess it weighs 75 pounds with the lights? The lights are pretty heavy, so the rack itself is fairly light. I removed the "side" portion from the old rack, so zipping my RTT cover on should be a breeze now that there are no steel bars in the way.

I also had to change the mouting system, as this was mounted on my old ARE camper shell on the taco. I wanted to use the gutter rail's, as thats what most use. I was going to buy some gutter mounts, but at over 100 bucks per set ( I wanted 3 sets) I couldnt justify the money on such simple bracketry. I made my own, and I am quite pleased with how they turned out. I was honestly a little skeptical to do this myself, but I saw a Defender 110 here locally, and checked out their gutter mounts. This is basically a copy of what I saw on the Defender, and they worked out very well. That 300+ bucks will go towards something a little cooler than brackets now!

I used 1/4 thick, by 1 1/2 wide flat steel for the mounts, bent them in my vise, and then welded short peices of tubing for the bolts to go through. I used 1/8 thick steel plate for the clamps, Cut them to shape, and bent the "hook" for the bottom of the gutter, then welded long bolts to the backside of them to complete the clamping system. About 2 hours worth of cutting and welding, and viola!

I got TOTALLY lucky on the rear lights. I completely forgot about them when I was doing my measurements/clearancing for the rack and the rear hatch, but it worked out. I have about 1/4" between the light mounting bolt and the hatch when its full opened.

Didnt have any time today to run the wiring, but will get to it soon enough.

I am hoping the color of the Jeep will grow on me, but for now, I have to use my imagination and pretend its another color (ANY other color). It all looks a little wierd as the rest of the truck is still bone stock, but it will come around soon enough. Waiting for my tires and wheels to get here, and starting to peice together the suspension. I think I will get the suspension/tires and wheels done first, then work ont he front bumper and interior.

Thanks, James

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0408.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0406.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0405.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0404.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0403.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0402.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0401.jpg

[ExpoMike]

Very nice!!!! I agree about the cost of mounts and have been wanting to do my own. I think you have motivated me to do something very similar.

Don't know if you have had it up there long enough to know but what type of decrease in gas mileage have you noticed?

Great job. :wavey:

[StumpXJ]

Mike, not sure yet on the gas mileage, just got back from a short ~30 minute trip, and didnt notice any added weight or wind resistance (although I know its going to effect it some), and didnt notice any added wind noise (its already fairly loud inside).

Thanks for the compliment! I really suggest you trying out the mounts yourself. In fact, if you want to do something similar to mine, I have plenty of the clamp plate that goes on the outside. Its already bent and cut, you just have to weld on the stud/bolt. Let me know if you can use it.

~James

[ExpoMike]

Mike, not sure yet on the gas mileage, just got back from a short ~30 minute trip, and didnt notice any added weight or wind resistance (although I know its going to effect it some), and didnt notice any added wind noise (its already fairly loud inside).

Thanks for the compliment! I really suggest you trying out the mounts yourself. In fact, if you want to do something similar to mine, I have plenty of the clamp plate that goes on the outside. Its already bent and cut, you just have to weld on the stud/bolt. Let me know if you can use it.

~James

Hi James, you're quite welcomed on the compliment, it is well earned. I will be interested in hearing how a longer freeway type trip does to mileage.

I would be interested in those clamp plates. I am looking to put 8 mounts (a little overkill but that's how I roll :victory: ). If you got 8 of them, I would be interested, just no idea what the shipping cost would be to San Diego.

Thanks!

[StumpXJ]

Hey mike, shipping will be about 8 bucks priority mail, next time I am in San Diego, you owe me a beer or two. Sound fair? :)

PM me your shipping addy.

~James

[ExpoMike]

Hey mike, shipping will be about 8 bucks priority mail, next time I am in San Diego, you owe me a beer or two. Sound fair? :)

PM me your shipping addy.

~James

Hey James, sent you a PM. You're on for the beers. Let me know next time you're in town. :chowtime:

[OverlandZJ]

James, that looks awesome!

Looking forward to see how you tackle the wiring into the cabin and your switch locations. I need to redo mine.

Also, how are your NATO cans secured?

[SEREvince]

Time to update your avatar! 199?-2007 Taco RIP!

[grahamfitter]

I never thought I'd say this, but the color is growing on me. Nice Jeep! :)

Cheers,
Graham

[StumpXJ]

Well, I decided to go forward with the dash reconfiguration, and mounting of my switches, scan guage, TV/Camera Monitor, and add a few 12v outlets. I have been contemplating for WEEKS on what I wanted to do, then I knew what I wanted, but had to figure ot how to go about it.

I have the bulk of it finished, but will not have pictures until tommorow after I re-install everything. I am pretty pleased with it all so far, the only thing left to do is run the actual wiring, and find a place to put a radio. I think I have the radio thing figured out, but wont know for sure till it gets here.

More on that stuff tomorrow

John, I am still deciding on where the wiring will enter the cab, but will takle that in the next couple of days as I reinstall the dash. I have 4 days off, through Tuesday so I will be able to spend some time with it. The Jerry Cans in the picture are just sitting up there to show how they will/would be placed. I dont plan on having them up there the whole time unless I know I will be needing them. I will have one can on the rear swing out gate that will stay on the whole time, similar to what I had on the taco. But, when I do put the cans up there, I will just do like I normally do and use a ratcheting strap through the handles and back down to the frame rails of the basket. The boxed portion holds the cans pretty firmly as is, and with a heavy ratchet strap, it should work just fine.

Vince, yes. yes I do. The Taco is still sitting in my driveway beleive it or not. It looks like it has been cannibalized by some hood rats as it is pretty stripped down. You are gonna like the snorkel on your taco, you get all sorts of goofy questions. See ya soon man!

Graham, thanks for the compliment, and I hope one day I can say the same thing about the color! The more stuff I do to the Jeep, the easier it is to look past the color...

~James

[Zam15]

Have you hooked up your lites yet? If so have you noticed any glare problems? I know when I have my rack w/lights that far forward I can barely see out the windshield of my Taco.

Nice start on the Jeep I am looking forward to seeing the rest of your build. :safari-rig:

[StumpXJ]

Zam, havent hooked up the lights yet, that will be in the next 2 days or so. I am fairly sure I will have to black out the hood for the glare, I imagine it will be bad since they are so far forward. When I had them on the Taco, they were behind that cab so there was no issue, but these are level with the top of the windshield.

I dont have a problem with blacking out the hood, it will be less "teal" that I have to look at...LOL.

I will know soon enough.

~James

[StumpXJ]

Ok, got the dash re-installed, and everything pre-wired.

I didnt get any before shots, because I can never remember the camera when I start on a project, so here is a photo of a similar dash, in a mostly stock configuration. Photo stolen from the net, not my actual dash.

http://4x4trailhunters.com/pictures/article_12_7.-Finished-Dash-Mount).jpg

Here is what I have after a lot (probably too much) of work. It looks like a simple thing to do, but it proved to be time consuming. Basically its a 2mm thick sheet of aluminum that I bent, and cut to size. I then cut out the openings for my 7 inch monitor used for my camera's (and the occasional DVD), Scan GuageII, and original A/C controls. I also mounted all of my switches, and added two 12 volt outlets on the left side. I did most of the cutting and drilling with my little milling machine, but it could have been done with a scroll saw and some patience. I had to move the A/C controls up to the old radio position, and I also blocked off the center air vent. The aluminum is basically screwed to the orginal dash face/plastic peice. I had to do quite a bit of trimming, both on the dash face and behind it to get everything to fit, but it worked pretty well.

I prewired all of the switches and two outlets with power and the load wires as well, but still have to hook up the equipment as I install it. I did this in an attempt to not have to remove the dash 30 times in the next few months as she is being built.

Obviously I have to find a new place for the radio, but I think I have it figured out where it will go. For wheeling and trails, I use the cameras, switches and scan guage the most, so I gave them the priority when it comes to real-estate. The main reason I need a radio?? To control my i-pod. I dont listen to the German radio stations, and all of my "CD's" are on the ipod, as well as my audiobooks for long trips. Not really concerned about fancy radio at this point.

Enough babble. Here are the after pictures

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0413.jpg

The open hole to the left of the picture is where the rear washer switch used to be, but I moved it over to the other side next to the defroster switch. I am making a new aluminum plate to cover this hole, and will also house my front and rear ARB locker switches.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0411.jpg


Thanks, James

[OverlandZJ]

:bowdown:

Outfreakinstanding....

[StumpXJ]

Thanks John!

Today I had to run a few errands and pick up some wire and relays, and on my way home to wire everythig up, I stopped by the post offcie to check the mail. I got a package from the guys who make the vinyl flooring for all sorts of vehicles, Automotiveinteriors.com. I decided to try this product, as an alternative to rhino lining the floor. I wanted something that was easy to clean, and wouldnt be destroyed by mud and dirt.

After picking this up, I decided to put in as much of it as possible instead of mess with wiring. Yanked out the front seats and center console, cleaned everything one last time, and was ready to start.

When I saw the size of the box this "Molded" vinyl covering came in, I was a bit skeptical. I mean, if its "Molded", how does it fit inside this little box right? according to the company rep, it came with the front section, rear section, and all new sound deadening/insulation material to cover the entire vehicle floor basically. This was all stuffed into a box that was about the size of a suitcase, and weighed about 50 pounds.

When I say "molded", this is what I was expecting, as it is the picture from the website that I bought this stuff from:

http://www.automotiveinteriors.com/carpetimage_200.jpg

Now, as you can see, this thing should just fit right in right?

Well, I opened the box, unfolded this stuff on the ground, and was not impressed for my 300 bucks. The material itself is perfect, its got a nice texture, it seems to be very tough, and is plenty thick enough to withstand a decent amount of abuse. But it aint "molded".

You could see in a few spots where they had heat pressed/formed a few humps and things, but that was about the extent of the "molding". Maybe I am expecting too much, but that picture is about as decieving as one could possibly be. I know that in order for this stuff to remain flexible, be boxed up and shipped out it would not be PERFECTLY molded, but come on!

I debated for about 30-45 minutes on stuffing it all back in the box and sending it back, but really couldnt think of another option for floor covering, and I did like the material.

I pressed on with the install. The rep from the company told me it required "minor" triming.... again, not exactly what the reality was. I started on the front section, which goes from the firewall, to the back seat edge. I fought (literally) this stuff for about 8 hours, and I FINALLY got it semi/sorta/halfway installed to a level where I can say I am KIND OF pleased. I am hoping that a few of the humps and wrinkles will flatten out with a little summer heat, and good ole gravity. I did stick the heat gun to a few of the areas, and the vinyl gets nice and flexible with heat. I am hoping the heat off the tranny and exhaust will aid in this process. I will finish the rear section tommorow and post pictures of this stuff. Its not perfect, but its better than stained carpet and a halfhearted attempt with roll on bedliner.

At this point, about halfway through the install, I cant really say I wouldnt recommend this to just anyone. Unless... you have 2 free days, lots of energy, even more patience, a decent understanding of upholestry and a friend to help would also be a good Idea. Even with that said, dont expect it to be easy or perfect. Maybe the rear section will go better for me. I probably shouldnt even do the rear section since its all getting covered with a platform anyway, but since I have it, I am going to put it in.

~James

[adrenaline503]

I am sorry to hear that the flooring is not what you hoped it would be. If it doesn't meet your expectations I would pull it out and mail it back for a refund. I dont know if there are any other options out there for you, but hopefully youll get something that you like. I can't wait for the pics.

[sandalscout]

Thanks for the heads up, I'd be curious to see how it turns out, if you wouldn't mind snapping a shot or two. I too decided to do this, from the same place, instead of rhinolining, but if it stinks, I'll look elsewhere.

[OverlandZJ]

Take a nice long drive and hope the heat helps it conform a bit better. If the cargo area section turns out to be junk i personally would return it and start looking for another option.

XJ's were available with molded vinyl flooring (alot of your fleet vehicles Police/Forest service etc) which may be a better solution. I'll look around and see if i can find a source for either OEM or decent replacement.

Thanks for the honest evaluation.

[StumpXJ]

Ok, I got the rear section done this morning, so the whole job took about 12 hours. I had already removed the old carpeting a few weeks back, so that will add another hour or so to the installation.

The rear section went in much easier than the front, as expected. It still is not perfect by any means, but I am over all satisfied. The molding and trimming could have been MUCH better from the factory, and they could have provided some sort of instructions or tips (they sent nothing). If I can give any advice with this stuff it would be to install it on the hottest day of the year, because heat is your friend with this product. I used a heat gun for some stubborn areas, and it helped tremendously, but the temp here is overcast and about 70 degrees (normally nothing to complain about).

I am very pleased with the actual material, and I think it will hold up nicely. In a scale of 1 to 10, I would rate the material at about 8-9. with the same scale, I would rate the ease of installation and quality of molding a very liberal "1". Enough babble, here are some pictures:

Again, this is what one would expect to get, as this is what is advertised:

http://www.automotiveinteriors.com/carpetimage_200.jpg

But this is what you actually get. This is the rear section. I think you understand my first impression:

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0416.jpg


Here is a close up of the texture. Its about 1/8 thick, and pretty tough.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0417.jpg

Starting to fit and trim the rear section:

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0418.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0419.jpg

Rear section mostly complete:

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0420.jpg

Passenger side front:

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0423.jpg

Driverside front:

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0421.jpg

Rear foot well:

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0415.jpg

Where the rear seat would normall be. I dont care about this area, and didnt spend much time with it as it will have a platform put in to be level with the rest of the rear section. I am not running any rear seat, and have removed all of the seatbelt stuff.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0424.jpg


In all honesty, the pictures dont quite do the finished product justice. I am actually overall happy with it, and will be very happy if the humps/bumps settle flat over the next couple of weeks. It was just a pain in the arse to install, and very misleading on what I was getting.

Once I get the platform built and covered, I am sure it will clean up the rear section to look pretty decent.

~James

[StumpXJ]

Ok, the second half of my day consisted of installing the rear platform. It went much smoother than the vinly flooring installation, and I am pleased with the outcome. I now have a perfectly flat, sturdy rear section to put whatever I choose (of course I have that all planned out as well :) ) There is quite a bit of room in the rear of these things, I have 5.5 feet of front to back space and a little over 4 feet of width, for almost 24 square feet of real-estate. This is with the front seats in the furthest back position, and about 3/4 inch clearance. I can also still lay the seats back flat if I need to. There is also a nice amount of storage under the front section, between to two bulkheads I made to support the front of the platform. I was going to cap off the ends/sides by the rear doors, and cut access from the top, but I think I will leave it open on the ends and just slide whatever I need to under the platform. There is pretty easy access from both doors, and the driveshaft hump keeps things separated from left to right. The bulheads keep anything from rolling front or back.

I had initially planned on installing the fridge on the left or right side behind the front seats, and have the fridge on a slide so it would come out the rear door for easy access, but upon further research (read: staring at it while taking breaks), I dont think it will work due to the limited space in the door opening. If the doors opened a few more inches it might work, but not a present. I will have to re-think the layout. It will be easier now that I have a nice clean flat space to visualize.

Let me know what you think!

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0431.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0430.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0429.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0428.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0426.jpg

~James

[ckale1]

Could you post up some pic's of where and how you ran your wiring for your lights? I just put a rack on my XJ, but have been hesitant about running the wires for rack mounted light's. Jeep looks good BTW.

[StumpXJ]

I havent gotten that far yet, I was going to do it monday, but the interior stuff came in the mail, so I did that instead. I will run the wiring this week sometime.

~James

[ckale1]

Any updates James?

[StumpXJ]

Doing it right now actually. Will have pictures in a few hours.

~James

[97 zj steve]

nice inside :clapsmile

[StumpXJ]

Thanks Steve! Its coming along. A few more things to add and the interior will be close to being finished.

Ok, I got the lights on the roof rack wired up. When I installed the switch panel, I pre-wired all the switches to 30 amp BOSCH relays, so all I would have to do is hook up the loads (lights, compressor fridge etc. etc) I used 30 amp BOSCH relays that I got at the local junk yard from the multitude of scrapped BMW's ( I do live in Germany....). They are very good relays, as proved from my Tacoma days, as I used the same type relays. I was debating for days on how to get the wires neatly from the roof rack, to inside the engine compartment where the relays where located. I mentioned it to my wife (who is an engineer, and often provides a great second opinion/alternative way of looking at things), and she suggested hiding them behind the snorkel, which is due here any day now. I took her advice, and ran them down the drivers side A-Pillar. The beauty of this is that 90% of the wiring will be hidden by the snorkel when it gets install in a couple days. As the pictures show, I made a small notch in the drivers side fender to accomodate the two wire bundles that power the 4 HID Hella 4000's, the 2 euro dim city lights, and the 3 Hella 550 that I use on the rear of the rack. Each wire bundle has 3/ 12 guage stranded wires inside. I used the same 3 stranded 12 guage wires to pre-wire the swicth panel and the relays.

I used simple wire looms (2 each per wire bundle) and stainless steel screws insulated/coated with silicone to protect the raw metal after drilling pilot holes. The pictures also show where the wire bundles come out under the hood. On to the pics.


Showing how the wires get run on the A-Pillar
http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0432.jpg

Showing the wires on the bottom half of the A-pillar
http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0433.jpg

Showing the notch made by my dremel on the passenger side fender. This pic does not show the rubber grommet I put on the sharp edge to protect the wire. Just used a large wire grommet, split down the middle.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0434.jpg

This shows where it comes into the engine compartment. You can also see the extra holes in the firewall (to the right of the brake booster) drilled for the wires coming from in the cab for the switches. I have also added rubber grommets to these holes.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0435.jpg

Here you see where I ran the wire bundles (5 total) along the OEM wire harness close to the firewall using zip-ties.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0436.jpg

Here you can see the Delrin plate that I machined in my mill to accept 8 of the Bosch Relays. I have 2 spare relays on the left for any future wiring deeds. This is all mounted on the OEM Relay box cover. It provides a nice sturdy place for the relays and wiring to be mounting, and also hides the wiring well, and is close to the stock battery position. (It was naturally black, but I sprayed it with grey primer so I could write on each relay so I knew which one does what.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0437.jpg

Just a test run of the HID's lit up with the covers on. I am going out to the field tonight for the initial aiming. Until then, thats all folks.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0438.jpg

I have a Snorkel coming any day, and that will most likely be the next addition. After that, I will be installing and or building a kitchen pull-out, depending on how the emails go with the Drifta company (trying to figure out if shipping to me is possible). My Buddy Vince (SEREVince) is also coming to the area this weekend for some training classes for about a month, so we will be working on a Toyota Taco I am asure somewhere along the way. He is buying my old Snorkel and shocks off of the old truck, so I am also sure we will plan a wheeling trip in the time he is down. Not sure if I will wheel the taco (it is semi stripped down at this point) or if I will take the Jeep with the stock suspension and street tires. :sombrero: :sombrero: :safari-rig:


~James

[turner]

That looks great man!! Are you going to possibly put a grommet or anything over the notched section of the fender, or just leave it? Your rig is coming along very nicely and lookin great! Even with that pimped shade of green!! Lol, just playin!!

[ExpoMike]

A trick I have heard being done, if you have a snorkle, just run the wires inside of it. You would have a hole near the roof line, to run the wires up to the rack and one inside the engine compartment to run to your relays. Seal them up with grommets and some silicone. Clean, easy and out of the elements.

BTW, did you happen to get those mounts sent out? No hurry, just remembered about them when I saw your post. :elkgrin:

[StumpXJ]

Showing the notch made by my dremel on the passenger side fender. This pic does not show the rubber grommet I put on the sharp edge to protect the wire. Just used a large wire grommet, split down the middle.

I have also added rubber grommets to these holes.



Turner, yep. I added Grommets to all the holes and the notch after the pics.

Mike I sent the brackets out on Tuesday of this week. It was the first day I had off in a while to be able to make it to the post office in time. It will take a little while to get to the West Coast, but you should have them soon. I thought about running the wires in the snorkel, but I was impatient. :) I will see how this works once the snorkel gets here, then make any changes if necessary.

~James

[OverlandZJ]

James, you'll have to move the wiring a tad. The snorkel has a bracket that attaches to the A-Pillar and sits flush against the windshield gasket.

I can post up a pic tomorrow am if it'll help you envision.

Good job!

[StumpXJ]

Ok, I figured it (the bracket) would be all the way to the left or the right of the pillar, but I guessed the wrong side. The wires should move easily to the left or right in the middle section.

Thanks John, James

[StumpXJ]

I managed to get my snorkel installed and mounted this afternoon, it pretty much kicked my butt the whole way, but its on and I am happy with it. Its a much more involved install that the on on my taco was. The snorkel does a great job hiding my rack wires, and luckily I didnt have to move anything to make it all work. One thing that surprised me was how much you can hear the intake noise with this big 4.0liter as apposed to my puny little 2.7 liter with the taco, plus the fact that it is mount on the drivers side instead of the passenger side like the Toyota. Sounds pretty wicked when I stomp on the skinny pedal! Pictures tomorrow, im beat!

~James

[StumpXJ]

Cross posted from another section

After attempting to get a "Drifta" kitchen shipped to me from Australia, I decided to make my own. The Drifta kitchens are extremely nice, and I would have purchased one on the spot if it was easily shipped to me, but its not. I sent an email to the company asking about shipping out of the country of Australia, got one response asking me which kitchen I wanted, then I heard nothing back from them after letting them know what I wanted. This was about 8 days ago, so I figure it would cost a small fortune to ship, probably close to what the kitchen actually costs.

I am by no means a carpenter/cabinet maker, and my finished product will probably reflect that, but it will work for my needs, atleast until Drifta gets a US or European distributor. I really like the quality of Drifta's kitchens, and I borrowed a little of the design for my build. I am already at about 150 dollars into material cost, about 4 hours of actual work, and countless hours of dreaming up the "perfect" layout. Here is where I am so far:

The stumptaco kitchen is 48 inches in length, 17inches tall, and 16 inches deep. It is made of birch ply, for strength, lightweight, and looks. It will be clear coated with a UV protectant polyurethane when its finished. I am making the grill cut-out section so that a Partner steel 2 burner stove fits in it with the lid closed. I have a white laminate top that is going on it, and lots of other bells and whistles planned, but that will come later. Here are the preliminary build shots.


Outer shell together, trying to figure out the drawer placement.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0439.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0440.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0441.jpg

First drawer hung, on roller slides.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0443.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0444.jpg

Both drawers in.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0445.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0446.jpg

Shelf above the drawers added.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0447.jpg


More later, just came inside for a quick break.

~James

[fiddy]

Very impressive!

[StumpXJ]

Thanks Fiddy!


Latest update:

The wife just got home, so I am calling it quits for the day. Below is the rest of my progress.

The left side of the kitchen will mostly house dry goods, (canned food, box foods like stuffing or cous cous etc, and the drawers wil also hold cans, and utensils. I am also making a small spice rack to hold my spices as I can never seem to keep up with my "camping dedicated" spice bottles. The slot above the drawers will be use for whatever, maybe longer things like aluminum foil rolls or saran wrap. I have to incorporate a knife block, and a paper towel holder somewhere in here also. Its harder to do than I thought, especially when trying to think ahead to keep everything in its place so it doesnt bounce around too much when offroad. Im sure I will have to make some changes and adjustments, but Ill figure that out after its shakedown run.

I decided to make this a half shelf, so I could store taller items in the front, like paper towel rolls, or cleaning supply bottles, or whatever.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0449.jpg

Here it is with the left counter top section on, grill cover lid on, and the grill shelf. I am finally going to break down and get a quality grill, I hope the Partner lives up to its reputation. Cooking while camping is probably the most fun part for me, so I am hoping it fits the bill. I used a piano hinge for the grill cover, and a spring loaded gas-less strut for the the holding/lifting duties. I will use this same type of strut on the front door that will cover the left side face of the kitchen.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0450.jpg

Here you can see the strut. I had never seen these in the states, but they are pretty common over here. They have a nut that you can tighten or loosen, depending on how heavy the door is or how much support you need. The spring assists you in the opening process, then the last 10% of travel is made much stiffer depending on how tight the nut is. The best part? They are fully stainless steel, and cost only about 10 euros.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0451.jpg

Here it is with the lid closed, I obvisouly still have to make the other door panels for the face of the kitchen. I have some 12mm thick Delrin sheet that I thought I would use for the front panel below the grill cover. The idea is that it would also be on a hinge, but would hinge down to create the perfect chopping board and prep area. I think I may do it, although that much Delrin is expensive it would be a pretty trick cutting board. Luckily I already have it in the shop! :)


http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0452.jpg


Just a close up of the latching system I am using for the lid and side doors. The lid will have one of these on each side, as well as the side door. They didnt have these in stainless, but they are galvinized so I should be ok for rust. I also used all galvinized screws for construction.



~James
http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0453.jpg

[StumpXJ]

So, here is todays progress, had a few hours to work on it today.

I started on the side door that covers the left of the kitchen, got it cut to size, and mounted using another piano hinge on the end. I also mounted a plastic collapsable paper towel holder, that when the door is closed, it has clearance to leave the paper towl roll on. sucks up a bit of my storage space, but in all honesty, I had planned to put a roll of papertowels in that spot anyway.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0455.jpg

With the door closed

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0456.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0457.jpg

Started on the fold-away shelf on the right side. This is just extra counter space, and will come in handy im sure. in the next picture, I am applying the PVC coated laminate stuff, that is on the surfaces. I needed some weight to keep in secure while the glue dried. I think the pictures shows how much weight it can hold. There is about 60 pounds on it with no trouble. I used extruded aluminum rods for the supports, and they get stored in one of the drawers when not in use.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0458.jpg

[StumpXJ]

Took her outside for some photos, and the fact that my garage is a giant mess.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0459.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0460.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0461.jpg

I added another strut to the grill cover. It was bothering me that I only had on on it. (maybe my OCD kicking in?)

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0462.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0463.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0466.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0467.jpg

Lots of sanding to do, then I will tear it all apart so I can seal it with the polyurethane. I still have to install the latches, and the cutting board, also a few other odds and ends (Knife block, lights for the grill area), buts its getting close.

Let me know what you think.

~ James

[ExpoMike]

Nice work!!!! Heck, you want to come and remodel my kitchen? :xxrotflma

[BC Explorer]

You are making me miss my Cherokee really bad now !
This is a excellent idea and would have made me keep my XJ instead of going YJ.
I wonder if something like this couild be made to fit in the back of my YJ.
Now I have another project to add to the list.

Awesome work !!
Can't wait to see it finished.

[DH2002]

awesome build up very smart to do it yourself

[BC Explorer]

Wow, I just went through Drifta's web site and those are great ideas.
The ideas would be endless building one of these boxes.
Well out comes the tape measure.

[Big Daddy Chia]

I'm gonna ask a dumb question. Is this going in the XJ????

[firemansxterra]

that build is looking awesome! i know you have spent a decent amount of time on it, but it looks like you have put a looot of time in it due to the quality of it...very nice design!

[StumpXJ]

Thanks for the compliments guys, I think I have just been lucky during this build, as normally I rush things, and it doesnt turn out so great. This time, due to work, I have had to spread the work out over a couple weeks and that is helping.

I am sure this would work in the rear of a YJ, of course it would have to be modified to suit the space difference, but it would work. Yeah, the Drifta website had me drooling for many days. I would still love to own one of their products, as they are extremely well thought out, and the pricing is actually very good for the quality of the product. (especially since I now know how much work goes into it!)

Big Daddy, yep its going into the back of my XJ. It wont staty back their permanently, but only when I go on trips.

Thanks fireman, I have about 12-14 hours into it right now. That includes lots of breaks and staring at it while I figure out the next move... :)

Cant wait to start using it!!
~James

[StumpXJ]

Well, the kitchen project has been put on hold until the cutting board material gets here, so I will share the newest good news:

This has been ordered!

http://i272.photobucket.com/albums/jj177/ClaytonOffRoad/XJ/Package%20Deal%20Long%20Arm%20Lift%20Kits/PD-XJ65.jpg


The guys at Clayton Offroad have been extremely helpful in working with my unique shipping requirements over here (no boxes over 70 pounds), and are working with me to get this stuff over here. It will come in 9 boxes (including new Bilstein shocks), but it will get here none the less!!

I also have ordered 5 new rubbers, and 5 new black steelies for PROJECT TEAL!

I am stoked!! Thanks to the folks on here who reccomend Clayton's, a great company to deal with thus far.

~James

[mizedog]

Great kitchen build! I might suggest that due its length, adding two small rubber casters on one end. The may mean triming the corners of you flip-up counter, but would make moving it around the garage and to/from the Jeep easier. I learned this the hard way when I was a working musician (always moving around big, heavy speaker boxes and amps).

As soon as I can sell my '08 JK :eek: , I'll be moving into a late 90's XJ. You're giving me great ideas.

[Backwoods Rambler]

As soon as I can sell my '08 JK :eek: , I'll be moving into a late 90's XJ. You're giving me great ideas.

WOW, the grass is always greener isn't it? :hehe:

[StumpXJ]

Got a few updates, the cutting board material came in on Friday. If anyone needs any of this stuff for whatever reason, I HIGHLY recommend the using www.cuttingboardcompany.com They will cut any size and any thickness piece that you will need, and it is very reasonable. I paid 22.50 for this piece, that needed to be exactly 23 1/2" X 11 5/16" (1/2" thick), that price included priority mail shipping to me. I ordered this on Monday, and I got it on Friday. Remember that I live in Germany, pretty darn impressive if you ask me. It is not officially mounted yet, but will be soon, and then the kitchen will be almost finished.

The wife and I went to IKEA today, and I picked up some dedicated camping knives, pots, frying pan, and utencils. I also picked up a rediculously strong magnet strip to hold everything at arms length while I am cooking. I was not to sure about using a magnet to hold this stuff until I realize how strong it was.

Here is a few mock-up pictures showing the cutting board in place where it will go. Obviously it will hinge up and be the "door" for the front section. Now I can figure out my latching system since I have all of my doors completed.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0468.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0469.jpg

This is the other reason I went to IKEA, to pick up the Diode light strip for my RTT. gpwpat did this originally a few weeks back, and looked like exactly what I needed. Here is his install thread, with way more pictures than what I did.
http://expeditionportal.com/forum/showthread.php?t=17289&highlight=ikea

Mine are the exact same lights, but I got the white instead of multiple colors. I put mine on the bar closest to where our heads lay, so they will point towards our feet. This will keep the direct beam out of our eyes, and will provide plenty of reading light as we both enjoy reading while laying in bed.

Its still light out, but when it gets dark I will snap a few shots.

You can see them right over my wifes shoulder mounted on the tubing:

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0472.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0470.jpg

(My camera sucks, sorry.)

More later. ~ James

[StumpXJ]

Ok, its dark out, and the lights work fantastic. I really wish I had done something like this sooner. Its hard to describe, the light is very easy on the eyes, but its also really bright. Worth every penny (or euro in my case) if you ask me! I forgot to mention, but all I did was splice it into a male cigarette plug. The cord stays in the tent side pocket when it not being used, then it just plugs into my cigarette lighter socket when we are camping. I wired the sockets to be "hot" full time.

Once again, my 70 dollar digital camera is not quite up to the task of good photos, or maybe its the operator but you get the gist of it.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0476.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0477.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0481.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0482.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0485.jpg

[Nuclear Redneck]

Very nice!

And the lights in the tent look pretty as well! Seriously, very good craftsmanship.

[OverlandZJ]

Awesome James! Is that a 6" suspension?

I dont remember if Germany uses road salt, if they do make sure you coat those control arm and disconnects exposed threads with anti-sieze.

I'm thinking i need a set of those LED lights.

Any idea where you and the wife will wind up when you return to the states? I'd sure like to cross paths with ya sometime.

[StumpXJ]

Hey John, it is the 6.5" kit. They guys at clayton told me this set-up could be used with anything from 4" of lift all the way up to 8.5" depending on which springs I choose. The kit I ordered is the 6.5 kit though. I figure with the weight that I will have on the jeep with armor and camping stuff, it will sag some, so it should be good to go.

I decided to go with the Interco TrXus tires, in 35 x 12.50 size. They are a little over 34 inches in total height. Its a little taller than I originally wanted to go with, but with all of the mud we have around here, I have a feeling it will come in handy.

Thanks for the heads up on the threads, yeah Germany does use road salt, and since the taco demise, I have been using anti-sieze on just about everything I have removed or replaced. This XJ has to last me a while... :)

We are not sure where we will end up, it really depends on where the wife gets her job. I can pretty much work anywhere. She has return rights to Jacksonville Fla. when our tour here gets finished, but neither of us have any desire to move to Florida. Ideally we want to live in the Northwest, perhaps the Portland area, but wont know until about 6 months before our time here is up which will be Oct 2010. My wife's family is in Peachtree City, Georgia, and we may end up there around the Atlanta area. I dont really want to, but would pick that over JAX any day. In all honesty, we wont know till we get there! Either way though, I am always up for a road trip. maybe we can all do a Expo Portal Jeep wheeling weekend somewhere.... sounds like fun to me!

You should not think twice about getting the LED's for your tent, they are the bee's knee's for lighting inside the RTT. Head straight to IKEA, do not pass go, do not collect 200 dollars. :)

~James

PS, I just finished clearing/sealing/painting the kitchen. She should be finished tommorow!

[StumpXJ]

Well, my last day of a 4 day mini vacation resulted in me finishing the kitchen. I decided to go with a teak colored sealer, and I think it turned out really good overall.

I am still debating on what to do as far as mounting it in the jeep or just keep it as a stand alone by adding legs on both ends. I think I may end up using it as a stand alone unit, that way I can use it under my awning, and there wont be anything permanent mounted in the rear of the jeep.

Anyway, here she is. I borrowed some stuff out of the kitchen for illustrative purposes.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0486.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0487.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0488.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0489.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0490.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0491.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0492.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0493.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0494.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0495.jpg

~James

[SEREvince]

Dude! Did you OD on coffee? I was just there what, Sunday?

Looks great!

I think this one is a nice prototype! You should start on the final product right away!


PS: Dibs on the "prototype"!

[OverlandZJ]

The StumpXJ is really coming around James, looking fwd to the pics with lift installed.

:safari-rig:

[Backwoods Rambler]

Oh man, that is cool! Great work! :clapsmile

[StumpXJ]

Thanks guys, yeah Vince, I was busy after you left Sunday!

Just got off the phone with the Clayton Off Road boys, and ordered a SYE and Tom Woods Drive shaft. This means the Jeep will be out of commision for a couple weeks while I install the lift and get a measurement to Tom for the drive shaft. Good thing the wife is going to Turkey for a month for her job in about 10 days! I will be needing her car.... :) This suspension and tire thing is getting expensive rather quickly. Just will be glad when its all installed!

~James

Oh yeah, I threw in a wireless winch controller while I was at it. :)

[StumpXJ]

Got the wheels, tires, and center caps in today from Summit. Stopped by the local auto hobby shop on the base and mounted them up and balanced them myself. One of the tires kicked my butt getting the bead to seat, but I managed to get it done after a bit of sweating and cussing.

I think with these should fit right on! I didnt have to waste $3,500.00 bucks on suspension afterall.... Not having any tire rub is overrated...LOL.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0501.jpg

At the last minute I decided against the bigger 35's and went for the more "conservative" 33's, although these are pretty big. looking forward to see how they perform.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0502.jpg

Now the suspension just needs to hurry up and get here!

~James

[SEREvince]

Jealous

I LOVE the TRXus!

[StumpXJ]

Green with envy huh? You were right dude, I think these will do just fine in Frances finest muddy trails...

I am commandeering your "Teal J" reference also, it has a nice ring to it. Actually, I saw another guy today while mounting the tires who had the exact same year and model, but it was a two door. The best part? It was TEAL!

~James

[IXNAYXJ]

Glad you went with the Claytons and TrXus...that combo has been working great for about 10k miles now on my rig. Really digging the kitchen, too...well done!

-----Matt-----

[fiddy]

The finished kitchen looks good!

[StumpXJ]

Thanks guys!

The suspension parts are starting to trickle in. I picked these up from the post office today! Hopefully that means everything else will be here int he next couple of days.

Billstein 5125's (mmm..... Newcastle)
http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0506.jpg

These things are big. The one on the right is off of my tacoma, which is sized for 2-3 inches of lift. The new Bilstein's for the jeep are a full 6 inches longer.

Cool stuff... I love new parts.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0505.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0504.jpg

~James

[StumpXJ]

The wife picked this stuff up for me today at the post office. I have about 80% of the suspension stuff in now! I am still waiting on the trackbar from Claytons, and the SYE and CV drive shaft from Tom Woods, then I will be ready to start work.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0507.jpg

Nice welds on this stuff, maybe one day mine will look like this. The johnny joints on the lower arms are freekin HUGE. Im talking as big as a persons fist. This stuff is very obviously made to take all the abuse you can throw at it!

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0508.jpg

Cant wait to start installing this stuff!

~James

[OverlandZJ]

http://4x4trailhunters.com/pictures/article_12_7.-Finished-Dash-Mount).jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0413.jpg




James.. i had a brainfart today... i'm working on installing my Roadless Gear interior winch control.

In the pics i copied above, where the B&M trans temp gauge sits, and where you have your rocker switches.. i removed the false info panel and figured i'd position the control here instead of my original idea of the cig lighter location.

I found i had to cut away a section of plastic (a 2"x3" section) behind to make clearance for the plugs/wiring. What i didnt realize is that it's actually a "cavity" used in the ductwork for the AC and Vent functions. Heat and Defrost do not use this cavity. Did you cut into this area and have you noticed a signifigant loss of airflow through the vents?

I figure i have two options, make a plate and recover the section i cut or continue and attempt to seal the cavity as best i can. The brainfart part comes from a quick decision to relocate the control from my original idea.. and didnt think it through entirely. :(

[StumpXJ]

John, I am a little confused, are you talking about you had to cut behind where I have my rocker switches mounted, or did you have to cut behind where my monitor screen is mounted?

If you are talking about behing my rocker switches, there is nothing behind there on my jeep. Its a big hole and I had plenty of room for my wiring if memory serves me.

If you are talking about behind my screen, yes, I had to cut into the plastic, and then I realized it was part of the duct work. I had to form a replacement panel out of flashing material, and I screwed it to the outer edges of the plastic and used silicone to seal it all up. I had to be careful not to go too deep because of the vacuum actuated door/flap that controls the flow of air. Luckily my screen is only protruding behind the panel about 1/2 of an inch, so I didnt need to cut too much.

Let me know if we are on the same page?

~James

[OverlandZJ]

Heres my rough cut...

http://i32.photobucket.com/albums/d24/ExpeditionXJ/xjwork9017.jpg


It's the area behind your rockers.. the available 1-1.5" wasnt enough for the controller so i decided to cut a relief. Flashing material.. good idea. I have a bundle left from redoing my house roof.. i bet i can get it sealed up well enough to not lose much airflow.

[StumpXJ]

Ok, yeah, I do remember that now...

I dont have a problem in that area because my panel comes out flush with the outer dash panel giving me a couple more inches. Yes, you will definitely have to close up the hole somehow. when I cut behind my screen there was zero air flow out of the vents until I did the flashing bit. On a side note, I would use shoe goo or even a hot glue gun for the sealing part of it if you decide to seal it. I used silicone, which worked great, but stunk for a while!

I want to get one of the in cab winch controls also, I got a wireless set-up the other day from Summit when my tires came in, and im not sure if would be too much redundancy on the controls. Probably so, but redundancy is cool. Post up some pictures when you get her finished up.

~James

[StumpXJ]

I had Wednesday off yesterday, so I started on the suspension. Got the crossmember welded/bolted on nice and securely, then installed the passgeger side upper and lower arms before running out of time. I plan to have the front mostly finished tommorow ( I have Friday off) and will post pictures of a jacked up/big tired jeep front end. I will not have enough time I doubt to start on the rear suspension. Here is how she sits right now. Half in my garage and half outside. It wont fit in anymore with the RTT and light rack....

Yes, the garage is a mess. Yet again. :D

~James

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0517.jpg

[StumpXJ]

Made some progress today. Got most of the front suspension on. I still am waiting on the track bar to get here (forgot to ship it) and I still have to hook up the brake lines and bleed them. I also have to set the track and caster, but that wont happen until the rear is finished. Hats off again to the Clayton guys, everything fit perfectly as it should, and looks killer. I cant wait to wheel/drive this thing when its finished the front suspension is super plush and flexy just by rocking the jeep back and forth.

As usual, getting the odl rusted/corroded stuff off is the hardest part, not to mention I am doing this in my gravel driveway. Its hard on the knees to say the least. I cant wait to get back to the states and build a real shop with 14 foot ceilings... hydraulic truck lift etc etc.

Pics:

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0518.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0519.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0520.jpg

~James

[SeaRubi]

looking good! having a big ol shop is over-rated. it's always there begging you to be in the shop instead of on the dirt :) with this setup, you've got really good incentive to not have an in-progress truck!

btw, that approach angle is killer :p

[absolute]

Looking Great Man!!

I love watching your builds! Very detailed to say the least!
:26_7_2:

[StumpXJ]

looking good! having a big ol shop is over-rated. it's always there begging you to be in the shop instead of on the dirt :) with this setup, you've got really good incentive to not have an in-progress truck!

btw, that approach angle is killer :p

I am honestly not sure if I have ever NOT had an "in-progress" truck. :) I mean, are they ever really finished?

Yes, the approach angle is what I was shooting for by not installing the rear lift, but it tends to wander when going down the highway at speed. I also get this odd clunking sound from my diffs and transfer case when in 4Lo. I am not sure what it is, but it will probably fix itself. :D

Thanks guys! ~James

[OverlandZJ]

Sweeeeet.

Start hitting the upper shackle bolt in frame now, they have been known to be a major pita. Theres a captive nut in the unirail, if you break it your in for some cutting. If you remove the frear bumper you can get to it with some penetrant and straw type tip.

[StumpXJ]

Thanks for the heads up John, I am sure it will be a major pita. The rear two lower arm bushing bolts on the front arms were completely seized to the sleeve in the rubber bushing. Had to cut them off, so my guess is the rear will be an uphill battle also. Not to fear though, I have a fresh supply of cut-off wheels, sawzall blades, breakerbars and BFH's to get most any stubborn item loose one way or the other. :violent-smiley-031:

~James

[SEREvince]

Made some progress today.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0519.jpg




AWESOME!!!

[StumpXJ]

It is still Teal, but it is WAY more badass now. With a huge help from SEREVince (Vince), we got the rear pretty much finished this morning. Everything went suprising smooth....until the drivers side front spring hanger bolt came into play.

I was a motorcycle mechanic in the States for almost 11 years, and I have dealt with my fair shair of "stubborn" bolts, but this bolt easily made it into the top three "biggest pain in my butt" category. It was seized inside the bushing sleeve, and it did not want to play nicely. I ended up fabricating/welding a slide hammer device with some scrap metal I had laying around to try and hammer/pull the bolt by the head out of the sleeve, but it still did not budge with just the hammer alone. Finally, Vince and I hooked a 5000 pound ratchet strap to the rock slider on his Tacoma, and connected it to my slide hammer while it was on the bolt head. We put an insanely large amount of pulling force on the head of the bolt with the ratchet strap, used almost an entire can of liquid wrench, and I proceded to turn the bolt with a 5 foot breaker bar. It FINALLY started coming out of the sleeve. We faught this thing for literally 2 hours. After that, it was a cake walk. :)

Still on the list of things to do to "finish" the entire suspension:

Install extended front brake lines and bleed
Install extended rear brake line and bleed.
Install front track bar
Install SYE and send a measurement to Tom Woods for my CV driveshaft.
Install the driveshaft
Install the JKS quick disconnects.
After all of that, set the track and caster on the front.

Not entirely sure how to go about setting the track (what to measure off of?) or setting the caster. The caster spec says 4.5-5 degrees, but in reference to what? Absolute vertical? Do you take the measurement on the knuckle? Hopefully John or someone can shed some light.

Here are some pictures. Not quite as Chicano/Hooptie style any more. :xxrotflma

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0521.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0523.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0524.jpg

~James

[SEREvince]

That is a thing of beauty! Teal and all:exclaim:

Glad I could pay back just little of all the hard work you've put in on the Taco.

Time to have a beer or three to celebrate :beer:

Drink one for me. I still have a paper to finish!

Cheers

Vince

[XXXpedition]

hey, with that color almost reminds me at my xj :-)))
mine was a bit bluer though...
looking good

[OverlandZJ]

:clapsmile Looks awesome James. Your work is really showing now.

I'm not an expert in front end alignment at any level, but i'll attempt to steer you straight... :elkgrin:


Centering the front axle side to side is achieved by adjusting your trackbar. I just did this and the most accurate way i found (after lying awake one night recently) was to take a piece of string with a small nut tied to one end. Hold the string against the unirail just infront of the coil spring and let it hang just infront of the axle tube. You'll see that the string will be just inside of the coil spring perch... measure the distance from string to the perch. Now, please notice that on the drivers side you'll be placing the string against the trackbar bracket as it sits over the unirail,so you'll need to take that thickness into consideration when you compare the distance side to side. Shorten of lengthen the trackbar to center the axle.

On my RE trackbar i disconnect the frame end and adjust the length. To reconnect i have someone turn the steering wheel which will move the vehicle side to side over the axle to align the bolt. No need to push the body over.

On a stock XJ the caster spec is 7* positive. Meaning the upper ball joint is rotated towards the passenger compartment compared to the lower balljoint. (vertical)

Now adjusting your caster on your rig will be a compromise of caster and pinion angle. I'm still working on mine... and paying a pro most likely wont help as it's going to come down to feel. Vibe from driveshaft vs wandering/heavy steering. Keep in mind caster has no effect on tire wear.. so it wont hurt as you drive and adjust periodically. I'd remove the front driveshaft as your adjusting to rule out any vibes from a bad ujoint or slip joint. Concentrate on steering first.

Alot of the guys running at our lift height state they are in the 3*-5* positive range. I have no idea where mine is honestly.

Take a peek at your pinion yoke, it should be slightly down from vertical (EDIT TO HORIZONTAL) to transfercase. Start there and see how she handles. Once you find something that feels good try the driveshaft, if you add heavy vibes start adjusting the pinion up till you find a happy medium.

Heres a few links to help if my shadetree mechanical explanations were of no assistance.

http://go.jeep-xj.info/HowtoAlignment.htm

Search results @ NAXJA for "adjusting caster"

http://naxja.org/forum/search.php?searchid=2321625

Hope this helps a lil James. OK, ready for second cup now.. :coffee:

[StumpXJ]

John, an absolute perfect explanation on all points. The string thing is genious, and setting the caster to feel makes perfect sense considering the extreme angle on the pinion. I was staring at the pinion angle on the front of the rig today and it is not exactly ideal to say the least...

Do any of the jeep guys rotate their knuckles on the axles and then re-weld? I know a lot of the Toyota guys do this. It would only be worth it if the upper arms could be adjusted enough to get a good pinion angle.

Thanks for the great ideas and info!!

[OverlandZJ]

Rotating the knuckles... not usually. Most find they can get an acceptable compromise with adjustments. Now if your building a Dana 44/60.. sure, set everything to spec at static ride height from the get go.

The Toyota front axle is signifigantly stronger and worthy of the mods when running a big tire vs the Dana 30. You really start pushing your luck with a Dana 30 and a tire over 33" unless you drop alot of money into it... and at what point is a D44 donor the better choice for a build platform.

If i were still running the rocks i would have built a HP D44 using Grand Waggy length axleshafts instead of another D30. But i would like manual hubs though..

[StumpXJ]

Did yours have the high pinion or low pinion 30 in it?

You are right about not messing with the 30 as far as rotating knuckles, just not worth the effort. My ultimate plan is to put in a 60 rear and 44 front when we get to back to the states, but that is still 2 years away... Arrghhh! Decisions decisions....

Finding a donor 44 over here would be like finding a needle in a haystack. I guess I will play with what I have and hope for the best until we get back home. Thanks for the links too, just got finished reading those.

~James

[OverlandZJ]

Mine is a HP D30, makes no sense in using a LP D30 when building considering a used HP housing is so cheap to aquire. Other than carrier and gearset it uses the same parts outward.. and you most likely are swapping those in a gear/carrier swap anyway. JMHO

Glad i could help, i'll bet others here will chime in with additional input as well. Again, i'm no expert and could use some enlightenment as well.

:beer:

[StumpXJ]

I hear you about the hp and lp, unfortunately mine is the low pinion. I just stumbled on this at NAXJA.

http://www.naxja.org/forum/showthread.php?t=935127&page=5&highlight=rotate+knuckles

It seems easy enough to do over a weekend, and I dont have to remove the axle assembly persay. It will be time consuming, but very little costs involved and the benefits would be huge I would imagine. I need to replace the upper and lower ball joints on both sides soon anyway....

This freekin internet is going to cause me to spend more time in my shop than I want to. I just dont want to be fighting poor handling and driveline vibrations after spending all this money on suspension and tires. I will give it a shot like it is now, and if it doesnt work to my satisfaction, I will break out the grinder. Thanks again, ~ James :smiley_drive:

[OverlandZJ]

LP... you sure? Unless someone swapped that axle in you should have a HP D30. I think it was 00 when the XJ got that LP axle.

[StumpXJ]

I could be retarded (entirely possible), but I am fairly sure its LP. I looked at enough in the last few days that I should be sure, but now you have me wondering. Its dark and cold outside right now, but I will double check in the morning. I did see quite a bit of orange RTV sealer type stuff around the diff cover that didnt look "factory", maybe it had been swapped. Not sure, but will find out in the morn.

~James

[StumpXJ]

Edit: I think I am confusing it with the rear diff.... I looked at that most recently in the past few days as I was installing the rear lift, but have been thinking of the front end tonight. I guess I am going to have to break out the flash light and go look now....

~James

[StumpXJ]

Still on the list of things to do to "finish" the entire suspension:

Install extended front brake lines and bleed
Install extended rear brake line and bleed.
Install front track bar
Install SYE and send a measurement to Tom Woods for my CV driveshaft.
Install the driveshaft
Install the JKS quick disconnects.
After all of that, set the track and caster on the front.

James

I have been working on making this list shorter over the last few days.

Last night:
I installed the front steel braided extended brake lines and got the system blead manually (by myself no less, using a little redneck engineering.... )

Installed the track bar and set the track as close as possible using the "overlandXJ method" (thanks John, worked like a champ!)

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0528.jpg

Installed the JKS Quick Disconnects. Nice product, hopefully they hold up well.

Today: Installed the Advanced Adapters SYE kit. This wasnt too bad honsetly. Looking at the instructions and reading the nightmares from other people doing them, I was a little concerned. It all worked out fairly well. A messy job, but MUCH easier now that my Jeep is a WHOLE lot higher! :) Its nice to be able to drain your engine oil into a 5 gallon bucket without using a jack...

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0529.jpg

Got the measurement for my Tom Woods driveshaft after the SYE install, and have emailed the info to them. I should have the driveshaft in a week or so.

Still on the list to do because of the suspension install:

1. Install drive shaft
2. Install rear extended brake line and bleed
3. Set Caster, its WAY off right now. I drove the jeep to the end of my street in 4 high and it was SCARY.
4. Drive it slowly to the base to use the lift and adjust everything, and make sure its all tight and lubed. I am DONE with working in the rocks in my driveway.

On the very near future list:

The day before I started the suspension, my water pump crapped out on me. Not exactly an un-common thing on XJ's and I was kind of expecting it any time because of the mileage and known weakness. So, I ordered a new water pump, new thermostat and thermostat housing, new upper and lower radiator hoses, and a new 3 core aluminum radiator. I got everything in so far except the radiator. This stuff will be installed in the next couple of weeks. While I was ordering those parts, I ordered an oil pan gasket, and new rear main seal set, since mine is leaking. I will replace this stuff one weekend in the next couple of months.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0526.jpg

I also ordered a set of frame stiffeners I saw on NAXJA from HD Offroad Engineering. These are plasma cut pre-bent pre-roset drilled 10 guage steel plates that get welded to the mid section of the frame. They are very nice quality and the price was very good considering the amount of effort and time they will save me. Just got to grind away the underbody coating and weld them on. Yet another weekend job in the next coule of weeks. This will make installing my sliders much stronger when I get around to it.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0530.jpg

When Vince was here, I got extremely jealous of his synthetic winch line, so I ordered one of those as well (its his fault). 100 feet of red amsteel blue sythentic winch line from viking offroad/winchline.com to replace my kinked up, skin shredding old steel cable.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0527.jpg

Of course, I needed a new hawse fairlead since my old roller fairlead was chewed up from the steel cable, so I placed an order with our friends at Sierra Expeditions and got this, along with some cool new SE stickers. (Thanks Wendy!)

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0531.jpg

We both have the same winch, the cheap little smittybuilt XR8, and while its not a warn, it does a very good job of getting you out of the nasty stuff. It has saved me multiple times, and I am very pleased with it. Yes, it is slow, but I can deal with that. Also, the "chrome" bolts rusted on both of our winches about 2 weeks after installing them, so a couple weeks back we found stainless steel hardware to replace all of the bolts. Problem solved. Also, the two chrome cross bars rusted, as well as the engage/dis-engage handle. We pulled the chrome bars off, I threw them in the lathe and removed the chrome plating, then we painted them with black spray paint. We also removed the handle, and gave them a good coat of black paint. MUCH better now. I want to get another one of these for the rear of my XJ!

The front bumper will most likely be my first armor build, and will happen very soon. I have just have to figure out a few more things, then I will start on it. I am a big fan of tube bumpers, so this will likely be just that. I also have to include a stinger, because I think they look good if done right. I wont try to fool you into believing I need a stinger, because I probably dont. But I want one, so thats that.

Thanks, James

[micahtbyrd]

I love how your build is comming along. I am planning very much the same build on my Xj in the future. Yours looks great I love seeing a a nise build with good products.
What trac bar did you install with your current setup, and how much lift are you running. I am planning on longarms and 33's with 4.5 lift in the future but haven't got a new adj trac bar yet.

Can't wait to see more. Micah.

[StumpXJ]

hey Micah. I bought the Clayton Offroad 6.5 long arm lift kit, and it came with their own adjustable track bar. They use HUGE Johnny Joints, and stock style rubber bushings. Everything built extremely heavy duty. I am running 33's with the 6.5" lift. I havent had any rubbing yet, with zero trimming, but of course ive only been about 200 feet so far.... I think I may have to trim a little from the bottoms of the fender flairs, but that should be about it. I am running a decent amount of backspace, so that helps as far as not hitting anything major.

Thanks for the compliments!

~James

[micahtbyrd]

Thanks i will have to look into their trac bar. Clayton's stuff is awsome. The arms I have seen are beef. Micah

[StumpXJ]

While I am waiting on the tom woods rear driveshaft, this weekends activities included building a new front winch bumper. I am big fan of tube bumpers, simply because I think they look better and are generally lighter than a plate style bumper. I tied into the frame using the stock 3 bolts per side from the original bumper, but added two more holes to the passenger side, and incorporated the driverside steering box mounts also for a total of 10 mounting bolts. It feels very stout, and should be sufficient for winching duties, it will also support the commonly weak mounting point for the stock steering box.

Dont really have any actual build pictures, but if I did it would just be raw steel, bent peices of tubing, and some plating for the mounts and winch plate, just use your imagination... :) Here is the finished product, with my newly revamped winch/synthetic line, and aluminum hawse as apposed to the old heavy roller fairlead, and lastly the Hella 700FF HID lights from the Taco.

(I needed new avitar material, so I limped up to the top of the hill in 4 hi for some better poser shots)

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0533.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0534.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0535.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0536.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0537.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0538.jpg


A few months back, my wife and I broke down in her car in France (alternator went out) and had to be towed back to Germany on a rollback (free of charge, thanks to ADAC!!). When the tow truck driver arrived, the rollback had a 12000 pound warn winch, and he had a wireless remote for it.... My wife said, "we should get one of those for our winch..." After picking myself up off the ground, I made a mental note of the date, time, and conversation that just took place, then had her sign a written copy of affore mentioned statement. Then I ordered one. I love my wife.

So, I decided this weekend was a good time to install the new wireless winch controller from Milemarker. It is a very simple install, and should be universal for most winches. I have not had a chance to test it in the field obviously, but it works for me at over 75 feet away, even though it is advertised at a 50 foot range. It was a simple install, and I reccomend to anyone wanting a wireless system.

Here is what you get:

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0532.jpg

The handheld remote is a little cheesy with the pull out antenna, but it works like a champ.

Here is where I mounted the control box on top of the steering column for easy access. Simply flip on the power switch, and you have a wireless controlled winch. Of course, the normal hand held plug in control cable still works normally.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0539.jpg

Thats all for now, ~James

[StumpXJ]

I love before and after shots. This is exactly 3 months of transition time (and about $5,000.00) since I first brought it home.

Before:

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0374.jpg



After:

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0533.jpg


:arabia:

~James

[Speaker]

Very very nice.

[OverlandZJ]

Looking great James.

[sami]

Have you installed the kitchen yet?

[StumpXJ]

Have you installed the kitchen yet?

Nothing to install really, just slide it in when I need, and strap it down. It is not permanent fixture of my Jeep, only when I am camping. It is finished and ready for its maiden voyage, but I havent been out with it yet.

Thanks!
~James

[GlobalMonkey]

Hi James, the Jeep looks great, but I do have a question. Is it street legal in Germany? From what I know they are pretty strict over there....(wheels, front bumper). Tomas

[highlandercj-7]

Nice job on the XJ, I'll be sure to look for it the next time I visit the KMC area. :safari-rig:

[StumpXJ]

Yep, its legal. It wouldnt be if I were not over here with the US Military. we have our registration/inspection on the military base, and dont follow the same rules as the German TUV. Thankfully. Because the German TUV sucks. There is a military guy driving around with a lifted Ford F350 diesel, with 44" boggers on it. The tires stick out atleast a foot beyond the fenders. I dont want to push my luck to that extreme, but they dont usually mess with us here.

Highlander, (per your PM) let me know the next time you are coming here, maybe we can hit up a dinner spot for a beer. I am here with my wife, who is a civilian (GS) civil Engineer for the Army Corps of Engineers. I am here as her dependent :) I work in banking at one of the local Credit Unions.

[StumpXJ]

I decided to attempt to break up the god awful teal color on my Jeep for Columbus Day...

Started about 8 this morning, stripped all the moldling, flares, and other bits off of it, then wet sanded the lower portion that i was going to paint. Taped it all off, and sprayed two coats of semi-flat black enamel, follwed up by two coats of rubberized textured black paint. Its not quite as rough as a bedliner type of coating, its about twice as rough as an orange.... (kind of hard to describe) It's basically the same stuff I use to coat all of my armor.

I think it turned out pretty good, now the teal isnt quite so 'in your face" (at least thats what I am telling myself)

Few more poser shots below. I am tired of working on this thing, I need to go get it dirty and do some camping before it gets too cold.

http://i114.photobucket.com/albums/n257/topfuel443/DSCN0545.jpg

I also painted the center section of my hood with the same stuff on Friday. It helped tremendously with the glare off of the overhead lights.

http://i114.photobucket.com/albums/n257/topfuel443/DSCN0546.jpg

http://i114.photobucket.com/albums/n257/topfuel443/DSCN0547.jpg

I also installed my Limb Risers, kind of hard to see in the pics, but they are there.

http://i114.photobucket.com/albums/n257/topfuel443/DSCN0549.jpg

http://i114.photobucket.com/albums/n257/topfuel443/DSCN0550.jpg

http://i114.photobucket.com/albums/n257/topfuel443/DSCN0551.jpg

~James

[SeaRubi]

Perfect! It needs some heavy pinstriping now and a couple dents for authenticity. :D

[sandalscout]

Looks great, I'm still not sure about stinger front ends (as far as looks) but it looks right at home on your's!

Has the vinyl flooring straightened out any?

[StumpXJ]

The vinyl floor has straightened out quite nicely. I wish I could do the install over again, because it would be much easier the second time around. I cut a little too much out around the shifter (the console doesnt cover it), and its bugging me a little....

Yeah, stingers arent for everyone. I like em though. :D

Thanks, James

[kcowyo]

Looking good. Breaking up all of the teal looks much better.

I see your TrXus took a bunch of weight to balance. Mine too. I'm hoping that won't be an issue down the road.

You build some wild vehicles. Hope you get out to enjoy it soon.

.

[StumpXJ]

Thanks KC! Yeah, the TruXus took a bit to balance them... I was going to Dynabeads in them instead of all of the weights. I still may do this, but in the mean time, I really need to paint the weights that are on there...LOL.

I am definitely getting out to have some fun in the next couple weeks, just waiting on the wife to take here big engineers exam (the PE exam) next friday, then we can get back to normal. She has been studying like a mad woman for past 3 months or so. The test is kind of the equivilent of the bar exam, but for engineers.

~James

[02TahoeMD]

Looks great, the two tone definitely is a HUGE improvement....great looking Jeep. Have enjoyed watching the build. Happy wheelin!

[Carman34L]

Very nice rig. I love it.

You should never need more than 1.75 ounces to balance a tire and it looks like you may have close to 4 ounce of weight there. I suspect that the heavy side of the tire and the heavy side of the rim are matched up. That typ of weight on your rim will reduce your tires life over time and could fall off and be vary hazardous. If you were to bump one loose on a trail then at highway speeds could come loose and you are looking at 1.75 ounce bullet.

Have them break the beads and rotate the tire 180 degrees around.

I worked at a specialty tire shop for many years and we did this all of the time. We have pulled weights out of fenders before.

Just a thought.

[OverlandZJ]

Loving it James, great job as usual. Curious why you didnt do the the rear hatch from the body line down as well?

How about a pic of the flooring with the interior reinstalled?

[StumpXJ]

Thanks everyone!

Carman, you are right, and thats the reason I want to go with Dyna beads. I mounted these my self (mechanic for almost 10 years), and broke the bead and rotated the tires multiple times to get the best balance possible by finding the heavy side. They are just hard tires to balance, some were beter than others. Before I bought these I did a lot of searching, and that was one of the biggest complaints... so I knew going in they would be tough.

John, you and my wife think alike. I am going to paint the rear hatch from the body line down, just havent gotten to it yet. Should only take a couple hours to do, but I a going wheeling/camping before I do any more to this thing.

Here a few shots for the day.

I got these awesome removable tie downs for my kitchen on the rear platform. They are really slick little gadgets, and work flawlessly. The bolts they came were long enough to go through the wood, and all through the unibody, so they are mounted very solidly. They are rated for 4000 lb vertical pull, so it should hold my 45 pound kitchen just fine...

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0568.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0553.jpg

This is how the kitchen fits in the Jeep. I put it in and pulled it out a few times by myself to get the hang of it, and its pretty simple. I slide it out to the edge of the bumper, fold down the outside legs, then fold down the legs on th bumper side. Then its easily movable as a stand up unit, even by myself.


All strapped in. The little 4 drawer craftsman tool box is bolted to the floor with (4) 1/4-20 bolts. I have learned my lesson the hard way in the past by not having tools onboard when you need them. Now that I have a Jeep, I am sure to bring them with me 24-7 :)

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0552.jpg

The orangish duffle bag holds all of the straps, shackles, bungees, and hi lift accesories. They are really heavy duty bags, and hold the weight and bulk with no problem. The little black bag is my MV50 compressor. You can also see the front tie down for the kitchen.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0557.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0560.jpg

[StumpXJ]

continued:

I can have the kitchen set-up and ready to cook in about 1 minute and 40 seconds by myself, including the unstrapping. If I have someone with me, it can easily be done in under a minute. mission accomplished. :)

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0567.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0566.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0565.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0564.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0563.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0562.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0561.jpg

[StumpXJ]

Couple interior shots for John. The sunlight was kind of funky, so the pics arent that great...


http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0558.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0556.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0555.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0554.jpg

And finally a couple poser flex shots at the future campsite.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0571.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0570.jpg

James

[sandalscout]

TOP NOTCH!!! Great job indeed!

[OverlandZJ]

I like those tiedowns...link?

The floor liner does look like it's self molding better with time, the floorboards under dash will probably get even better once you start using the heater more. I may follow your lead with this product.

I hear ya about getting out... i havent still (i'v had the RTT close to a year now) and it's killing me. Turkey Day is the next planned outing.

BTW, your better half is one smart lady. ;)

[StumpXJ]

Yes, she is very smart, and way cool because she digs my jeep and related habits. :1888fbbd:

I got the mounts on here actually, here is a link (which has a link to the Mfr.)

http://expeditionportal.com/forum/showthread.php?t=19236

Honestly I am quite pleased with the vinyl flooring. It was very misleading on what I was actually getting, and was a pain in the arse to install, but the outcome has been 100% what I wanted from a vinyl floor. The best part about it is I can spray it with simple green, and wipe it out with a towel and it looks like brand new. I hadnt cleaned this stuff since I installed, and today I did just that. It looks new, and it was full of mud and crap as our fall weather (read: RAIN) has been set-in for the past few weeks. I highly recommend doing it, just be prepared for what I mentioned.

In the pictures its kind of hard to tell because the floors are shiny after I cleaned them and the reflection/glare makes the ripples that are still present much bigger than they actually are. It has laid down quite nicely.

Thanks! ~ James

[conifers4]

Outstanding:bowdown:

[BigAl]

Looks great, what are doing for a spare? Swingout?

[OverlandZJ]

Thanks for the update James. I remember fall in Germany, it was miserable.

Al reminded me of our upcoming projects. I'm still not sure on a design yet, but i did narrow down my search for a good spindle to these two vendors.

www.4x4labs.com Heaviest i'v found available (3500lb)and my first choice, espescially if i end up with a single swingout.

http://www.ironpigoffroad.com/fab/diy.shtml I'm hearing good things about this 2000lb spindle and probably my choice for a dual swingaway design.

I hope to get mine done soon, looking fwd to what you come up with. Maybe we should compare notes.

[AlabamaDan]

Great build thread!

[StumpXJ]

Thanks Dan!

John, yeah I agree. My next two projects will be my rear bumper/swing out (partially because I am currently illegal without my spare), and welding on my frame stiffeners so I can mount my sliders. Mine will be a single hinge ordeal, just have to get the hinge kit here... Thanks for those links, I will check them out.

Going wheeling this weekend in France with a Jeep group from the base, its at a French offroad park, and they are having a "night driving" event, so I will get to put the HID's to use. Should be fun, and will allow me to find any bugs in my setup. Looking forward to trying out the camp kitchen finally as well!

~James

[rctr03]

try not to cut the fenders. just my .02 cents. worst mistake that i made.

jimmy

[XJLI]

try not to cut the fenders. just my .02 cents. worst mistake that i made.

jimmy

whys that?

[rctr03]

1 inch goes to two and if you are not real careful you can cut into the inner fender liner in the back. i wish i had gotten a 4.5 inch lift and not had to cut the fenders. i have a 98 that i am starting now and i will have a different approach. good luck, i like the rack and lights.
jimmy

[BC Explorer]

try not to cut the fenders. just my .02 cents. worst mistake that i made.

jimmy


I have to agree, if you don't need to cut them and don't suffer from severe rubbing don't cut.
I started off with a little trimming and then a little more and finally a bushwacker setup which cut into the rear spot welds or you can cut around them and fold up the spot welds. I also found if you did not seal off the the cut edges you are asking for rust problems and in the rear quarter sections there were enough problems.

The start with no trimming (and when I liked my XJ most)
http://i96.photobucket.com/albums/l171/yuchym/PICT0116sample.jpg

Then the first trim job and no flares (front was first)
http://i96.photobucket.com/albums/l171/yuchym/PICT0364web.jpg

And then the final chop job...
I also found the mounting screws for the Bushwackers kept ripping out of the sheet metal.
http://i96.photobucket.com/albums/l171/yuchym/DSCF2516.jpg

[BC Explorer]

Hey James,

I think your XJ looks great and very capable offroad and for extened trips.
I have been watching your build and it has been making me miss my old XJ and ponder the idea about getting another.

A job well done

[StumpXJ]

Well, I went wheeling/camping this past weekend in France, and I have a few things to add.

I destroyed my front fenders because I didnt trim enough. Before I went, I trimmed a little, and checked it by flexing as much as I thought it would flex, and I thought I had plenty of room. (I also didnt want to trim if I didnt have to). It was no where near enough. Basically, the lower rear portion of both fenders is rolled into the fenderwell area. The longarm set-up flex's ridiculously well, and my new TruXus tire lugs made mince meat out of my fenders. I didnt hear it, nor feel it, just happened to see when we got out of the Jeep. I am fairly sure I can straighten it out to be pretty decent, but I will definitely be needing to do some more trimming.

The problem with this is that I need to run a flare of some sort, and the stockers arent going to cut it (especially now that the metal insides are completely mangled). The Bushwackers would be IDEAL in terms of plenty of clearance, and keeping my Jeep legal by covering my tires. I know they are not the best in terms of toughness, but I will have to take my chances. So, I am going to order a set soon, plus I think they look pretty cool....

I forgot my camera on the trip, but have a couple that a friend took, and will post them below. I will post the fender carnage tomorrow when it is daylight out.

Other than needing a re-gear and a locker for the front, I was impressed with the Jeep. It was WAY muddy this weekend, and I got stuck a few times (along with everyone else) because of it, but overall it did very well.

On another note, my Camp Kitchen freekin ROCKS! It was a huge hit and and even bigger success. I got a Coleman two burner "perfect flow" stove just before the trip, and made some of the best camp food that we have ever had. Everyone, especially the European's were very impressed with it, and I think the kitchen had the most photo-ops of the entire trip. I have to add to the kitchen:

1. Lantern pole on one of the corners.
2. LED lights under the overhang above the stove
3. A clip of some sort to hold a trash bag on the side
4. Cut a hole in the side so my gas regulator/pipe for the stove will work better.

I am going to be switching to a bulk propane tank next week, and will have to set-up a tree and/or manifold that will allow me to hook up several things at once, as well as run the tent heater at night without having to change the small bottle halfway through the night.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/jeep1.jpg

Did I mention it was muddy? The wife was happy though....

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/jeep2.jpg

pretty happy myself.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/jeep3.jpg

This was pretty cool. It was a recovery I did on a little Suzuki Sami that had dropped its front end into a HUGE hole created by two Uni-Mogs earlier that day. The Sami rolled over on its side and its front, so I winched it back onto 4 wheels, and pull him back out of the hole. He wasnt hurt, and wheeled the rest of the night.

This event was a "night driving" event, and was pretty cool to see all the rigs using the auxillary lighting. It made the offroad place a LOT more challenging than in the daytime, but the big HID's provided plenty of light and then some.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/jeep4.jpg

Thanks for all the compliments and suggestions guys!

~James

[BC Explorer]

"The Bushwackers would be IDEAL in terms of plenty of clearance, and keeping my Jeep legal by covering my tires. I know they are not the best in terms of toughness, but I will have to take my chances. So, I am going to order a set soon, plus I think they look pretty cool...."


http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/jeep1.jpg

I agree with you the Bushwackers do look cool and this pic of your truck is making me feel real bad that I sold mine.
Awesome looking ! any pics of the camp kitchen in use ?
And the bulk propane is the only way to go, I can last a week on mine running everything from lantern to stoves.

[tommym]

Check out the CLAYTON 5.5 Long Arm
Its bullet proof:ar15: www.claytonoffroad.com
hmm.... I always get into trouble when I list things I "want" to do to vehicles, but I will give it a go:

Many of the items will be coming over from the Taco.

Full length roof rack, HID hellas on front, just like the taco, space behind the lights for a few items, probably the size of Jerry Cans. Then at the very rear of the rack will be the RTT. I have the rack, but I will have to extend it and do some modifications to it, especially the mounting.

Front bumper and winch will be first, I am pretty sure it will be a tube/plate hybrid, and will have a stinger, about the size of the taco.

The rear bumper will be next, and will include a tire gate, Jerry can mounts, and possibly high lift mount, but it may go somewhere else.

Kick out sliders like the taco, once the unibody gets beefed up.

all my elecronice gizmos, fridge, cameras, TV monitors, DVD, Navgation, stereo (this thing still has the factory tape deck!), etc will come over.

I will be going with the Rubicon Express 5.5" Longarm kit, unless I can be talked into something different. I want longarm, but not a rediculous amout of lift (8 inches etc.) I will run the Cooper STT's in probably 33 inch size. I would run the 285/55's, but we have too much mud around here for an AT tire. I need the full mud terrains.

probably some soft 8 wheels, or I may just paint what I have.

I want to re-gear to 4.56's, and an ARB in the rear.

The interior will get a revamp as well, I will be building a custom dash area to house my switches, Scan Guage, and anything else out of machined Delrin plate. Also, the mud around here does not bode well with carpet, so that will most likely come out and get rhino lined on the inside, or atleast in the cargo area. Not sure if I am going to use a drawer system or just keep it open, but that will come once I get it all figured out.

Thats a pretty substantial list, and will most likely EAT most of my budget. I will be doing all of the wleding and fabricating myself, but steel over here in Europe is rediculously expensive, as well as most anything else. I will have to pay for the lift kit in euros and buy it from here as its too heavy to ship from the states, so that will eat about 3000 bucks, not to mention the ARB, Gears, SYE, Tires/wheels, and I am MAKING myself get a new Engel out of the deal :victory: Budget will non-existant after all that!

Cant wait to start on it!!!!!!!!!!!!!!!!!!

~James

[OverlandZJ]

Mud...YUKK. ;)

Whats your backspacing? 33x10.5's for the win... :shakin:

Do some searching for Bushwackers, lots of sets seem available cheap.. even new unused sets. Why spend full retail when they are so readily available. Also, read up @ NAXJA on alternative mounting vs the sheet screws.

And congrats on the rig's maiden adventure, but was hoping for fully setup pics.

[StumpXJ]

Check out the CLAYTON 5.5 Long Arm
Its bullet proof:ar15: www.claytonoffroad.com

Ummm.... thanks Tommy? I already installed the Clayton 6.5" long arm kit. And I agree, it appears to be pretty darn bullet proof.

John, I was kicking myself because I forgot the camera, I think my wife may have a pic or two of the set-up on her phone though. We didnt get everything set-up till after dark, so the pic is probably not too great.

I will look for a used set before I order, I know I have seen a few sets in the past for sale. And yeah, I wont be using the sheet metal crews that they come with since that seems to be one of the biggest problems.

Backspacing is 4", should have gone with 4.5", and a 10.50 tire. Yeah, you told me so....LOL. Hindsight is a b*tch.

~James

[SEREvince]

I haven't been on here in a while, but I just got fully caught up!

I'm loving the rig! I was a little skeptical at first since, you could never really "replace" the Taco.

Anyway did you ever get the dyna beads? When I saw that I remembered I have 4 bags at 7oz each and I think I even still have the little install bottle if you're interested.

Cheers

Vince

[StumpXJ]

Hey Vince!

Yeah, I ordered the Dyna beads a few weeks ago, and they should be here anyday. I ordered enough to do all five tires, so hopefully they do the trick.

Got a locker on the way for the Jeep, should be a lot better in a few weeks!

Get the springs and shocks on the taco yet?????????????????

~James

[SEREvince]

Yup, everything is on, plus I've knocked out a few other little odds and ends that have been on my list.

I'm prepping for an Italian 4WD Jamboree next month.

I still need to do the rock lights and figure out a mount for my hi-lift and I'm calling it done for a while.


At least till after Christmas!

Ciao

Vince

[OverlandZJ]

James, NIB Bushwackers.

http://www.naxja.org/forum/showthread.php?t=975436


If i can assist..

[StumpXJ]

Hey John, I saw that yesterday. I think I have decided to go with TJ flares though after reading how much trouble the bushwackers have been. Not to mention they are only a fraction of the cost. Thanks for looking out though!!

~James

[Tanto]

One more suggestion: Tube Fenders (http://www.jeepforum.com/forum/showthread.php?t=432269)

As a warning, you'll be in your garage/outside a while looking at your XJ figuring out how to do this once you look at that thread.

[cshontz]

One more suggestion: Tube Fenders (http://www.jeepforum.com/forum/showthread.php?t=432269)

I love it how he keeps it nice and runs it too.

[OverlandZJ]

Hey John, I saw that yesterday. I think I have decided to go with TJ flares though after reading how much trouble the bushwackers have been. Not to mention they are only a fraction of the cost. Thanks for looking out though!!

~James


Utilizing four TJ rear flares?

[adrenaline503]

Wow, those tube fenders are awesome. I used TJ flares in my XJ, really easy to do.

[StumpXJ]

I am picking up a set of TJ fender flares this weekend, and I will determine if I want to use the fronts or hold out for two more rear flares. I may use the fronts, but it looks like a LOT of trimming to get them right.

I have seen that Tube Fender thread also, that guy does some amazing work for sure. That is an option as well, but its a whole lot of work.

I will know more once I actually get a set in my hands, but I have to something one way or the other.

~James

[Jackel18]

I am picking up a set of TJ fender flares this weekend, and I will determine if I want to use the fronts or hold out for two more rear flares. I may use the fronts, but it looks like a LOT of trimming to get them right.

I have seen that Tube Fender thread also, that guy does some amazing work for sure. That is an option as well, but its a whole lot of work.

I will know more once I actually get a set in my hands, but I have to something one way or the other.

~James

you should use four rear flares, looks better imo. My brother in-law and i did rear TJ flares on his MJ and it looks pretty good. I'll be doing the same to my MJ in the spring.

[StumpXJ]

My normal group that I go offroading with decided to go for one last camping trip this year, and planned it for this weekend, Friday, Sat. and Sunday. There were 6-8 of us planning to go on this trip a few weeks ago, and we bounced many different ideas around about which direction we wanted to go, and what countries to visit. By the time Wednesday of this week rolled around, it appeared as though I would be making a solo trip as most of the guys were either tied up fixing vehicles, work related stuff, or just plain didnt want to camp in the cold wet winter in Europe. All of which I understand, but I wasnt going to let it stop me, especially since I had already taken Friday off from work, and had the "ok" from my wife about going. These opportunities are rare....

Thursday at work, I did some searching on where I wanted to go, and decided to just make it a short trip over into France. Since I was going solo and into an unfamiliar area, I decided to hit the designated camping spots if at all possible. This was harder than I initially realized, since it is now so late into the season, most places were closed for the winter, especially the farther South I went into the mountains. I decided that my first stop would be Bannes, France, in the Champagne-Ardenne region. Basically, in the middle of nothing, and I was fine with that. I would drive down to this spot on Friday, camp friday night, then head back in the general direction I came until I got to my second spot of the trip, Neufgrange, France in the Lorraine region. Also, in the middle of nothing.

The purpose of this trip was simply to "get out", do a little exploring of an area not well known for much, and test out my camping set-up. Just a last hoo-rah for 2008 if you will.

Loaded up the Jeep Friday morning, and had make one pit-stop before I officially got underway. I snapped this picture in the parking lot of a "baumarkt", which is similar to a Lowes, Home Depot, or large hardware store. I needed to stop here to get a new clip/pin that holds on my sway bar discconects. I lost one while wheeling a few weeks back, and figured it would be a good idea to have the sway bar hooked up, especially with all of the weight I added on the top of the roof rack. Found what I needed, hooked up the sway bar, and was ready to roll.

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0604.jpg

I checked the forcast before leaving, and it was calling for "spotty" rain showers, with a possible thunder storm moving through on Friday night. No problem, this would give me a good opportunity to see how water proof my tent and awning was...

Just a few spots along the way. This was at a parking area where I stopped to stretch my legs, and eat a packed lunch. Certainly looks like rain in my future...

This is pretty much what it looked like for my whole trip. Rolling hills, open fields, and high winds with low cloud cover. The perfect European Winter day.

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0608.jpg

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0607.jpg

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0606.jpg

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0605.jpg

I finally made it to my first destination, Bannes, France. Like I mentioned, I was going to be utilizing camps grounds for my stops. Although this one was like a ghost town, it was open.

First camp site, all set-up:

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0611.jpg

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0610.jpg

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0612.jpg

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0614.jpg

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0609.jpg

Continued....

[StumpXJ]

More camp site shots:

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0613.jpg

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0615.jpg

Inside the tent, with the LED light strip working like a charm.

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0616.jpg

The kitchen in night mode:

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0617.jpg

On the menu for Friday night:

Jack Daniels Honey Teriyaki marinated beef tips, cooked with sauteed onions
Chicken and herb wild rice, courtesy of Uncle Ben's
Onion Baguette, topped with Lurpak butter (Hey... I was in France)
Coke for a drink, supercharged with Jim Beam.
Mmm Mmm Good!

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0619.jpg

After an outstanding meal, flawless camp kitchen operation, and decent chef work, the rain started.... and I mean it started.... and it never stopped until I left the next day. I had to lower one corner of the awning to let the rain water run off so it wouldnt pool up and destroy the awning canvas. I also closed up the kitchen, and head upstairs to the "living room".

Since the weather was crappy, and it was cold to boot, I decided to watch a movie, and enjoy the heated space thanks to my catalytic heater.

A little Bourne Ultimatum anyone?

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0621.jpg

Having the laptop was great for movies, luckily I had my 12 volt to 120 volt inverter and was able to run the laptop on the power cord instead of just the battery. My computer battery is pretty old, and only good for about 45 minutes.

The next morning, I awoke to rain. Lots of rain. Everything was thoroughly soaked outside, but I was high and dry inside the tent. I slithered out of the warm, dry tent into the cold wetness that could be called nothing less than miserable.

I made the most of it anyway, and had breakfast. Once again, compliments of the camp kitchen.

Ham, pepperjack cheese, and grilled onion omelet, a few pieces of baguette with butter, and some OJ.

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0622.jpg

I packed up the Jeep while it was raining constantly, hating life every second of the way. It was nasty to say the least. I was honestly contemplating going home instead of heading to my second scheduled stop, but then I thought WWEPPD? What Would Expedition Portal People Do? So after loading all of my rain soaked gear, I forged on for my next destination.

One of many random little French villages that I passed through.

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0624.jpg

More open road...

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0625.jpg

Finally arriving at my second destination, I was pleased to see a nice calm lake near the camping spots.

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0627.jpg

Continued.....

[StumpXJ]

Another shot of the lake as I drove in.

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0629.jpg

I arrived at this place around 4pm. It was not raining, and appeared to be clearing up a little, but the grounds were completely soaked. I managed to talk the owners into letting me set up on the edge of the water where a HUGE pile of asphalt was, on a section that had been spread out with a tractor. It was nice and flat, and better yet it didnt have any pools of water from the rains. They agreed after realizing I was not in a "caravan" as that is what they are used to seeing.

The second camp site:

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0630.jpg

The local French folks think I am a bit "odd" having a tent on my roof. The sad part is my kitchen was as well equipt as some of their motorhomes.

The kitchen ready for another round:

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0634.jpg

On the menu for Saturday night:

Herb crusted chicken, with a little Asian flair.
Asian salad with sweet sesame dressing, dried cherries, and fried wanton things for croutons
Medditeranean couscous
more French baguette
and yet another superchared coke.

Yes, its a bit jumbled with foods from all over the place, but it was excellent none the less.

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0638.jpg

French wild beasts were surounding me while I had my dinner. They were hungry, and agressive (also know as feral cats). After I got back from my shower, I realized left the rear hatch open on the jeep. I went to the back to close it when two of the cats jumped out of the back of my Jeep. I almost had to take another shower after that to say the least.

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0637.jpg

Up to the living room for another show. This time it was a more proper adventure movie...:

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0642.jpg

A great nights sleep, with no rain! Woke up around 8am, and made breakfast.

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0643.jpg

Scrambled eggs w/ham, bacon, toast, and pancakes. A hungry mans breakfast. I am used to cooking for more than one and didnt want to waste any.... yeah. Thats my excuse.

On the road back home...

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0647.jpg

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0648.jpg

The only casualty of the trip was my oil guage in the Jeep. The sending unit must be clogged, because it was going haywire.

http://i114.photobucket.com/albums/n257/topfuel443/France%20Camping%20Dec%202008/DSCN0652.jpg


It was a great trip all in all. It would have been nice to not have quite a smuch rain, but I did manage to make a list (longer than I would hav elike) of things that need to be fixed, modified, or purchased to enhance my camping trips for 2009. It never ends.
Thats all folks!

[idaxj97]

wow all i can say is i hope one day i will be able to do something like that. thanks for the report.

[Zeero]

Fantastic build-up man.

I love seeing guys like you just get into it and do it all themselves...building and designing and making it happen.

Nice clean work....enjoy it!!!

[XXXpedition]

a question and a hint...
first off, i love the switch panel next to the gauges and some other mods but i don't just want to write too long ;-).

secondly the question:
i was always wondering about the steel ropes between roofrack and bull bar...
what are they actually for?

and the hint:
with all that weight on the roofrack i would recommend more support brackets. best to go with a flat steel running along the gutters and having the rack sit on those (like on some expedition defenders). the unibody doesn't like the punctual stress over time... (i learned it the hard way)

[Zeero]

Those "steel ropes" are actually called "Limb lifters" and the purpose is to "lift" and push away low hanging plantation and "limbs" from the windshield so you can see where you're going in thick vegetation. :)

They also help protect paintwork to a small degree.
:)

[jeepmedic46]

Nice platform, Nice toyota too:)

[SWbySWesty]

Ok, I got the rear section done this morning, so the whole job took about 12 hours. I had already removed the old carpeting a few weeks back, so that will add another hour or so to the installation.

The rear section went in much easier than the front, as expected. It still is not perfect by any means, but I am over all satisfied. The molding and trimming could have been MUCH better from the factory, and they could have provided some sort of instructions or tips (they sent nothing). If I can give any advice with this stuff it would be to install it on the hottest day of the year, because heat is your friend with this product. I used a heat gun for some stubborn areas, and it helped tremendously, but the temp here is overcast and about 70 degrees (normally nothing to complain about).

I am very pleased with the actual material, and I think it will hold up nicely. In a scale of 1 to 10, I would rate the material at about 8-9. with the same scale, I would rate the ease of installation and quality of molding a very liberal "1". Enough babble, here are some pictures:

Starting to fit and trim the rear section:

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0418.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0420.jpg


In all honesty, the pictures dont quite do the finished product justice. I am actually overall happy with it, and will be very happy if the humps/bumps settle flat over the next couple of weeks. It was just a pain in the arse to install, and very misleading on what I was getting.

Once I get the platform built and covered, I am sure it will clean up the rear section to look pretty decent.

~James

this is exactly what I have in my 1996. Once installed, you are going to LOVE it. It cleans with a rag and doesn't poke holes. It's really good stuff to have in something that you can get wet/muddy or whatever and just wipe it out! I'm glad I'm not alone in this stuff!

[StumpXJ]

Thanks, its been installed for about 10 months now, and I do love it. I will get a new front section in a few months to replace the one I have now, I screwed up and cut it a little too much around the shifter and it doesnt cover a small area around the center console. No big deal, but it bugs me.

A bottle of Simple Green and an old towel and the interior lokks brand new. I am also going to install two marine deck plates in each front floorboard to allow me to rinse it out without having standing water.

~James

[XJINAZ]

Hi James,

It looks like you may state side now days. Do you still have this vehicle? Have you found any problems with mounting your rack at six points? I'm wondering about stress points and maybe even tearing of the drip rail. I've completed my roof rack ( mounted like yours ) and now wonder about the unibody/beer can effect. I've had my XJ twisted enough to make it difficult to close the back door. Sorry if I've missed a post of yours about this.

Thanks,
Lloyd

[GlennA]

That is one outstanding XJ in my opinion. If I had only had your vision when I had mine back in the mid 90's.

[StumpXJ]

Wow... thanks for dragging this up from the dead. I need to do some updating for sure.

The rack has been working flawlessly, especially the mounting. I have wheeled the crap out of it, and had it flexed as much as it can physically flex with no issues to speak of. I have had over 500 pounds on the rack while stationary (camping/sleeping on the RTT) with no issues from the rails.

I am honestly getting ready to re-do the rack, but not because of the mounting or anything other than the fact I dont like my rack, and my RTT is about to go on my trailer.

Hope that helps....

Glenn, thanks for the kind words!

~James

[Funrover]

Sweet!!

[StumpXJ]

Just doing a little update since its been a while since I have posted anything in here lately.

I had to get a new transfer case since I broke my old NP231. I had a front driveshaft come loose from the tcase side on my jeep (pulling into my driveway no less..) and it got bound up between the body and yoke. Needless to say, something had to give as the jeep was still rolling forward. The tcase broke completely down the middle. I decided that since I needed to replace it, I might as well upgrade, so I put in a NV241OR (Roctrack) 4:1 tcase out of a 2006 Jeep TJ. The lower gears are sure nice on the rocks! It was basically a direct bolt in. No issues at all.

Here is the broken tcase:

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0864.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0863.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0862.jpg


This is the only picture I have of the 4:1 241OR that I put in. Its a cell phone pic

http://webmail1.webmail.aol.com/44148/aim/en-us/mail/get-attachment.aspx?uid=1.25629069&folder=Inbox&partId=4


I also built a radio holder for my dash since I am using the normal radio spot for my TFT monitor for the cameras. I also added inside and outside temperature gauges I got from ebay.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0874.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0873.jpg

Since I knew I was coming back to the states soon, I decided I needed a CB set-up, so I built an overhead console to house that. I also added MUCH better lighting in the console as I was going. Just a simple little Cobra radio, with WX. I am using a K40 48" fiberglass whip mounted on my front bumper. The radio works great!

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0870.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0876.jpg

I also installed the Roadless gear wireless winch controller onto my winch a couple days ago. I bought two of these controlers since I plan to use one for the front and rear winch. That wont happen until I rebuild the 8274 Warn for the front, and build a new bumper to house it. I will then put the Smittybilt XRC8 in the rear bumper.

The little controller works great so far.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/Photo_062309_002.jpg

On the list of things to install, and I already have the parts to do it:

1. Xantrex Dual Battery set-up with remote panel (courtesy of Sierra Expeditions)

2. New rear main seal

3. Oil filter Orings

4. Oil sending unit

5 Crank Position Sensor

6. Install Rock Krusher rear diff cover

7. Install sliders


On the list of things to do:

1. Install carpet on the rear storage are for the dogs. They currently have no traction which makes for stressful times for them while offroad.

2. Re-do roof rack. I am going to build a hybrid top-hat/roll cage set-up. I will also fabricate some sort of swing down light bar for the Hellas. My RTT is going on my trailer that I am currently working on, so no need anymore for the roof rack.

3. Re-do front bumper to accommodate new roll cage and Warn 8724 winch.

4. Build rear bumper with tire swingout.

5. Re-gear and add rear locker. I already have a front locker, but want to install an ARB in the rear. I have already paid the guy (a friend) to do the gear install, but have to buy the parts still.

That about covers it for now.

~James

Also, I need to trim the rear fender wells to match the front. I would like to get a little more flex out of the rear, the stock shackles are junk. This is a pic from this week in the Northern Georgia Mountains

http://i114.photobucket.com/albums/n257/topfuel443/North%20Georgia%20Aug%202009/DSCN1097.jpg

[SWbySWesty]

looks like you have some good plans! I'm excited to get started on my build in mid-September.

[Hilldweller]

It's fun to watch that thing wheel, btw.
And it suits him. His overall personality, that is. I like when a truck "fits".

http://img.photobucket.com/albums/v352/billpearlman/100_3673.jpg

[OverlandZJ]

Looking good James!

I'd love to see what your up to with the trailer build..

[XXXpedition]

looks awesome!!!
man, i miss my xj - your color reminds me a bit of the one i had, but i think it's the one a little lighter...

great build-thread!:victory:

btw: how the hell did you get the front bumper hoop through TÜV?????

[Root Moose]

IIRC (it's been a while), U.S. and Canadian military personnel don't have to adhere to the local German regs.

[getlost4x4]

very nice set-up cherokee. i really like your portable kitchen. if i didn't have two kids taking up the back second row i would do the same.

[XXXpedition]

U.S. and Canadian military personnel don't have to adhere to the local German regs.
hmmmmmm, maybe i should try to go all-amerikan as well :elkgrin:

[StumpXJ]

very nice set-up cherokee. i really like your portable kitchen. if i didn't have two kids taking up the back second row i would do the same.

Thanks! I now have my two kids (2, 90 pound dogs) in the back, so I am building a trailer to hold all of my camping gear so they have a spot to hang out in the Jeep with us.


IIRC (it's been a while), U.S. and Canadian military personnel don't have to adhere to the local German regs.

Thats correct! We still had fairly strict requirements, but nothing compared to the TUV.


looks awesome!!!
man, i miss my xj - your color reminds me a bit of the one i had, but i think it's the one a little lighter...

great build-thread!:victory:

btw: how the hell did you get the front bumper hoop through TÜV?????

Thanks! I think there were a few shades of teal... I have seen several other now that I am stateside.


Looking good James!

I'd love to see what your up to with the trailer build..


Thanks John, I think most people will call me crazy when I post up my trailer build, but I found it better to work with what I had. :victory:

A trailer thread will be started soon, I have made a lot of progress in the preparation stages, but now the real work starts since I have a 'clean' slate.

[The Swiss]

A trailer thread will be started soon, I have made a lot of progress in the preparation stages, but now the real work starts since I have a 'clean' slate.I'll be looking out for that one.

[Explorer 1]

So many good ideas! I've printed out some pictures to put in my "improvements" file.

Thanks,
Fred
Explorer 1

[Capt.Crunch]

One of the greatest XJ's I've ever seen!! Awsome!! Is it locked by any chance?

[StumpXJ]

Figured I would update a little on my thread.

I just got finished installing my dual battery set-up. I am using a Xantrex Pathmaker 100 isolator/connector and the remote control panel. Had a little trouble with a bad connection between the remote and main panel, but once I figured it out and fixed it, everything worked like it should.

I installed the auxillary battery in the rear section of my XJ, since there is absolutely no room under the hood for it if you want to keep the stock airbox, and I do because I have my snorkel. This is actually better for me (I think) because I am going to be running a rear winch soon, and will have a place to hook to the winch to without going all the way to the front of the truck. Right now, the front Optima is running only the Jeep and the front winch, the aucillary battery is now running everything else. (Soon to be rear winch, 6 HID aux lights, rear halogen lights, fridge, compressor, inverter, camera, monitor, rear 12 volt sockets, etc.)

Turned out pretty good, was a pain getting all the pre-existing wiring to the rear, but its done. For now I have a deep cycle/starting (800amp) marine battery until I get something in the dry cell group. Installed my littel MV-50 in the box, and the inverter 700watt/1400watt on the top. I also added 3 12volt sockets on the top as well for whatever...

Not many pictures in between, but you get the idea.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1274.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1273.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1345.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1344.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1343.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1342.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1339.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1340.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1341.jpg


~James

[StumpXJ]

The other major project was for me to trim the rear fenders. I trimmed the front about 6 months ago, right before I shipped the jeep from Germany. I put off doing the rear since it is much more involved than the front. On the unibody XJ, when you trim the rear fenders (actually cut them, not just fold them over) you also cut the inner fender, so you have to go back in a weld in a panel to hook the outer shell and inner body back together. The picture should show the rest of the story. Turned out great, and I am very happy to have plenty of tire clearance when flexing.

Pics may or may not be in perfect order...

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1202.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1204.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1205.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1206.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1213.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1218.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1219.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1220.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1221.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1224.jpg

Continued.

[StumpXJ]

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1231.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1233.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1234.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1235.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1236.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1239.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1241.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1242.jpg

All finished!

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1251.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1252.jpg

[Root Moose]

Nicely done with the rear fenders.

[StumpXJ]

I also managed to rebuild an old 8274 winch that I got for free from my Dad's friend. It will go on the front, once I re-do the the front bumper, and I will move the smitty built to the rear bumper when it gets built (hopefully sooner than later)

Here it is all torn apart. I ordered a few parts for it, seals, bushing etc.

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1127.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1128.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1129.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1131.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1132.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1126.jpg

Here she is, after a good bead blasting, and fresh paint/rebuilding.

Just finishing up the solenoid box re-wire, and need to spool it with cable then it will be ready to bolt on.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1305.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1306-1.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1310.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1306.jpg

~James

[achampagne]

wow, you've got some skills!

[OverlandZJ]

Very nice James, the Warn looks new. I really like your approach to the second battery location and it's compartment.

[StumpXJ]

Lets see... what else have I done to this thing.

Replaced some unit bearings in the front.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN1194.jpg

Removed my milemarker wireless winch set-up

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0532.jpg

And replaced it with the roadless gear set-up. works great so far, I have another of these units for the rear winch also.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/Photo_062309_002.jpg

Also got a chance to let the 241OR Rocktrac 4:1 Rubicon transfer case do a little work.... Its awesome. I know I already posted about it, but it really is nice to have 4:1 in 4 low.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/241or.jpg


Installed an Aussie locker in the front (no pics of that)

Still need to install the frame stiffeners from HD offroad,

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0530.jpg

Got some Brown dog motor mounts to put in as well...

I will get to it all eventually.

~James

[StumpXJ]

Wow.. didnt realize there were replies already, I was busy posting....LOL.

Thanks everyone!!

~James

[Root Moose]

Why did you switch the wireless remotes?

[Stumpalump]

Nice job on the rear fender trimming!

[Hilldweller]

Nice, Stumpy.
Now I understand why you didn't make it on the camping trip.

I'm thinking of dual batts and an inverter/power station in the rear ---- 2000 watt so that I can bring my ac compressor with me to air-up.
I like your box idea; I was going to make one out of aluminum...

[StumpXJ]

Bill, that was fun stuff, the reason I didnt make the camping trip was this.

http://i114.photobucket.com/albums/n257/topfuel443/house/MULCH.jpg

Thats 11 cubic yards of mulch, an entire dump truck load. Thats an 18 foot wide door in the background. I spent the entire weekend spreading that out around the house.

Then I had 10 yards of rock delivered on Monday.

http://i114.photobucket.com/albums/n257/topfuel443/house/DSCN1258.jpg

http://i114.photobucket.com/albums/n257/topfuel443/house/DSCN1259.jpg

http://i114.photobucket.com/albums/n257/topfuel443/house/DSCN1260.jpg

http://i114.photobucket.com/albums/n257/topfuel443/house/DSCN1261.jpg

http://i114.photobucket.com/albums/n257/topfuel443/house/DSCN1262.jpg

http://i114.photobucket.com/albums/n257/topfuel443/house/DSCN1263.jpg


Then I closed in underneath the rear porch with lattice and a gate for storage.

http://i114.photobucket.com/albums/n257/topfuel443/house/DSCN1265.jpg

http://i114.photobucket.com/albums/n257/topfuel443/house/DSCN1266.jpg

Those three honeydo's almost killed me...

You should just get a CO2 set-up, forget the compressor. I hooked my little compressor up just as a backup. A 2000 watt inverter is HUGE! How many amps does the compressor pull?

~James

[StumpXJ]

Why did you switch the wireless remotes?

Chris, the milemarker unit worked great, the only reason I switched is because I knew I was going to add a rear winch and wanted both of them to be wireless and the same manufacturer. The two roadless gear units cost less than one milemarker unit, and there is no wiring in the cab unlike the milemarker. Its a WAY easier install basically.

I also like the Roadless gear remote better. Bigger buttons to push. The milemarker unit has very small buttons that are impossible to push with gloves on while winching.

~James

[Hilldweller]

You should just get a CO2 set-up, forget the compressor. I hooked my little compressor up just as a backup. A 2000 watt inverter is HUGE! How many amps does the compressor pull?

~JamesCO2 is nice on little day trips but is big/heavy/bulky on longer trips. My 1hp compressor can tuck behind a seat and still fill tires almost as fast as your tank.
I think it pulls 10 amps and the 2000w inverter 20. Grainger is in our building and I can get one at their employee price...

I need an easy day in the woods to play with the dog and sit around. Maybe build a fire.
You busy Sunday?

[BlueBomber]

Is your battery vented? batteries put off hydrogen vapors when charging. http://www.toolboxtopics.com/Gen%20Industry/Battery%20Charging%20-%20A%20Multitude%20of%20Hazards.htm

I know most racing org. make you put your battery in a box and vent it outside if you mount it in the passenger compartment.

[SWbySWesty]

Wow awesome box idea with the dual battery setup. You guys with your XJ's way ahead of mine are inspiration for my Sour Grapes build. Keep this stuff coming!

[StumpXJ]

Is your battery vented? batteries put off hydrogen vapors when charging. http://www.toolboxtopics.com/Gen%20Industry/Battery%20Charging%20-%20A%20Multitude%20of%20Hazards.htm

I know most racing org. make you put your battery in a box and vent it outside if you mount it in the passenger compartment.

Of course it is...

There are (2) two inch holes on the lower quarter panel (inner side) that is open to the air, and the battery box. XJ's arent exactly air tight.

Bill, I could be free on Sunday, what you got in mind? We all (Dogs included) need to get out for a little R&R.

SWbySWXJ, it takes time... You will get to where you want to be with the XJ, then find out something else you want to do. Thanks!

~James

[Hilldweller]

Bill, I could be free on Sunday, what you got in mind? We all (Dogs included) need to get out for a little R&R.
~JamesSomewhere by a lake or river.
Maybe Cooper Creek or Vogel. Grill meat; let the dogs frolic.

Somewhere without so much mud. I have to post some pics from last weekend with Bob at the Steel Soldiers Rally.
Mud.
Couldn't see a square inch of my Jeep anywhere. Just mud.
$18 so far at the U-Warsh-It and I'm going to have to do a few water crossings still...

[Willman]

This is one big jeep!

You have one of the best camp kitchens out there!

:)

[StumpXJ]

Bill, sounds good to me. Like I said before... I hate mud. However, if it keeps raining like it did today, it may be unavoidable. We can firm things up towards the end of the week.

Nic, thanks man. I have really enjoyed the kitchen, but it needs a new home inside my trailer. Tired of having to decide between taking the dogs or my gear and kitchen. Once I get caught up with some other stuff, the trailer will be my winter project.

~James

[Hilldweller]

We can firm things up towards the end of the week.
~JamesPM me your #.
My hard drive had a mechanical crash on Saturday and I'm having the data recovery blues bad... ...still no email too.

this is a camp kitchen to aspire to --- military kitchen from the Steel Soldiers Rally
http://img.photobucket.com/albums/v352/billpearlman/052.jpg

and this is the ridiculous mud from Durhamtown Plantation; one hour of wheeling
http://img.photobucket.com/albums/v352/billpearlman/072.jpg

the xj that didn't make it out
http://img.photobucket.com/albums/v352/billpearlman/074.jpg

[RedDog]

http://img.photobucket.com/albums/v352/billpearlman/072.jpg

If the tailgate wasn't open on that thing one would have no clue what colour it was.

[SWbySWesty]

wtf happened to that XJ?

[StumpXJ]

Yeah, that XJ has seen begtter days.

PM coming Bill.

~James

[xr8dxj]

Is that a "LaneChanger" on the mirror? I have one too. I bought it at Wal-Mart in '97-ish and it has been on the XJ ever since! It is my oldest "mod" on the Jeep!
http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0870.jpg

[StumpXJ]

Yep, I found that one in Germany. some chick was throwing it out on the military base, and I snagged it. Its awesome once you get used to it! Lanechanger II or III I think?

~James

[Explorer 1]

Your weldng skills make me blush at mine.

Maybe you should be a teacher with all your abilities. I remember that my jr high metal shop was one of my all time favorite classes, so much practical stuff to learn and apply.

How did you get such a nice cut on the rear fender wells when you cut them out????

Thanks,
Fred
Explorer 1

[StumpXJ]

My dad has owned a hotrod and fabrication shop since I was 4 years old, ive been using a grinder and welding since I was probably 8 years old. I dont want to sound like I am 'tooting' my horn here because im not trying to, but I am pretty darn handy with a cut-off wheel. Thats all I used is a thin (1/16th thick, 4.5" dia.) cut-off wheel on a die grinder. Its amazing what you can do with those a some patience.

The welding was pretty straight forward, just a million tacks on the outside, and some one inch beads along the inside. Little light grinding when finished, and some bodywork (courtesy of my dad, as I hate doing it.).

Yours looks great to me, nothing to be ashamed of for sure! My pops always says, it doesnt matter what it looks like until its finished. Then it counts.

Thanks for the compliments, looking forward to seeing yours finished!

~James

PS, yeah, shop class was awesome for me as well. Learned lots of great things in there.

[Weasel Mender]

Stump,
some more pics and details on that neat radio console would be appreciated. I am looking to build one my self and am a shameless copycat and idea rustler.

Weasel

[StumpXJ]

Weasel, I will see what I can do for pictures. Its just made out of 1/4" birch. I dont have any plans or anything, just kind of built it organically.

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0874.jpg

http://i114.photobucket.com/albums/n257/topfuel443/Jeep%20pics/DSCN0873.jpg

This is all I have right now, but look in my next post, there should be a few more. I can take some of whatever you need though.

~James

[StumpXJ]

Figured I would post up a little laptop mount I fabircated. I have been wanting to make or buy a mount for my laptop since I can now use it for navigation, but the prices on the pre-made stuff (RAM, Etc) is a bit much. Especially since I am currently unemployed. I have a small machine shop at my house, and like little projects like this. Time I have, extra money I dont.

Everything I used I had a scraps. It is 90% finished, but I still need to:


Cut off about 2" of the vertical mount, as its a little too high.
Add a locking screw/pin for the rotating portion of the actual mount.
Make a quick disconnect for the entire mount, since it will only be used when I do road trips or exploring, not for daily driving.

It can also be used by my passenger/navigator/wife for whatever (surfing, watching video etc) just by spinning the mount to that side.

This laptop is a touchscreen/notebook type laptop, so it keeps the size down to a minimum, and can be easily used with the navigation software without needing the keyboard.

I drove around with it today, and its very stable, although the real test will be on some washboard roads. So far so good though.

I think the pics will be self explanatory, but I will add info to a few. The round tubing is 3/4" HREW, and a piece of 1 inch 1/8th thick angle for the seat mount. The laptop tray is all machined Delrin. and holds the laptop very securely with the latch system on the rear. Obviously, doing this my self I was able to customize it to fit my computer, as apposed to a universal type mount.

I ran out of Argon in my Hobart MIG set-up, so I used my other welder with flux core. Crappy splatter, but I magaed to get most of it off.



The pics:

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1353.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1355.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1357.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1358.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1360.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1363.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1383.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1384.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1385.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1386.jpg

[StumpXJ]

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1387.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1364.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1365.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1366.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1369.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1370.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1371.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1372.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1373.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1374.jpg

[StumpXJ]

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1375.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1402.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1403.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1404.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1376.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1377.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1378.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1379.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1380.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1382.jpg

[StumpXJ]

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1405.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1406.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1407.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1408.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1409.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1410.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1411.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1412.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1413.jpg

[idaxj97]

nice.... did you get a wireless internet for the jeep or are you picking up reception for your house?

[Hilldweller]

It's starting to resemble the Borg Mothership. As a geek, I mean that in a good way.

[StumpXJ]

nice.... did you get a wireless internet for the jeep or are you picking up reception for your house?

Yeah, its just picking up the wireless from the house in the pics, but I will be getting an wireless internet card for it soon.



It's starting to resemble the Borg Mothership. As a geek, I mean that in a good way.

Yeah. I officially have enough gadjets in this thing. I think im done. This is what happens when you are unemplyed and bored.

~James

[Weasel Mender]

Yeah. I officially have enough gadjets in this thing. I think im done. This is what happens when you are unemplyed and bored.

~James[/QUOTE]

You could be suffering from both of the worst human maladies at the same time like I am.......acute boredom and acute poverty! At least you can throw money at the boredom until it goes away

Weasel:p

[Explorer 1]

Unemployed huh......

Too bad you don't live closer to L.A....I would put you to work with my XJ...with all the things I've seen you do on this thread I could start a little side business with your skills. :drool:

Thanks,
Fred
Explorer 1

[OverlandZJ]

:drool:

Very nice bud.

[SWbySWesty]

sweet mount.

[BIGdaddy]

thats SO cool!

[bobDog]

So this is all PhotoShop...right? :sombrero::coffeedrink:

[jeepmedic46]

Very cool, Wish you lived closer maybe you could install one of those in my Kj.:ylsmoke::smiley_drive:

[crosbike]

how did you attach the delrin to the stand? Your jeep inspires me.

[StumpXJ]

Thanks everyone, still need to do a little tweaking, but the mount works very well.

Crossbike, I didnt take a pictures of it, but on the backside there is a peice of 3/16th steel plate that runs from top to bottom, and a standoff/solid rod that I turned down in the lathe to fit into the tube welded to that plate. I just used 4 machine screwes drilled and tapped into the delrin to connect it all. I will take a pic of it tomorrow as I plan t finish up/modify a few things now that I have had a chance to use it.

Thanks, James

[VE2WHZ]

i very like your tread


very nice

[StumpXJ]

Alrighty, I got around to finishing up the laptop mount today. After driving around with the mount as it was, I realized it was a little shakey front to back. The way the mount is traingulated, its very solid from left to right, but not much to stabilize it front to back. So, I welded on a little tab and mounted it to the console, and now she is solid as a rock.

Also, I needed to shorten the over all mount about 2 inches, add a thumb screw to lock in the plate in either the driver or passenger position. Got all that accomplished this afternoon, so here is the update.

Here is the plate I welded to the stantion to mount the Delrin to.
http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1467.jpg

I turned down this rod in the lathe so it fits nicely into the tube. I also cut a small shallow groove for the thumb screw. Obviously this was all done before the welding.

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1468.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1469.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1470.jpg

This is the thumb screw I used. I have no idea where it came from, but it works great for what I wanted. I dont usualy throw out anything like this stuff as I usually end up needing it down the road... point in case.

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1471.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1472.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1473.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1474.jpg

Welded up the bracket for front to back support, little overkill since its mounting into plastic, but I had some scrap laying around.

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1475.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1476.jpg

[StumpXJ]

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1477.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1480.jpg

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1481.jpg

Someone asked me if the passenger seat still moved forward... yep, it still does.

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1483.jpg

I countersunk/drilled two dimples in the rod. Each dimple is a locking point for the mount, one for the driver position, and one for the passenger position.

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1484.jpg

Drivers position:

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1485.jpg

Passenger position:

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1486.jpg

View from the drivers seat.

http://i114.photobucket.com/albums/n257/topfuel443/fabrication%20stuff/DSCN1488.jpg

[crosbike]

looks great. thanks for the picture of the back of it.

[Cnickgo]

Stump that mount is excellent!