Project Overlander

[Topgun514]

I use that term loosely being the company I am in but after just seeing this site today I feel I should show a few pictures of my Jeep that I have named the Project Overlander on Jeepforum.

I've posted this in the tech section but I figure I will post over here too. Maybe get some of the expedition guys opinions and techniques and such

Here is my build, It will not be like Erics, BMyohn, or any of the major builds, but I want to show poeple and bounce ideas of everyone about my build as I do it.
Project Overlander will be a Low Lift (~3-4 inches max, 31's Max tire) but be a great overlander. Trails, mild offroading, great on road (95% on road) and great in snow driving. My other goals are camping spots, and best fuel economy for my 1988 XJ 5 speed.

If you have ideas, or questions, or comments please let me know. This is not my first build but my first build where I have fairly exact plans on how I want the finished product to look.

As for what I have already stock
Aluminum rims (wider, lighter)
235/75 BFG AT's
Rear Hitch
Toolbox in the rear (its out for around town with basic tools, but for longer trips I have a tool set)
Perfect Condition Jeep

Just took off the RR Tow hooks for my new bumper. Bolts in so much beefier with steering brace...1.75x.120 dom tubing with quarter inch plates tie ins. Got it local from a welder for cheap. I may get the prerunner skid to attach to it but i may throw fogs where that would be. I really like it so far and i just gotta paint it. Also, cleaned up the music playing devices with speakers and finally have some shots of my lift.-2 inch BB rough country
I also undid my rear sway bar but dont know how to slide the bar out without taking the tires off
Next is drill out that broken shock mount...all my other shocks are on except one.
Fog Lights( maybe )
Roofrack...or waiting, seen as I would not entirely use it often.

My goal is to try to get the most amount of weight out, (trim, take out carpet, anything)
Get as MUCH gas mileage as possible, so there goes the idea of Bored TB
And in the future have her sit at 3 inches of lift.

My ideas are really needed for the part of gas mileage. I do not want a cone filter, bored TB lowers gas mileage, would a free-er flowing muffler help, TB SPACER:eek:, snorkel?

Here are the pictures, I am pretty pleased with her. Just need to trim when this snowstorm passes.

what i started with
http://i170.photobucket.com/albums/u256/Topgun514/jeep3041.jpg
http://i170.photobucket.com/albums/u256/Topgun514/jeep3042.jpg

now
http://i170.photobucket.com/albums/u256/Topgun514/SDC10071.jpg

http://i170.photobucket.com/albums/u256/Topgun514/SDC10072.jpg

I have 2 Handheld CB's, and this is how i cleaned up my Ipod player
http://i170.photobucket.com/albums/u256/Topgun514/SDC10068.jpg

Need to trim
http://i170.photobucket.com/albums/u256/Topgun514/SDC10069.jpg

http://i170.photobucket.com/albums/u256/Topgun514/SDC10070.jpg

Started a bit of taking out unneeded parts, I have trimmed about 20 pounds off of her, looking to trim about 80 more pounds before summer. The lighter, the easier parleys canyon is (for any SLC/ Park City people understand)

Found out from my mom were doing a camping trip in august to glacier national park. 3 weeks in glacier should test this overlander...need a roofrack. I will be lifting it a bit more and getting new rims. Also, I will be adding a wind fairing to this big rack.

here are some shots... and the guy i got this from has a garage, 3 inch springs, LCA's and ill be doing the back end. Things are coming up quickly, and I will be adding exhaust soon too for extra mpg's

its a surco, 50x60
http://i170.photobucket.com/albums/u256/Topgun514/SDC10178.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10179.jpg

[Topgun514]

Updates, added a wind fairing and a bit of lift while getting those blocks out of there.
4 inch front, 3 inch back (I am waiting for the backs to sag from the AAL and adding another leaf) LCA's all in...she rides like a fat girl now, i love it, here are the pics. I am getting new rims and maybe bigger tires.
http://i170.photobucket.com/albums/u256/Topgun514/SDC10183.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10184.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10185.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10186.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10187.jpg

Updates,
After a squishy brake problem, my mom decided to throw me money to get them looked at for my 21st b-day. I got in expecting MC or air in the lines and 30 seconds into the job, I get pulled in to show my wheel dangling off with 3-4 inches of side to side travel. My bearings exploded and the mechanic said i had a few more miles before my wheel flew off. New hub bearings later, perfect brakes (the wheel was moving so much it was pushing the brakes apart giving a squishy feeling.

All due tooooo, my old tires, the lug holes were warn and ovaled, and too much backspacing for too long

New rims, canyons. Freshly painted front bumper, Tire on roofrack, and some new speakers (but I dont care) My lift is evening itself out pretty well and the AAL out back is very smooth. I may do some helper springs to get her all even but am working on drilling out my old broken shock bolts that are stuck in there. I have been driving shockless for about 1000 miles :)
Also, im gonna do a quick alignment in the driveway hopefully today to get rid of a bit of wobble.
Very happy so far, the list for future goes:
Muffler
Intake
Even out lift
Tires
Trim a tiny bit
Be awesome
Constant Maintanance

Updated photos (what poeple actually wanna see)

http://i170.photobucket.com/albums/u256/Topgun514/SDC10236.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10232.jpg

[Topgun514]

Just got back from moab...WOW. Enough said. Nothing in the world could have prepared me for how beautiful and just amazing it was. I only had 2 days of exploring and did not do hardcore trails but did some mild offroading and more exploring. I feel guilty because I did not get to see everything but wow- I am speechless.

I have like, 200 pictures but will only show a few.

Wow
Warning signs leading to Shafer's Trail. This is a dirt road circling the rim of canyonlands. At spots I was less than 1 foot away from the edge of falling off 1200 ft to the canyon floor
http://i170.photobucket.com/albums/u256/Topgun514/SDC10269.jpg

http://i170.photobucket.com/albums/u256/Topgun514/SDC10291.jpg
This is taken from my drivers side...It got narrower too and had steeper sides in most parts. This is the only part I felt ok with letting both my hands off the wheel and stick
http://i170.photobucket.com/albums/u256/Topgun514/SDC10295.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10307.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10330.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10336.jpg
A 3-4 foot bull snake
http://i170.photobucket.com/albums/u256/Topgun514/SDC10359.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10381.jpg

[Topgun514]

Nice jeep on potato salad...MUCH steeper than in pictures. Holy crap, Its hard enough to walk on it
http://i170.photobucket.com/albums/u256/Topgun514/SDC10486.jpg

Me on potato Salad...I could only approach it. It is so steep even to approach the rock I saw trucks not even able to make it to the slick rock. I am happy I could plant some tires on it and bounce around on it. Bigger Tires and a roll cage I'll feel better
http://i170.photobucket.com/albums/u256/Topgun514/SDC10487.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10490.jpg

Didnt get much further than that...its tough stuff


On the Jeep though. Death Wobble got so bad I loosened a tranny bolt I believe and my car stalled out coming downhill from Canyonlands. I got it aligned and I was over an inch off alignment.


On the way down, I averaged 20.68 mpg, at nighttime with traffic to draft behind.
With the jeep fully loaded up with close to 300 pounds of gear on the way back (daytime heat and no other cars to draft), my MPG is averaged to be about 24-25 mpg!!!

[Topgun514]

Here is the current Progress Report:

Since all of the above has been done...

New Cherry Bomb Exhaust, nice, deep throaty sound and not as loud as I thought it would be
Radiator Flush


Future plans to FINISH (no such thing though) the project:

Paint to another color, yellow, light green, anything but black...so hot.
Even out the Lift
31x10.5's All Terrains
Snorkel
Front sway bar adjustments

That will do it and hopefully be done in about one more year!

[Amauri]

Welcome to Expo! :ylsmoke:

[JPFreek1]

Coming along nicely. Keep us posted as you build her up. What are your plans with it long-term?

[mudbutt]

Which shock bolts are broken? The rear is more common.

Assuming it's the rear, there is an easy fix.

Get a set of JKS bar pin eliminators (BPE's).

Use a hammer and punch to knock the nut out through the topside of the mount plate. They are spot welded in, but are easily knocked out.

Get a nut to match the bolt that comes with the BPE's. Use some masking tape to hold the nut and a washer in a box wrench and slide it up into position above the the shock mount plate.

Bolt up the shock and enjoy......

[SWbySWesty]

welcome to Expo. If there was one thing I would do differently.....forget about mpg. The XJ isn't that great to begin with and as you add bumpers, racks, etc, you start getting heavier. The best thing to do is gear the axles for the size tires you have. (IMO)

I get 18-20 mpg at 65mph highway. Besides that, your Jeep and progress looks great!

[DrMoab]

Welcome to Ex-po.

I see you are in SLC too. Cool. There are several of us here who have roots with NAXJA and still do a lot of runs with the IC chapter. You should poke your head in there and see whats up. Several of us have been bitten hard by the expedition style of travel and moved away from the harder core stuff, hence the reason we hang out here too. :D

[Topgun514]

Thanks for the replies guys.

I have a bar pin in the mail, my plan is to knock out the old bolts and just but a bolt sticking through the bottom and then put the nut underneath and line it up. Just how my old XJ was and it was fine when replacing shocks because of the access holes and a 15 mm wrench that fits nicely in there! Saves me about 50 bucks for bar pins.

I also now need a new closed style coolant res. because my threads blew off just 2 days ago and because closed style cooling sucks...its gonna cost me a trip to the junkyard, no biggie though.

Future plans are even the lift out, repaint to a sun loving color, 31 inch A/T's snorkel, within the year from now til next july. After, my longer term is 3.55 axles from a newer jeep with an 8.25 rear and non-vac disco front. Add more performance mods, maybe 4.2/4.7 stroke (in the next 10-15 year outlook!!!)

Sooner, within 2 years I would like a good cooler or ARB fridge as well but my camping gear is very good so far, so as for my idea of an ARB simpson II pop up tent, may be overkill. This will be tested in August when I overland Glacier Nat Park...more hiking I bet but driving from SLC to practically canada will be a test too.


As for mpg, I still would like to increase as much as I can with my set up. Regearing and performance will help but I push 24 mpg fully loaded with extra gear at 65 so keeping it around there will be very nice.

[The Adam Blaster]

If you do end up going with an RTT I'd suggest going with a more stout roof rack.
I used to have a Surco as well, and found it wasn't that strong.

[Topgun514]

I think the RTT is out the window for turning my back area into sleeping quarters. If I take out the plastic molding in the back trunk section I can fit a small fridge/ storage in the area above the wheel well and when I get to a location I can throw most of my crap on the roof and sleep in the trunk or tent.

So no RTT.

Just got a new Coolant bottle and WOW, mine was toast, I thought it was stock to have the threads be litterally pointing upwards and round on the bottle itself.
I bend the bracket a tiny bit too so the bottle comes in contact with the hood a bit less hopefully.




A thought I did get though for the future is a small internal roll cage type thingy and putting rings on it to stretch a hammock in the back seat area. My head would be nearest the trunk with my feet going barely in between the glove compartment.

Or just putting the sleeping pads in the back and sleeping there. No problems there at all :bike_rider:

[Amauri]

I wanted to build my own RTT and stuff but I decided to keep it simple and just use a hammock. Easy to set up and I get to sleep outside. I'll get an RTT when I'm old. :coffeedrink:

Edit: Here's a guy that did something similar to what you want:

http://www.expeditionportal.com/forum/showthread.php?t=30484

[The Adam Blaster]

I'm planning a weekend, well, an overnight trip on the weekend of Labour Day..
I'm going to yank the back seat right out and build an impromptu sleeping platform on one side out of plywood and 2x2 and 2x4 supports to cover the gap in the foot well. This will be on te passenger side with the front seat pushed all the way forward.
I'm going to be storing the spare tire stapped down in the cargo area, so when I'm ready to crash for the night I'll have to toss the tire out on the ground and then lay out my sleeping pad and bag.

If you already have your spare on the outside, you could make the sleeping area more permanent, and store your gear on the other half of the XJ's cargo area. (Sleeping only one person in the rear anyways...)

You can keep it simple like I plan to do and just lay a piece of plywood on the floor and support it in the foot well area.

[Topgun514]

Thanks Adam,
I have thought about this but my jeeps a daily driver and I typically camp with 2 or more poeple. My gf will sleep in the vehicle too (where the roofrack REALLY comes into play)

All my stuff can fit on top and 2 people can sleep fine in the back with just sleeping pads. I am 6 feet tall so its almost a squish but is just fine for me.

My interior space is very plentiful to be honest, my main concerns at this point are evening out the lift (for anyone with an AAL or shackles)- My sleeping bag and pad are nice and my tent is nice too just in case anyway!

I love the suggestions though, keep em' coming!

[Topgun514]

Well some updates on this:

After my big trip planned to glacier national park, it could not have gone any worse for the XJ. About 30 seconds into the drive leaving the gas station out of SLC, my mom goes to plug in her cell phone into the 12V. I take off Jimi Hendrix for a few minutes as my 12V powers my ipod adapter. Blam...no stereo, no 12V. The older fuse must not have handled the new power source and that blew my radio and 12V. No worries though, my mom and I can chat for 8 hours to Helena.

I go to pull over about 15 minutes in because I already am going crazy thinking "No worries though, my mom and I can chat for 8 hours to Helena...AHHHHH" So I try to pull over just like any other Jeep owner would do and turn the car off and on again to have it miraculously start back again. Upon going to pull over, Death Wobble comes with a vengeance. My rear shocks have litterally been ripped from the bar pins and now I am driving a boat...the death wobble was due to this...I knew I had weak shock mounts but DAMN.

So I keep on truckin' because I can fix it in Helena. About 100 miles out my clutch goes a tad soft though, adding insult to injury. 200 Miles out and its still getting softer, finally, I have no clutch come 250 miles out of Helena.
We pull over to stop and the previously filled Master Cylinder is BONE dry. My feet are covered in DOT3 from the leak. I go under to bleed the system and just get a hot explosion of DOT3 in my face. Satan himself might have walked away from me with the thoughts in my head.

Thankfully, my Mom, calms me down, and teaches me a new method of driving. I throw the Jeep in first let the starter get me going, timing my shifts on a given interval that does not grind gears. Long story short, we limp into Helena.

The next day the Jeep goes into the shop for a new MC and shocks put BACK in, we take my Aunts Subaru up to Glacier. Now, I have the cleanest running Jeep I joke, but it was a great trip and gorgeous country. I loved every second of exploring Glacier and its a place I know I will be back to.

http://i170.photobucket.com/albums/u256/Topgun514/SDC10673.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10669.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10623.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10606.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10593.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10588.jpg
http://i170.photobucket.com/albums/u256/Topgun514/100_0819.jpg

As for progress on the Jeep, some have seen my new parts car that I am just taking a few things off of then getting rid of. One of which was the tires. So here are the new(ish) 31x10.50R15's. They are mostly great on tread besides one tire which is very low. There was also a spare tire brand new-BRAND NEW, 235/75R15 which will replace my even smaller spare tire. No full sized spare just yet. These will only be until Xmas when I get 4 new ones. I have also mounted a shovel for easy access, fixed that center console that the top flies off of it, and gotten a few more Overlanding things: Camp stove that is thinner than the Coleman 2 burner, plates, flashlights, and cookware. I maximized internal space by fitting everyday carry tools in the center console, straps and jacks under the rear seats, and other space saving techniques. (Parts Jeep is the new tan/grey one- first 2 shots are my Jeep without the tires mounted, just showing the parts jeep)

http://i170.photobucket.com/albums/u256/Topgun514/SDC10700.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10698.jpg

Here are some pics of the tires and shovel mounted:
http://i170.photobucket.com/albums/u256/Topgun514/SDC10708.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10707.jpg



Once I can sell the parts jeep for enough, I have been quoted by a friend who will paint my Jeep white. This will be great for temperature. Also, getting rid of those vinyl seats will help my rump. Stay tune for more updates. Id like to do some camping up at Big Cottonwood soon so you can see the Jeep in Camper mode hopefully

[Mr. D]

great job coming along nicely

[BEVAN]

Awsome XJ If I had it to do all over again i'd set mine up to run 31's not 35's....Do you have the internal slave cyl on your xj still ?

[Topgun514]

Yup bevan, internal slave and so far that seems ok still. If the tranny goes in the future its gonna have an AX15 swap but for now this ba 10 is still kickin'

[BEVAN]

we have some very good u-pull junkyards here, let me know if your looking for anything specific...skids are like 5.99 each.

[Topgun514]

Some updates:

I am in the middle of a cool little comfort swap. WJ seats in a RENIX XJ. A tad bit of welding (which apparently I am allergic to the fumes of cutting/welding metal. That is another story)
I also got this time to set up some rear storage. I of course then took amazing pictures of me in camping mode but NOOOO, the only photos that didnt come out with my camera were those ones.

Other than that, threw some old 31's on, which are going bad, I will get new ones on at Xmas. A few things in the works on cleaning up the sagging back end (barely noticeable but I notice.) Got some new straps, and also cleaning up storage for everyday carry. Tools in the arm rest area, tow straps and jacks in underneath the seats in the rear, and spare fluids, first aid, and a blanket in the rear area I made. Fire extinguisher is underneath my seat.

Here is what you really want to see

http://i170.photobucket.com/albums/u256/Topgun514/SDC10707-1.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10708.jpg
Seats
http://i170.photobucket.com/albums/u256/Topgun514/SDC10718.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10717.jpg

Storage- Thinking about throwing some mesh up on that.
http://i170.photobucket.com/albums/u256/Topgun514/SDC10716.jpg

[billyzj]

cool pics ...i wish we had places like that in fl.:safari-rig:

[Topgun514]

Just got some new tires, I was gonna go All Terrains again but wanted to try something new. These Goodyear Wrangler Duratracs are very impressive so far and I have about 30 miles 4x4 and extreme snow conditions. They are excellent and very solid on the road. I am impressed on my ride quality too, the All Terrains were always so hard but these really smooth things out, no more clunks over bumps, and hard braking and steering is improved as well.

I also have put on strokedjeeps.com bored TB to 60 mm for renix, which has made driving much more enjoyable, even with 31's, I do not need to constantly downshift on the highway comparing to when I was on 235's- I cannot even imagine what will happen with new gears (not likely happening soon :) )but this is a definite improvement and super easy- once you realize the TPS goes under the throttle edge- I am not too smart I guess.

Also, got the other seat welded in, so nice to have comfy seats, riding and driving enjoyment has increased about 15 hp I think.

Here is a shot- only angle I could get really in the driveway
http://i170.photobucket.com/albums/u256/Topgun514/SDC10749.jpg

The seats kinda match too- black front, grey stockers in the back
http://i170.photobucket.com/albums/u256/Topgun514/SDC10748.jpg

http://i170.photobucket.com/albums/u256/Topgun514/SDC10747.jpg

Tread pattern
http://i170.photobucket.com/albums/u256/Topgun514/SDC10742.jpg
Tires- about how much lift do you think this is, I am contemplating dropping it 1 inch?

http://i170.photobucket.com/albums/u256/Topgun514/SDC10745.jpg

[Topgun514]

Additions as some have seen is the tire carrier.

http://i170.photobucket.com/albums/u256/Topgun514/SDC10758.jpg
http://i170.photobucket.com/albums/u256/Topgun514/SDC10753.jpg
I threw some paint on this tire so it is all blacked out.


I also have since been in contact with someone who will give me a 1 inch spacer for my front and I am going to switch this out for my 2 inch and drop the front to be equal with the rear. I figure for the time being, I do not want to upgrade the front end parts and joints as well as I do not have the funds to. I do not want to build out of my means and dropping it will be a bit safer too and fine for 31's. I also had really poor heat in the vents so I found a lose cable- a zip tie later and I am blowing hot air.

I also did some Autopal h4 upgrades to the 55/60W lights, SO much better than stock.

Come more warmth I will be putting in the lift pucks (lowering pucks?) and redo-ing the cooling system with a new radiator- probably new Tstat and waterpump too. Preventative maintenance is the summer job as I will be doing much more overlanding with her hopefully. Then some differential fluid changes I think at least in the rear.

[Scott Brady]

Thanks for the update. I love the fact that your project thread has just as many trip photos as truck photos.

You need to apply for the ExPoordition!

[Topgun514]

As many know by now, I got in a small accident a bit more than a month ago. This weekend looks like I will be going to the shop and fixing it. As with an accident, I have slimmed down my budget and the Jeep. The roof rack is gone for accident money but for the best.

I was going to use my tax money for a snorkel but this will take precedence getting "Jays Jeep" back onto the road (my name is Colin btw, its just the name). I can wait another year and as I am in college I have no problems taking this slow, especially due to the economy. Once the jeep is fixed (damage yet to be determined) then I will do as much preventative maintanance before May. This will circle around "cleaning up" the XJ and replacing that leaky radiator - probably a T-stat too- for Moab. Getting a fan shroud as well as fixing or replacing that broken sway bar mount. Hopefully finding time to even out the leaf springs too.

Just an update for everyone!!!


As for futuremost plans. A snorkel and roofrack lay on a list for me. I hope for an ARB or Garvin rack, or making a rack that looks almost like a Hannible. Stay Tuned!

[Topgun514]

More plans become held off:


The hit my car took was apparently worse than I thought. The frame mounts for the LCA's are bent a bit and the shop wants 7-900 for fixing it. I got quoted by a local offroad shop to build new long arms and install for 600 though so it looks like I will be getting some long arms. This was not part of my build or my budget so after this, it will be preventative maintance of tune up parts and radiator stuff. Then the Jeep will be parked most of the year.

I am very sad to say bigger plans and trips are gone now. It pains me to think because of gas, college, economy etc, that I slowly lose a joy I hold so dear. But the future prospect of jobs and riches excite me. Who knows what the future holds?


Of course- Jays Jeep will ride like a Cadillac. Bright side of everything.

[Topgun514]

Another Update and I will add pics later!


The accident got all fixed for a bit under 500. For that price, I got my LCA Axle mounts welded in a heavy duty fashion as well as gusseted, my brakes got adjusted and I got Rubicon Express Adjustable Control arms to adjust for any camber issues and a yearly alignment. I am very excited about the Superflex joints and the ride is much smoother.

I also just put in a new (used) radiator with metal tanks but of course, my battery is now dead.

So, list of things:
Battery
Fan Shroud
Tune up
Adjust lift in rear

Next weekend I am planning on getting a craigslist ARB Rack too which will really set everything off.

Just Empty Every Pocket