The cosmetic cleanup of OverlandXJ

[OverlandZJ]

A few have asked me when i planned to share my recent work on the Cherokee with the
folks here as i have elsewhere. I realize this wont be a popular cosmetic
upgrade to some here but i'm happy with how it's coming together. I'm the type
who tends to be a little...different. I apologize in advance for your lack of
taste. :shakin:

I originally built this rig back in 00-01 as a rockcrawler. Started loosing
interest in it and the rig pretty much sat except for the occasional camping
trip when a hectic job schedule allowed. Decided a few changes were needed if i
was to travel any distance with this Jeep... then i stumbled upon Expeditions
West and the Expedition Portal. :wings:

First on the list was the removal of some lift, about 3" and a change from 35"
Swampers to a 33" tire. This helped, but it wasnt enough of a change to enjoy
driving on the interstate. Next came a LongArm suspension when a bud had a group
buy on RE components, so i picked up the longarms and a new set of uppers. This
really changed the handling characteristics and i decided i can live with an XJ
again. :wings:

But there was a problem.. my rig was butt ugly with trail scars and mismatched
sheetmetal. (kinda like it's owner) But it was in excellent mechanical
condition, part of my relaxation comes in the form of a cold beer and a wrench
hanging with friends on the weekend. Time to clean her up.

I knew what i wanted for awhile, something that could blend in and not bring too
much attention.HA! I decided on Olive Drab and some camo accenting. I started by
ordering a set of seatcovers in camo from www.seatcovers.net They had a hard
time fitting a set of covers for my seat, they didnt have a proper template and
after a few failed sets they offered my money back. I wanted their product as i
had seem them on another rig and they were a quality item, so i refused a refund
and insisted they make a set to fit.... but i was willing to help in any way i
could. I ended up buying a seat and having it shipped to them directly for
proper measurements. I ended up with a set of covers that fit fantastic and i
was loving the product. In the end it cost me double, but i got what i wanted.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/HPIM1960.jpg


Now i had a base to match the camo interior on. I then ordered some material off
ebay that closely matched the seats and redid my headliner.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/camoheadliner001.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/updatedZJ004.jpg

I wasnt happy with the soundbar being painted OD, so today i also covered that
in the same camo material, the sunvisors are next. Pics of these when installed.

[OverlandZJ]

Did a few more mechanical upgrades and maintenance for a bit. Decided i NEEDED
an RTT and decided to sell my 52 Willy's M38 project to fund the purchase.
Fortunately a local Jeeper (and member here.. LJRockstar) saw my ad and offered
me a deal. His Overland RTT and cash in exchange for the Willys... after
promising it would be a stock resto i agreed. Unfortunately i sold my matching
52 model year M100 1/4 ton trailer a year prior and only had the capability to
install the RTT on the rig. After aquiring Thule towers/crossbars the RTT was on
the rig. Then i aquired another trailer... which will be it's own thread later.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/OverlandonXJ007.jpg

But she's still ugly ya say? I had a plan! A friend and local NAXJA Chapter
member just happened to be a professional bodyman.So some more dealing and i had
the bodywork lined up, which took some time to get started but it happened a few
months ago. Thanks Keith!

http://i32.photobucket.com/albums/d24/ExpeditionXJ/XJbodywork008.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/XJbodywork009.jpg


Took her home and primered the fresh bodywork. Started some other little
modifications and starting prepping for paint.... as i learned how to do it. An
old friend and former employer George from AJP, www.armyjeepparts.com had just
what i wanted in a color. George had a shade of OD color matched to old NOS
parts from late WWII through Korean era Jeeps, this is a semi-gloss paint and
exactly what i was looking for. Once the paint was aquired i started gathering
the rest of what i would need. HVLP gun, chemicals, sandpaper etc while i did
some other minor body work to the Cherokee. Swapped in tinted glass in the rear
doors and cargo area, rear 1/4 protection among other mods.

[OverlandZJ]

Since i dont have a garage big enough to paint a rig in i needed somewhere to
spray the Jeep. Again, a friend from NAXJA offered up his assistance, just had
to wait for good weather and our schedules to allow 2 days to get it done. This
happened about 6 weeks ago finally. I spent 8 hours on a saturday sanding,
sanding, sanding, and sanding some more, prepping, i was tired and didnt want to
shoot that day. ( OK, i was scared )

http://i32.photobucket.com/albums/d24/ExpeditionXJ/XJsandmask024.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/XJsandmask027.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/XJsandmask031.jpg

So sunday rolls around and i head back over to lay some color. I was hesitant
because i'v been told i'm anal and a perfectionist when i do a job. Yeah, i was
shocked too. So i dove in, started the heaters, wiped it down, and mixed paint.
Laid down the "tack coat" and had a much needed smoke. Then back to another full
coat. Baked for 1/2 hour, then laid down 2 more coats and baked for 2 hours. i
was scared to death of runs, so on the last coat i held the gun back too far and
laid down a dry coat which gave the surface some texture... which is fine for me
as i dont ever intend to wax this thing. No clear coat at this time either. I
may in the future wetsand and clear this after i spray my trailer and gain a bit
more experience. I know, wheres the damn pics already..

http://i32.photobucket.com/albums/d24/ExpeditionXJ/XJpainting029.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/XJpainting033.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/XJpainting037.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/XJpainting040.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/XJpainting044.jpg


Pulled the masking off, reassembled it for the drive home quickly as we were
expecting a torrential downpour that evening. I thought about parking it under
the Gazeebo but i could fit it, i had to risk the weather.

[OverlandZJ]

So i let it dry for about a week, then started reassembling. Painting bumpers,
installing my old mods etc.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/xjreassembly001.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/wwinchinstalled002.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/XJreassembly2009.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/XJreassembly2010.jpg


All that work and this is probably my favorite accomplishment.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/xjreassembly2004.jpg


As she sits today, i figured i'd snap a pic of the RTT open, installed some LED
lights on bottom of RTT and on Jeep hatch. And some more interior work as i
mentioned earlier while grilling for dinner. Oh, i picked up my new tires as
well.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/33X10BFGMT001.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/trailerrtt005.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/trailerrtt006.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/trailerrtt003.jpg


It's not done yet, and wont be till i sell her. I'm in the middle of a new front
axle build, teaching myself to install ring and pinions now. Tires go on with
new Bilsteins when the axle gets installed.. hopefully in a few weeks. Then i'm
gonna want to get out!

Whatcha think? I'm thinking i wanna be the Chip Foose of Expedition builds, PM offers.

[MDZJ88]

I LOVE it!

A friend actually directed me to AJP yesterday because I want to paint my ZJ a desert tan(or possibly an olive drab similar to your color) to replace the uglyyyy lavender paint it has now(not the ZJ in the avatar, this is a new one).

Once again, I love what you've done with your XJ. Nice work!

EDIT: Noticed you're from PA! We should get together sometime and do a trip! You'd have to bare with me because, as my join date suggests, I'm just getting into this hobby...err...obsession. (Though I'm a very experienced camper)

[olympiccop2002]

That looks great! I love the color! Very, Very Nice! :wings:

Bjorn

[OverlandZJ]

Thanks Ben and Bjorn, much appreciated.

Ben, AJP has the desert tan paint in stock, but i dont know for how much longer. George mentioned it's a slow seller. I'll have to mention how popular it seems to be getting and have him hold off discontinuing for now.

If you wanna come and pick the paint up hit me with a PM, we'll meet for a cold one and lunch.

[weezerbot]

Wow very nice, love the color choice!

[cshontz]

Very excited to see the new meat on, John.

[riverfever]

Way to go John! That looks incredible. I've always wanted to learn to paint but I get globs when I White Out stuff. Thanks for sharing.

[IH8RDS]

Looks good John, I too want to see the tires. :Astrologist:

[OverlandZJ]

Soundbar is covered and installed... much better than the OD paint. Sunvisors are next.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/camosoundbar004.jpg

[StumpXJ]

http://i32.photobucket.com/albums/d24/ExpeditionXJ/trailerrtt003.jpg


A true inspiration for my build. Thanks for posting this info John, it looks fantastic, and even got my wifes approval (which as most know can be hard to get sometimes).

I cant wait to start on mine when I get home, I am writing this from a huge Ferry boat on the way back from Finland. We strapped the RTT to my wifes little suzuki wagon, and set out for a 4,800 kilometer round trip. Sure will be nice to do it with the XJ instead!

~James

[DH2002]

looks freakin sweet

[The Swiss]

http://i32.photobucket.com/albums/d24/ExpeditionXJ/33X10BFGMT001.jpgWhat size are those? Taller but narrower; I love it!!!

[OverlandZJ]

Thanks for the compliments guys, like i said i know it's not a style alot would go with but i'm a little "OFF". :)

James, i'm envious of your travels over there, what an awesome experience it must be. My travels throughout Germany consisted of peering out a window of a Chopper. The wife sounds like a keeper, treat her right! I dont need my wife's approval (so long as i dont get any ideas about her Grand Cherokee).

Michael, the new tires are 33x10.5 vs the 33x12.5 on the rig. They look taller from the wear, weight and few lbs underinflated. Once my new axle is done i'll paint the wheels and mount the tires.

I also stumbled upon this yesterday, i had forgotten i picked it up some time ago from DesertDude. It's an interior winch control that will reside in the original cig lighter location.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/xjwork003.jpg

[Haggis]

Your XJ looks awesome! Love the camo interior and the way cool paint. Nice Job Sir!!! Wouldn't mind seeing that rig in person someday...hint,hint,hint.

[Tanto]

(so long as i dont get any ideas about her Grand Cherokee)

Humm, we can fix that.;)

The XJ looks great by the way, really digging it.

[DaktariEd]

I apologize in advance for your lack of
taste. :shakin:
:xxrotflma

That made my day!

Great looking rig...and the colors are great, too! You've got some skills!

http://www.geocities.com/daktaried/safari.gif

[Maximus Ram]

OXJ, looks real nice.
How do you like those lights. I looked at some today after seeing them here, but was wondering just how much light they put out.....

[MDZJ88]

http://i32.photobucket.com/albums/d24/ExpeditionXJ/xjwork003.jpg

Stop using the ZJ as a workbench! Haha.

[OverlandZJ]

OXJ, looks real nice.
How do you like those lights. I looked at some today after seeing them here, but was wondering just how much light they put out.....


Love them, how could i not for under $7 each?

I picked up one of each to see how well they worked and which design i would prefer. The Oval unit worked perfect for my rear hatch when open, i can swivel it to illuminate the entire cargo area or swivel out to illuminate 10' behind the rig.

The round one (under RTT floor) does not swivel, but it is adjustable from one LED to all 3 LED's being lit. I need to stop and pick up another.. or more.

These are not real bright, and i dont need them to be. Just some extra lighting around and under the RTT when needed outside the Jeep. These are more of a spot than flood pattern.

I confess to getting these at Wal-Mart. They use 2 AAA batts.

[OverlandZJ]

Soon Mark... soon. I havent camped since Montana/Wyoming last Sept. I'm due. BTW.. friend called the other am, Bear walked through camp (outside Wellsboro) just looking at him ~30' away last Thursday am.... and i missed it. Not alot of Bear in Philly.

Ben, thats an XJ hood... shame on you.

Thanks Ed and Tanto, big compliment coming from ya'll.

[kcowyo]

I wanna say what I think of the new interior and exterior of the OverlandXJ, but the potty mouth filter won't let me.....

But I really, really like it. :REOutArchery02:

[gabe]

Were you in Delaware, where Kieth works? I also see Ben's MJ in the back ground a little more dented then I last saw it. I like the look you ended up with, the black trim pulls it together nice. I was going to go with dead grass and black trim, myself but went all black instead.

[OverlandZJ]

Were you in Delaware, where Kieth works? I also see Ben's MJ in the back ground a little more dented then I last saw it. I like the look you ended up with, the black trim pulls it together nice. I was going to go with dead grass and black trim, myself but went all black instead.

Yes, we did the bodywork in DE where Keith works. Missed ya at NAC-Fest.

Thanks KC, sagebrush liner in yours would look *******!

[BIGdaddy]

nice work :REOutArchery02:

[MDZJ88]

Ben, thats an XJ hood... shame on you.


Oh wow... I am now going and standing in a corner. :peepwall:

[Backwoods Rambler]

All that work and this is probably my favorite accomplishment.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/xjreassembly2004.jpg



Man, I've been looking for 3 of those!! Please tell me where you got them?

[OverlandZJ]

Man, I've been looking for 3 of those!! Please tell me where you got them?

From a Grand that had work done in a buds bodyshop. But they are available on ebay and here.

http://www.justforjeeps.com/ovbade.html


:beer:

[JPFreek1]

Awesome, awesome job with the work! Congrats on an amazing XJ!

[Backwoods Rambler]

From a Grand that had work done in a buds bodyshop. But they are available on ebay and here.

http://www.justforjeeps.com/ovbade.html


:beer:

Thanks man! Great work btw. Lovin' the color!

[stick]

Looks real good John. I love the color and the camo interior. Sent you a PM with some questions about the seat covers.

[mrbishi]

awesome rig - a great inspiration!!!!

[pixeldzn]

From a Grand that had work done in a buds bodyshop. But they are available on ebay and here.

http://www.justforjeeps.com/ovbade.html


:beer:

I like the look of those too! Not sure I am ready to pay almost $60 a pair though.

[OverlandZJ]

I like the look of those too! Not sure I am ready to pay almost $60 a pair though.

I think I might cut a sticker like this on my plotter. 2 color with silver on top and black below.

(I can make a few extra if anyone else is interested)

http://www.extremejeepclub.com/imghost/overland_sticker.gif

BTW, sorry if I hijacked!


I wouldnt have it if it wasnt for my buds generosity.. and i only have the one right now (dont tell anyone..shhh) i will grab another for the pass side.

If you print those stickers up i'd like a few please.

Thanks again for the compliments guys/gals.

[IH8RDS]

I like the look of those too! Not sure I am ready to pay almost $60 a pair though.

I think I might cut a sticker like this on my plotter. 2 color with silver on top and black below.

(I can make a few extra if anyone else is interested)

http://www.extremejeepclub.com/imghost/overland_sticker.gif

BTW, sorry if I hijacked!


I would be interested a couple too.

[turner]

I would love some! Those look great!

[ckale1]

Count me in

[jim65wagon]

Man! The XJ looks sweet! You are spot-on with the paint color and the camo interior is the cats***! I applaud you, sir,
:clapsmile I've always wanted to tackle painting a ride myself but I could never srew up the courage to do it. Very nicely done.

[1speed]

The Jeep looks great. Might have to paint my dually that color.

Yes to the stickers also.

[OverlandZJ]

A friend and i did the R&P install yesterday, got this pattern on the second attempt. Gonna finish it up today and throw a few welds on the new axle, install next weekend.

Cant wait to mount up the new tires and see how she sits.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/Gearpattern1.jpg

[IH8RDS]

That looks pretty good. How does the coast side look?

[OverlandZJ]

Heres the coast side Scott. Backlash is at 10 on a used gearset. Transfered my gears to a new housing. Am i good to button it up?

http://i32.photobucket.com/albums/d24/ExpeditionXJ/gearpattern2.jpg

[IH8RDS]

First try?! On used gears???? That looks pretty good. I have chased and chased a good pattern on used gears and have come to the conclusion that I will now only run used gears in the front. Back gets new ones now. I say button her up.

[OverlandZJ]

Four changes to pinion to get the right feel, second attempt on carrier.

I have to pick up a 1/4 to 3/8" adaptor to check pinion preload with an inlb torque wrench but it feels real good... nice and smooth. This is a new front housing, i suspect mine is tweaked.

Appreciate the feedback!

EDIT: BTW, backlash is 10. I should be right in center of spec for used gearset right?

[IH8RDS]

For new I would go 7, but 10 on used is just right.

For running torque on the pinion preload I use a digital snap-on torque wrench. A bit pricy, but it does running torque, nm, in and ft lbs with a touch of a button.

[IH8RDS]

Do you remember what shim you used for pinion depth?

[OverlandZJ]

Thanks again Scott! I posted looking for feedback at NAXJA but all the gear guru's must be wheelin this weekend.

I'm a bit of a perfectionist... just couldnt believe the result after attempt two. Kept wondering... what am i missing or interpreting wrong!

[OverlandZJ]

Do you remember what shim you used for pinion depth?


We started with the shim pack that was on the pinion from the old housing, it was too tight. We added till it felt right. IIRC it was .073 at start and ended at .086. I have the details written down in garage.

On carrier initial pattern read too tight on RG side... felt tight and notchy too, we took a stab at .013 and resulted in the shown pattern.

Oh wait... .083 was the preload shims. I'll check what we did behind the pinion baffle when i see the changes we listed.

[IH8RDS]

You may get some noise because of the gears being used. They wear into a set pattern. It all depends on how they where set up initially. I had one set that I just couldn't get right no matter what I did because initially it was set up with the pinon too deep. The front is not very critical because 9 out of 10 times you will only run 4wd off road at slower speeds. The rear is constantly being used there fore the noise of used gears will be allot more evident.

[IH8RDS]

Oh wait... .083 was the preload shims. I'll check what we did behind the pinion baffle when i see the changes we listed.

I cant remember what pinion shim I used for the dana30. Your pattern looks good though

[IH8RDS]

One more question... How did you rotate the pinion when getting that pattern? I usually wrap a towel tight between the flange and the housing when rotating to get a "load" on it.

[cshontz]

Don't button it up! A blue or white marking compound would look much better against the olive drab body color than yellow.

[OverlandZJ]

You may get some noise because of the gears being used. They wear into a set pattern. It all depends on how they where set up initially. I had one set that I just couldn't get right no matter what I did because initially it was set up with the pinon too deep. The front is not very critical because 9 out of 10 times you will only run 4wd off road at slower speeds. The rear is constantly being used there fore the noise of used gears will be allot more evident.

Just got back from friends garage. During initial setup we used a shim equal to the baffle that sits behind the inner pinion bearing race, so we had to pull it all apart to remove that shim and install the baffle.We used the shim so we wouldnt ruin that baffle if we had to readjust pinion depth. Total was .044shim in addition to the baffle on pinion.

We then rechecked backlash.. it loosened up to 12 inlb. But the pattern got even better! This should help with any noise issue with used gears as well... correct? We used a piece of wood between the housing and ring gear to induce about 40inlb drag... or "load".

I had to stop at Sears hardware on way there this am to get a 1/4 to 3/8 adaptor to check pinion preload, it was 10 inlb before we tore it apart and 6-8 after the baffle was installed. So i took .006 out (in .003 increments) of the shim pack and now have 12 inlb of preload.

Everything is now in spec and i have a real nice pattern. I'll post a pic or two tomorrow... i forgot the camera.

Thanks for your input this am Scott! :beer:

[IH8RDS]

When you take it out for the test run. If you want to tighten it up more, just remove .003 shim from the right side, and put it in the left. That will get you back at between .009 and .010.

[OverlandZJ]

When you take it out for the test run. If you want to tighten it up more, just remove .003 shim from the right side, and put it in the left. That will get you back at between .009 and .010.

Deep pinion? Dont think it's needed Scott after the rework mentioned above. But i'll get a few more pics of the "better" pattern for your input.

:Mechanic:

[IH8RDS]

My bad... I thought you where talking about the backlash.

[IH8RDS]

I saw the pattern up on NAXJA. Looks great. Definatly button it up.:bowdown:

[OverlandZJ]

I saw the pattern up on NAXJA. Looks great. Definatly button it up.:bowdown:


:xxrotflma

Heres the final pattern for those who didnt cheat and check NAXJA. ;) Thanks again Scott, owe ya a cold one... or ten.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/pattern3001.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/pattern3002.jpg

[OverlandZJ]

Installed the new axle this weekend. I left the axleshafts and driveshaft off so i can adjust castor and alignment, then check for vibes once the other parts are installed.

Did a number on my knee a few weeks ago and i had a rough time getting this in... took all day yesterday. But it was worth it, she already handles and rides better, old axle housing way certainly tweaked.

Found i need to do something about my JKS quick disconnects, the pivoting bushings are locked up. Road salt usage here makes things others use non practical. Looking at RE's newest disco's, i'm wondering if the baby Heim joints could survive winters here.

Tires next..


http://i32.photobucket.com/albums/d24/ExpeditionXJ/axleinstall001.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/axleinstall005.jpg

[DH2002]

very nice looks good

[AlabamaDan]

Nice Rig! I like the Color!

[OverlandZJ]

Thanks guys.

Caster and alignment is set. Tires get mounted tomorrow before work.

[GregCamp]

Sweet XJ! Great Job!
Im trying to find myself one now..

[OverlandZJ]

Sweet XJ! Great Job!
Im trying to find myself one now..


Where are you located? Looking for a stock vehicle or something with a few mods?

Heres a link to NAXJA (North American XJ Association) which has regional classifieds within the Chapter forums and another FS/WTB forum at the bottom of the index.

http://naxja.org/forum/index.php

You can also try your luck at;

www.jeepsunlimited.com/forums
www.jeepforum.com


Best of luck.

[toyrunner95]

so why are you selling it after all that work man, it looks soo good. im not a fan of olive drab, a bit cliche' for me. but its good nonetheless.

[OverlandZJ]

I'm not selling it toyrunner...

:smiley_drive:

[OverlandZJ]

Quick pic.. i'll post some more tomorrow after work if the weather holds out.

Tires and Bilstein 5150's are installed.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/33x10sinstalled001.jpg

[Big Daddy Chia]

Quick pic.. i'll post some more tomorrow after work if the weather holds out.

Tires and Bilstein 5150's are installed.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/33x10sinstalled001.jpg


Punk where that pic i asked of ya. Geeze. Slacker :shakin:

[OverlandZJ]

Scott, i'm sorry bud. I totally forgot about you needing the pic. I'll take a few and PM them to you this weekend.

:oops:

[Maximus Ram]

OXJ,the rig is looking awsome. Got a question....have you experienced any death wobble with those tires. I'm chasing DW on mine and just can't get rid of it. And I'm only running 31's. have done everything I can think of or have read. Changed the ball, new track bar, rotated balance tires, different tire pressure...the only other thing I can think of would be the shocks. They are the cheapo rough country ones....maybe better shocks would cure it....:(

[Big Daddy Chia]

OXJ,the rig is looking awsome. Got a question....have you experienced any death wobble with those tires. I'm chasing DW on mine and just can't get rid of it. And I'm only running 31's. have done everything I can think of or have read. Changed the ball, new track bar, rotated balance tires, different tire pressure...the only other thing I can think of would be the shocks. They are the cheapo rough country ones....maybe better shocks would cure it....:(


New tie rods, check the pit man arm.

[Maximus Ram]

New tie rods, check the pit man arm.

both of those are new.....

[Big Daddy Chia]

both of those are new.....


what about steering stabilizer. I have replaced everything on my xj but the ball joints on the steering knuckles, have a 3.5 inch lift and 31s and have no death wobble.

[Maximus Ram]

steering stabilizer is new too.....
steering problems rank up there with electrical in my book as a majorPITA to track down....

[OverlandZJ]

Bone stock rig? Oh wait, you mentioned RC and 31's. 3" lift?

Have you checked the unit bearings for play? How do the control arm bushings look? Are the stock control arms still straight?

Bent/dented wheel? Inspect the framerail where the steering box bolts up, they have been known to have issues albeit on lifted/wheeled XJ's.

Is it truely DW or a vibe of some kind? If it was DW you'd know why they call it that...

[Maximus Ram]

Oh no, it's DW.....no mistaking it.
Now the steering box is one thing I had not thought about.....I'll give that a look. Basically it has a 4.5" lift and I have put on new and upgraded parts to bring everything back into the correct geometry. So I will check that box...may have to(should) get the stiffener for it.
Thanks....

p.s. Sorry for the hijack

[OverlandZJ]

Yesterday i did some more front end work, adjust trackbar a bit and recheck alignment and changed the toe-in to 0* since i run a NP242 transfercase.

Greased the rig, and installed a new drivers wing window... after having to break it to gain access to my locked Jeep with keys in the column. Twice in a month... i must be getting old.

Today i decided to install the interior winch controller i bought 2 years ago...

I originally planned to install it in place of the factory cig lighter. While tearing into the dash i changed my mind and started putting it next to the radio and HVAC controls. Found that i needed to cut into the plastic dash housing behind the cover panel... thats when i realized i had cut a 2"x3" hole out of my AC ducting... :oops:

After some discussion with James (stumptaco) here i found a solution that should allow me to continue my install and retain most of my airflow through the vents. Thanks James... saved my bacon on this one.

It's installed loosely, i need to finish by running the wiring through firewall and to my winch. I'm glad i decided to put it here. Now i have to find a new home for my external CB speaker which sat in this location.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/winchcontrollerinstall003.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/winchcontrollerinstall002.jpg

[IH8RDS]

Thay looks like a good spot.

How did those gears turn out?

[OverlandZJ]

Thanks Scott..

Axle is in but still havent installed the shafts to see if i get any noise, i wanted to finish up everything else first. Didnt want to confuse any tire humm for gear noise...

In the meantime i installed new ujoints in the axle and driveshafts.

I have a valve stem that needs replacing, i'll stop tuesday and get them all changed. Should have thought of it when i mounted the tires.

[OverlandZJ]

I got a better pic of the new tires. Cant emphasize enough how much better it's handling now, like gramma's Caddy.

I'm considering Currie's swaybar, awaiting elcoyote's report on his impressions once he gets the MJ completed.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/xjwork9011.jpg

[IH8RDS]

Painted the winch :victory:

The devils in the details ;)

[stick]

Very nice John :26_7_2:

[OverlandZJ]

Yesterday i was working on the XJ some and decided to air out the Overland RTT. Took a few more photo's as i only had a few with it open. Weather here is getting nice and cool overnight and i'm feeling the bug to get out, thought about running in the house and grabbing a few pillows and sleeping bags. :jumping: Then i was reminded that it was my 22nd anniversary... :oops:


I started working on my rain/shade awning that will be deployed off the back of the Jeep. I'm utilizing some Milspec OD canvas that i bought off this site.. wish i could remember who it was. This should blend in well with the whole OD theme of the rig. I'll post a few pics of it when it's further along.



http://i32.photobucket.com/albums/d24/ExpeditionXJ/DSC_1491.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/DSC_1503.jpg[/QUOTE]

[kcowyo]

^^^ - John, that's hot. :drool:

.

[BigAl]

Painted the winch :victory:

The devils in the details ;)
I've never seen that done:clapsmile. How did you adjust the caster? Did you cut off the Cs and reweld?

[OverlandZJ]

Thanks Mr Hilton... when you going to share what you'v been up to with the LC?

Al, sorry if i mislead. I have been making small adjustments looking for the best compromise of handling and pinion angle by adjusting the control arm length. At the moment i have great handling, but i havent installed the front driveshaft yet to see if it induces any vibe. If it does, and i expect it to a bit, i'll adjust some more till i have a good compromise.

[OverlandZJ]

I kinda neglected this thread here. I have been back and forth to SC since Jan after my Dad had a bad stroke so things have moved extremely slow. At this point i had to choose between a sick parent and my employer.. it was an easy decision, back to SC i go. :smiley_drive:

Figured out a way to use the OD Canvas i picked up to use as a shade awning. It's a bit labor intensive but it'll work for now.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/Johnnyspics023.jpg

After another 6 weeks in SC i got home and was ready to spend some time in the woods, so a bud and i packed up and hit the Pa Canyon area for some much needed relaxation.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/BearRun5-0915.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/BearRun5-094.jpg


I have NAXJA's NAC-Fest event in 2 weeks so a bud loaned me his M416 since my project is so far behind. I'll mount the RTT on it this weekend and see how i like the RTT/Trailer combo. I have a feeling i'll be itching to get my project rolling as i dont like dealing with the RTT on a taller rig.

Thanks Erik, appreciate it bud.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/Erik4162.jpg

Quite a few more things planned to get done before a Utah trip next spring. I'll update as i go along.

[jeepmedic46]

You did a great job. Looks awesome.:smiley_drive:

[RgrBox]

Man that's a great job you did there.. That color is a dream color.. I love all things Military in color.. and OD is one of the best.. the job you did on the interior is perfect.. I have a friend who works at a bank " I know ".. who has re done all of his chairs in DPM Camo for his office.. looks too kool.

Anyway, hope your dad is doing better, and keep up the great work.

RB

[Ol Yeller]

[QUOTE=OverlandXJ;401619]I have NAXJA's NAC-Fest event in 2 weeks so a bud loaned me his M416 since my project is so far behind. I'll mount the RTT on it this weekend and see how i like the RTT/Trailer combo. I have a feeling i'll be itching to get my project rolling as i dont like dealing with the RTT on a taller rig.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/Erik4162.jpg[QUOTE]

Just curious, but why do you not like the RTT/trailer setup? I plan to do that with my M416. I know a few people have ran that setup, but I've never talked to them to see the pro's and con's. To me it makes perfect sense to mount the RTT on the trailer vs. the vehicle. That way you're not having to run around with the added weight on you Jeep. Particularly if you're wheeling.

[StumpXJ]

Re-read it, he is saying he does NOT like it on his vehicle. Thats why he borrowed the 416, so he can mount his RTT to it, and see if he likes it better than on the top of the XJ.

I totally agree with both of you, I cant wait to get my RTT on a trailer, it will make life much easier.

John, did you figure out the window prop problem? Are you in SC now or? when are you heading back?


~James

[OverlandZJ]

The RTT on top of my rig would be fine if i was able to just sit in camp for the duration, but i find i dont sit still very often lately. It's a bit of a pain to remove and reinstall the cover standing on my bumper and tire.... getting back down with a bad back and knee has it's issues as well.

Not to mention the event i speak of is wheeling in an offroad park, i'd hate to hit a limb or damage the RTT in another way.

James, i fly back down on the 16th just after NAC-Fest. Bringing my parents and their Camper up to Pa for a few months. Then i'll take them back.

Off to pick up my RTT... :smiley_drive:

[FourByLand]

John,

Sorry to read about your father, how is he recovering? This thing has come together quite nicely.

Looking forward to seeing your trailer set-up!

http://i32.photobucket.com/albums/d24/ExpeditionXJ/DSC_1503.jpg

[OverlandZJ]

John,

Sorry to read about your father, how is he recovering? This thing has come together quite nicely.

Looking forward to seeing your trailer set-up!




He's coming around, albeit slowly. Still a lengthy road ahead, thanks for asking Louis.

I thought seriously of painting the Jeep a close copy of your color, but in the end i didnt want to worry about the care of it. Toss a hose and soap at mine and it's done.

RTT is on, and what an improvement in ease of setup. Something to be said for being able to reach everything at chest height. Raised the pintle mount up and leveled it off a bit more, towed like a dream as well.



http://i32.photobucket.com/albums/d24/ExpeditionXJ/RTTw416.jpg

[FourByLand]

Glad to hear it.

I think you made a great decision on color choice, looks like a Jeep should IMO!

Thanks for the pic!

[RgrBox]

Man, these trailers have got me thinking I need to start a trailer project..

[Capt.Crunch]

I've seen your threads on other forums and actually followed it to this forum, which in case I'd like to say thank you. haha Anyway, this is one of the greatest jeeps I've ever seen. It gives me as a 17 year old alot of inspiration! Great work.

[Capt.Crunch]

oh and what axles are you running?

[OverlandZJ]

Thank you for the compliment, and welcome to Expo.

I'm running a HP D30 front axle, and an XJ D44 rear. Both with 4:56 gearing and disc brakes. Lockrite in the rear, and removed the Lockrite up front and sold it.

[AlabamaDan]

...
Now i had a base to match the camo interior on. I then ordered some material off
ebay that closely matched the seats and redid my headliner.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/camoheadliner001.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/updatedZJ004.jpg

I wasnt happy with the soundbar being painted OD, so today i also covered that
in the same camo material, the sunvisors are next. Pics of these when installed.

I've commented before how cool your XJ is and it still is. I'd like to hear more about your headliner, sunvisor and soundbar install. I need to do all the same things. Maybe you could spin off a different thread on it. Either here or NAXJA.

[RgrBox]

Wow!

I love that...

I need some seat covers.. I got a English Setter puppy, and he likes to get dirty..

[OverlandZJ]

I've commented before how cool your XJ is and it still is. I'd like to hear more about your headliner, sunvisor and soundbar install. I need to do all the same things. Maybe you could spin off a different thread on it. Either here or NAXJA.


Heres my NAXJA thread..

http://www.naxja.org/forum/showthread.php?t=942417


What do you need, a detailed how to? I still need to finish one sunvisor, could take pics of that... if i can remember to.

EDIT: Dan, heres a little something i typed up for someone doing their headliner awhile back. Hope this helps. The soundbar is basically the same.. just make sure any cut/folded over material overlaps towards the rear of the vehicle so it's less likely to be seen. This may not be an issue with padded material however.



OK, once the headliner is out of the vehicle pull the old material off it. A set of sawhorses and a sheet of plywood make a good work table. A hand holding the headliner is highly recommended as well.

Then you need something to remove all the old foam, i have used a hand brush and vacuum brush attachments with good results. You want to get all that stuff off so you have a clean solid surface to glue the new material down.

Once it's nice and clean lay the new material over the headliner. Position it so you keep your maximum leftover material. You want the material to just overlap on all edges, the rest will be trimmed. Apply something to clamp one end of the material down with... clothes pins worked well for me.

A second hand from here really helps.

Fold back the new material exposing half the headliner... this is where you spray the glue. Practice laying the material back down a few times working from the center out.. trick is to position it the first time so you wont have to try and lift it once it's embedded in glue. Once you feel confident your ready.

Before ya start spraying adhesive a few points..

The adhesive comes out almost like a silly string when nozzle is correctly adjusted, i like the med setting. Watch your overspray as you wont get it off any material you accidentally hit. I like to do this outside as i dont have to worry about floors etc. The temps your working in will affect the setup time of the adhesive. You want it nice and tacky when you lay the material, not WET... you'll see what i'm talking about.


Once you feel ready again fold back the material half way back and make a nice crease. Spray the adhesive on the headliner and material, wait a few minutes letting it tack up, then hit it again, then do it a third time. You want to be liberal with adhesive, not drench it each coat. Then with your assistant slowly lay the material to the headliner working from the center out and to the outside edges. Go slow here and you'll avoid most wrinkles. If your laying it down and feel wet glue coming through stop and let it tack a bit more.

Once you get this far you have the skills. Just repeat for other side. Let it dry nice for a few hours or overnight. Then trim your excess around the edges. Flip it over and take a razor knife to the holes for sunvisors, overhead lights etc.

Remember, take pics along each step.. maybe a third person can snap these. This way you can do a nice writeup for others wanting to do this as well.

Good luck, it's easier than it sounds bud. Take your time and you'll be happy with the results.

[OverlandZJ]

Wow!

I love that...

I need some seat covers.. I got a English Setter puppy, and he likes to get dirty..

www.seatcovers.net

These are wearing like iron.


My apologies for lack of updates, being unemployed the funds divert to the mortgage and childrens needs first. I have aquired a few items which i will update later when i get the associated parts for installation.

I'd like to publically thank StumpXJ for his generosity in providing me with a power inverter i was in need of. I owe you bud.

[Explorer 1]

Your "product" looks rather tastefully done!

I wrestle with some of the same issues in that I use my XJ for exploring and camping trips but at the same time want to be able to take it just about anywhere and not have a dry fall or rock garden stop me.

Looks like you done a fine job.

Thanks for sharing,
Fred
Explorer 1

[comrad_zeelaagee]

me likey the seclusion3D pattern- not the best for here in the west... i could see doing that in a digicamo pattern myself.

[bigredcherokee]

Miss my XJ. I really like the Camo them you have going. Keep up the good work.:smiley_drive:

[gasman]

hey overland .. i know we've kinda swaped pics over on naxja some time ago. and again .. nice rig, with the intrest everbodys showing in your headliner i hope you dont mind me postin up one or two of mine.. just to show another variation of the camo theme.. and for those asking it aint that hard to do.. mine has been done for a couple of years now and still looks like the day it was installed .. now for the bonus, after christmas a freind of mine will be finally making some custom seats for me in camo and black to match. i will prolly post up some pics of my updated interior then.. maybe someday i will get to see you jeep in person .. now that would be cool !!!

http://i69.photobucket.com/albums/i60/superfitter/IMG_0703.jpg
http://i69.photobucket.com/albums/i60/superfitter/IMG_0702.jpg

wood grain gone repainted all interior panels..
http://i69.photobucket.com/albums/i60/superfitter/IMG_0723.jpg
http://i69.photobucket.com/albums/i60/superfitter/IMG_0725.jpg
and just because im so proud of her rig and trailer
http://i69.photobucket.com/albums/i60/superfitter/IMG_3450.jpg

[RgrBox]

I've got to tell you, that you've done a great job on your rig. The color inside and out looks great. How has the camo material inside effected the sound? Looks like a think material that insulates well.

RB

[OverlandZJ]

gasman, i have PJ's just like your headliner material! :sombrero: Looks to be a fleece material?

I dont mind at all, the headliner is something most XJ owners end up replacing as you know.

You know i'm a fan of your M101 build, sweet setup. We should meet in Northern Maine sometime. :smiley_drive:

EDIT: The interior looks good to. Krylon Fusion? Hows it holding up? I need to do something with my plastic trim.

[gasman]

thanx rb.. insulation value .. maybe? as far as sound deadening maybe ? i have no carpet on the floors anymore so that would be hard to notice. now im running 35'' procomps as well, great tire, not too loud but not the quietest either..

[gasman]

gasman, i have PJ's just like your headliner material! :sombrero: Looks to be a fleece material?

I dont mind at all, the headliner is something most XJ owners end up replacing as you know.

You know i'm a fan of your M101 build, sweet setup. We should meet in Northern Maine sometime. :smiley_drive:

EDIT: The interior looks good to. Krylon Fusion? Hows it holding up? I need to do something with my plastic trim.

i got pj's like that too.. my buddy said i should wrap my kids in velcro so that if i roll over the kids will stick to the roof. yes it is a fleece matierial i bought at wal-mart. i think i paid 25 bucks . the glue cost more..

yes krylon fusion..yes its holding up very well. there are signs of wear on the door plates at the floor from people scuffing there feet on the way in and i have a few scratches in the cargo area but.. im not easy on it either.. its a wheelin rig.and i painted it a couple of years ago. im planning on making some diamond plate door panels soon cuz im tired of cleaning the mud out of the carpet on the lower portion of the doors .

northen maine you say ?? i wood be up for that. for sure . aint never been there before..

[RgrBox]

thanx rb.. insulation value .. maybe? as far as sound deadening maybe ? i have no carpet on the floors anymore so that would be hard to notice. now im running 35'' procomps as well, great tire, not too loud but not the quietest either..

I have a Landrover, so I understand the value of insulation.. it only takes one rock to make you feel like you were shoot at by the local Taliwackers..

RB

[OverlandZJ]

I made a comment in the Jeep pic thread and didnt mean to take it off-topic so i thought i'd update here.

This coming Sept myself and Gasman here will be traveling from the east coast out to Utah and Colorado, meeting a few of you here and at NAXJA hopefully. If you see two OD XJ's running across 70, in Moab/Powell, or the San Juans wave as it'll be Brian and i.

Anyway, the comment i made is that i'v decided i'm done with the XJ and will part it out after this trip, Many parts will find their way over. After 15 years and a severe distaste of rust i'v decided on another vehicle. I have a few spots in my floor and recently found windshield rust allowing water to seep in.

The good news is that there seems to be plenty of interest in OverlandXJ's body by people willing to do the work it needs.

This will be the new project..


OverlandZJ, the 98 Laredo with 4.0 and 242.

I have done a full tune on this, flushed and installed new fluids, and picked up Leather seating for it. It's dirty and smells of my BIL's dog, but once it warms i'll strip the interior and redo it.

I'll start a new thread sooner or later..

http://i32.photobucket.com/albums/d24/ExpeditionXJ/Dads98ZJ001.jpg

[alexfm]

Forgive me if its too soon to ask, but are you willing to ship the front bumper when you part it out?

Thanks,

Alex.

[StumpXJ]

Hey John...do me a favor and slap yourself for me will ya? Are ya kidding me? The OverlandXJ is epic. It would be a sin to part it, and the Jeep gods will make that ZJ into your worst nightmare because of it... say it aint so buddy!

It would be a shame to part it out right after an awesome trip like that... ANYTHING can be fixed.

:victory:

So if you were getting rid of that rear quarter armor....I may "know" someone who would be interested. Just sayin' (like a bunch of piranhas...)

http://i32.photobucket.com/albums/d24/ExpeditionXJ/DSC_1503.jpg

~ James

[OverlandZJ]

I'm just ready to move on James... but i invite you to join me in the WRT permit to attempt to convince me otherwise. :sombrero:

Consider them yours.

[DrMoab]

I would like to publicly tell you I think your nuts too. I told you in a PM but I ain't afraid to publicly say it either. :D

[john101477]

I am not even a jeep guy and i think your makin a mistake. The ZJ is just to much of a family cruiser. i do how ever understand your rust issue. like what you did with the XJ. i am a camo freak as well. If I can make it camo it gets turned to camo. Anyways what ever you end up doing I hope it works for ya.

[Root Moose]

Surely the rust can't be that bad.

I can't be bothered to do body work any more. I had rot in the top of the windshield frame on my XJ. Took it to a body shop (local Chrysler dealer actually) and they fixed it for a couple hundred bucks. No biggie.

Now, if you are using that as an excuse to get another Jeep, well, forget I said anything. :)

[Backwoods Rambler]

I went with a friend while he test drove a '98 ZJ w/I6 the other day. It was a SUPER nice ride. I can see why you would want to upgrade.

Personally, I would ony upgrade if it had the v8, but that's just me. Also, I would move directly into a WJ :smiley_drive:

Have fun with the new project. Will any items swap over from the XJ to the ZJ? Front bumper, sliders, roof rack, ect..?

[OverlandZJ]

I would like to publicly tell you I think your nuts too. I told you in a PM but I ain't afraid to publicly say it either. :D


No one has ever accused you of holding back.. :sombrero:



Surely the rust can't be that bad.

I can't be bothered to do body work any more. I had rot in the top of the windshield frame on my XJ. Took it to a body shop (local Chrysler dealer actually) and they fixed it for a couple hundred bucks. No biggie.

Now, if you are using that as an excuse to get another Jeep, well, forget I said anything. :)


I know it can be fixed.. and it would be fun to do so. I just dont feel like it. I'v known for quite sometime i wanted something different.



I went with a friend while he test drove a '98 ZJ w/I6 the other day. It was a SUPER nice ride. I can see why you would want to upgrade.

Personally, I would ony upgrade if it had the v8, but that's just me. Also, I would move directly into a WJ :smiley_drive:

Have fun with the new project. Will any items swap over from the XJ to the ZJ? Front bumper, sliders, roof rack, ect..?


I also have a V8 ZJ in the driveway, and attempted for sometime to talk the Mrs out of it. No dice... so i'll deal with the 4.0L.

I'll be swapping over my XJ's axles, HP30 with 4:56, rear XJ D44 with 4:56, Lockrite, TSM rear discs. My NP242, The entire front suspension.. mostly RE longarms. My new 33x10.5's onto the Canyon wheels, all my interior ad on's, my winch. Plan is to use stock bumpers with Iceland Offroads winch plate.. maybe in the future his glass bumpers.

Idea is to keep this Jeep as light as possible. Roofrack and sliders were sold sometime ago, if by chance i can modify the front bumper to fit i MAY keep it. I'm looking to have a rear carrier kinda similarto Detours XJ tailbone system.

I dont think i'll go the OD and camo route this time.. not sure it would look good on the ZJ. I like ZJ's that have the "White Out" treatment... all the body cladding/bumpers as well.

[DrMoab]

It's not exactly OD but I loved my cousins XJ with a camo paint job.
http://i58.photobucket.com/albums/g265/DrMoab/Geostash07/IMGP4857.jpg

[StumpXJ]

It's not exactly OD but I loved my cousins XJ with a camo paint job.
http://i58.photobucket.com/albums/g265/DrMoab/Geostash07/IMGP4857.jpg

Come on Ryan... Thats a funny looking XJ. I know you arent new to this stuff... :elkgrin:

(that does look pretty cool, in a mad max sort of way, but I agree with John on this one, I am painting the top half of my XJ white to match my trailer... )

[OverlandZJ]

That's an effective camo job Ryan.. made it appear to be a ZJ. :sombrero:

[DrMoab]

Come on guys give me a break. I type XJ all day long and the X and Z buttons are next to each other.

You know what I meant. :D

[OverlandZJ]

OverlandXJ has been dropped of insuarnce, tag re-registered and parts have started to be sold.

OverlandZJ has been insured, registered and inspected, currently being driven.

I'll start a new thread soon, still doing some maintenance and cosmetic work on it, lift and other mods to come.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/98ZJ%20laredo/98zjwashed.jpg

[Haggis]

What's the chances this one will make it to a Ridgerunner event? We never got a chance to oogle the last one. :elkgrin:

[OverlandZJ]

What's the chances this one will make it to a Ridgerunner event? We never got a chance to oogle the last one. :elkgrin:


Sorry about that.. things have been rough the last few. Still dying to get out and see the Elk herd.. maybe later this year for a shakedown run.

[BEVAN]

Sweet, Glad to hear...sad to hear about the XJ but The ZJ will be cool..(I had the same thoughts) there was a limited 98 4.0 ZJ that was calling my name...It was tempting !

[OverlandZJ]

OverlandXJ is no more. Looking fwd to getting back to work on the ZJ. I'll start a thread in a month or two when it starts.

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

http://i32.photobucket.com/albums/d24/ExpeditionXJ/xjcut2.jpg

http://i32.photobucket.com/albums/d24/ExpeditionXJ/xjcut3.jpg

[taggart_lumpy]

:(

[bldeagle10]

that, is tear worthy.. why the need to chop it up?

[OverlandZJ]

that, is tear worthy.. why the need to chop it up?


I couldnt find someone who wanted to put the work into the shell that it needed. Son ended up with engine in his YJ, i kept many parts, and sold/gave away many parts. Scrap man stood me up for two weeks, so i broke out the sawzall and borrowed a trailer to get it out of here so the neighbors didnt have to look at it.

[bldeagle10]

good enough excuse i guess, sad to see it go.