IntrepidXJ's Buildup Thread

[IntrepidXJ]

Figured I'd start one of these Buildup threads here, maybe get some ideas and share some of my own, too :)

Some of you on here know me, some do not. For those that don't, I have been wheeling a 92 XJ pretty regularly for the last few years. However, that vehicle ended up headed towards the more hardcore wheeling and rock crawling:

http://www.myxj.net/trail/MoabCO/21_Road_4-29-06/photos/DSC09335.JPG

http://www.myxj.net/trail/MoabCO/21_Road_4-29-06/photos/DSC09367.JPG

http://myxj.net/trail/Mission_Impossible_4-21-07/photos/IMG_2956.JPG

While I enjoy rock crawling, I also wanted a vehicle that I could use for camping, photography and scenic back-road adventures, etc.... Obviously I was very familiar with the XJ platform (plus I had a lot of parts laying around) so I picked up a 2000 XJ back in February for this purpose.

My first goal is to get it ready enough for a Western Trek I am planning to CO/UT/WY/SD at the end of July, so I have a lot of work ahead of me.

[IntrepidXJ]

Here's what I started with:

http://i33.photobucket.com/albums/d65/rlngstrt/2000JeepCherokeeSport016.jpg

http://i33.photobucket.com/albums/d65/rlngstrt/2000JeepCherokeeSport013.jpg

I threw some recovery points on and took it to Missouri before I had even owned it for 3 weeks:

http://myxj.net/trail/WinterFest2007/Thursday/photos/IMG_1614.JPG

http://myxj.net/trail/WinterFest2007/Friday/photos/IMG_1915.JPG

[IntrepidXJ]

Since then I have been adding more stuff to get it ready for my trip (here's some of the bigger items I've added recently):

rock rails:
http://myxj.net/2000Sport/progress4-3-07/photos/IMG_2411.JPG

front bumper
http://myxj.net/g2/d/59994-1/IMG_3271.JPG

rear discs
http://myxj.net/g2/d/82578-1/14.jpg

rear bumper/tire carrier
http://myxj.net/g2/d/82670-1/IMG_3407.JPG

winch
http://myxj.net/g2/d/83868-1/IMG_3978.JPG

Now I've just got a lot of parts sitting in my garage waiting to get installed
http://www.myxj.net/g2/d/83350-1/IMG_3740.JPG
http://www.myxj.net/g2/d/83345-1/IMG_3738.JPG

even an HP D30 with 4.56's and an Aussie laying around waiting :)
http://myxj.net/g2/d/83564-1/IMG_3898.JPG

I'll keep you updated as I continue to work on this project.

[JPFreek1]

Very cool stuff! Definitely keep us updated as you complete your build. I'm looking forward to hearing what your thoughts are on the rig once it's finished up so keep us posted! Good luck. :cool:

[IntrepidXJ]

Well, I finally started the first steps towards getting my new suspension installed. I got the rear axle removed (so I can regear it and install the locker easier) and most of the rear suspension out.

http://myxj.net/g2/d/84308-1/IMG_4225.JPG

http://myxj.net/g2/d/84300-1/IMG_4235.JPG

Also got a little something in the mail today ;)

http://www.myxj.net/g2/d/84316-1/IMG_4229.JPG

guess i won't be driving my jeep for at least a few days now :)

[IntrepidXJ]

18 days before I am supposed to leave......

TC removed

http://myxj.net/g2/d/84369-1/IMG_4239.JPG

the goodies going in (SYE, 2Lo, Speedo gear)

http://myxj.net/g2/d/84393-1/IMG_4251.JPG

http://myxj.net/g2/d/84411-1/IMG_4256.JPG

done

http://myxj.net/g2/d/84403-1/IMG_4265.JPG

started on the 8.25 (going to 4.56 gears with a no-slip)

http://myxj.net/g2/d/84346-1/IMG_4276.JPG

should have all day tomorrow to continue working :)

[FourByLand]

Looking good, keep us posted!

[OverlandZJ]

Coming along nicely Randy. :Mechanic:

But your running out of time... :shakin:

[IntrepidXJ]

Well, I finished up the internals of my 8.25 this evening. 4.56 gears are in, and the No-Slip is installed. Now I just gotta throw it back under the Jeep, install my new perches (at the proper pinion angle), and re-route the hard brake lines the way I want.

The No-Slip

http://myxj.net/g2/d/84486-1/IMG_4325.JPG

Done.

http://myxj.net/g2/d/84488-1/IMG_4326.JPG

More work tomorrow evening.....

[IntrepidXJ]

transfercase back in (along with the new heat shield over the muffler, and tranny mount)

http://myxj.net/g2/d/84563-1/IMG_4341.JPG

Gas tank skid on, too :)

http://myxj.net/g2/d/84514-1/IMG_4346.JPG

http://myxj.net/g2/d/84535-1/IMG_4356.JPG

Got most of the day tomorrow to work on it some more.....

[IntrepidXJ]

Little more progress from yesterday.

First, I had to rob some other parts from my 92. I thought my stock shackles would work, but I was wrong. Also needed the bumpstop plates anyways.

http://www.myxj.net/g2/d/84586-1/IMG_4363.JPG

http://www.myxj.net/g2/d/84571-1/IMG_4365.JPG

perches ready to go on.....once I figure out the proper pinion angle

http://www.myxj.net/g2/d/84576-1/IMG_4358.JPG

also decided to add a piece of metal to the top of the passenger side UCA mount

http://www.myxj.net/g2/d/84594-1/IMG_4368.JPG

then did a little painting on my freshly built HP D30

http://www.myxj.net/g2/d/84612-1/IMG_4377.JPG

http://www.myxj.net/g2/d/84622-1/IMG_4399.JPG

...and finally I started fixing my exhaust from last month's wheeling mishap

http://www.myxj.net/g2/d/82973-1/IMG_3540.JPG

tacked the new tail pipe in place to test fit under the XJ

http://www.myxj.net/g2/d/84661-1/IMG_4392.JPG

welded up

http://www.myxj.net/g2/d/84630-1/IMG_4393.JPG

now i just need to bolt it back up :)

2 weeks from today, I am supposed to leave!

[IntrepidXJ]

well, this is the weekend i need to try to get this thing driveable again! so i got a long weekend in the garage ahead of me. but here's some pics from this evening for now

driveshaft repaired
http://myxj.net/g2/d/84751-1/IMG_4534.JPG

Red Top installed with marine terminals (winch hooked up)

http://myxj.net/g2/d/84759-1/IMG_4527.JPG

front bumpstops added

http://myxj.net/g2/d/84729-1/IMG_4536.JPG

front axle gone

http://myxj.net/g2/d/84741-1/IMG_4542.JPG

hopefully get the new one in tomorrow...

[Clay]

Looking good.

[IntrepidXJ]

Just finished 12+ hours in the garage working on my Jeep.....and got some more work to finish tomorrow.....but I'm getting there. Of course, here's some pics:

Setting pinion angle
http://myxj.net/g2/d/84774-1/IMG_4548.JPG

perches welded on
http://myxj.net/g2/d/84788-1/IMG_4557.JPG

rear axle back together!
http://myxj.net/g2/d/84818-1/IMG_4572.JPG

now to finish the front.......starting with new ball joints

http://myxj.net/g2/d/84784-1/IMG_4555.JPG

working late into the night
http://myxj.net/g2/d/84838-1/IMG_4582.JPG

front axle almost in......but this is where I called it quits for the night
http://myxj.net/g2/d/84850-1/IMG_4588.JPG

[stomperxj]

Great buildup so far!

[IntrepidXJ]

well, i hit a snag last night. i spent over 24 hours in the garage this weekend getting this thing back together (did i mention it was over 90 degrees and very humid), and when I went to take it for a spin, the damn thing will not come out of 4wd......I was too exhausted last night to look into it any further.

.......so tonight after work, I have to open up the transfercase again and see what I did wrong....hopefully something simple.....

[IntrepidXJ]

well, it got me to work today.....still a few bugs to work out and a few more things to wire and install.

http://i33.photobucket.com/albums/d65/rlngstrt/2000JeepCherokeeSport001-1.jpg

http://i33.photobucket.com/albums/d65/rlngstrt/2000JeepCherokeeSport004-1.jpg

[XJxplorer]

Hats off to you for working so hard! Looks awesome..

What front bumper is that??

Mike

[IntrepidXJ]

Hats off to you for working so hard! Looks awesome..

What front bumper is that??

Mike

Thanks Mike :)

That is a Protofab bumper: http://protofab4x4.com/products.php?ID=05

[IntrepidXJ]

got a bunch of the little things I needed to finish done on Saturday. here's some pics as always :)

Lower Quarter guards on:

http://myxj.net/g2/d/84863-1/IMG_4650.JPG

Warn TC skid on

http://myxj.net/g2/d/84879-1/IMG_4685.JPG

CO2 tank mounted

http://myxj.net/g2/d/85004-1/IMG_4662.JPG

fire extinguisher and mag light mounted

http://myxj.net/g2/d/85014-1/IMG_4666.JPG

hood vents installed

http://myxj.net/g2/d/84956-1/IMG_4691.JPG

[IntrepidXJ]

oh yeah....i'm leaving on Thursday :wings:

[IntrepidXJ]

Let's bring this back from the dead....

Time for front suspension version 2.0 :)

http://myxj.net/g2/d/110455-1/IMG_0449.JPG

...just need to find the time to install

[\\'anderer]

Let's bring this back from the dead....

Time for front suspension version 2.0 :)

http://myxj.net/g2/d/110455-1/IMG_0449.JPG

...just need to find the time to install

Is that a T&T kit? I have been waiting to get T&T long arms for the XJ.

[IntrepidXJ]

Is that a T&T kit? I have been waiting to get T&T long arms for the XJ.

sure is :wings:

[Fergie]

I am very interested in the truss system...very nice.

Keep the pics coming!

[IntrepidXJ]

I am very interested in the truss system...very nice.

I have the truss on my other XJ already. it's a very nice part at a decent price.....I added my own mounts to that one, though. Here's a few pics of that one:

http://pictures.myxj.net/d30overhaul10-6-06/DSC00057.JPG

http://pictures.myxj.net/d30overhaul10-15-06/DSC00124.JPG

http://pictures.myxj.net/d30overhaul10-21-06/DSC00036.JPG

http://pictures.myxj.net/d30overhaul10-21-06/DSC00057.JPG

http://pictures.myxj.net/d30overhaul10-31-06/DSC00017.JPG

http://pictures.myxj.net/NYDrush12-20-06/DSC00044.JPG

[Fergie]

I have the truss on my other XJ already. it's a very nice part at a decent price.....I added my own mounts to that one, though. Here's a few pics of that one:

http://pictures.myxj.net/d30overhaul10-6-06/DSC00057.JPG

http://pictures.myxj.net/d30overhaul10-15-06/DSC00124.JPG

http://pictures.myxj.net/d30overhaul10-21-06/DSC00036.JPG

http://pictures.myxj.net/d30overhaul10-21-06/DSC00057.JPG

http://pictures.myxj.net/d30overhaul10-31-06/DSC00017.JPG

http://pictures.myxj.net/NYDrush12-20-06/DSC00044.JPG

Did you add your own mounts just to have a stronger attachment, or was it motivated by something else?

I need to find me an HP 30 housing to start building for my WJ!

[Green96D1]

great looking cherokee

looking forward to more pictures:jumping:

[JChatary]

Holy transformation! Very nice looking rig you have there! :Mechanic:

[DaJudge]

What was thinking behind going with the Y-link? Ride, flex, just wondering.

Glen

[IntrepidXJ]

What was thinking behind going with the Y-link? Ride, flex, just wondering.


Main reason for going to the Y-link is the ride both on and off road.

I don't need anymore flex than I already get with my short arms.....I just want a better ride (especially when driving fast on the back-roads)

[DaJudge]

Main reason for going to the Y-link is the ride both on and off road.

I don't need anymore flex than I already get with my short arms.....I just want a better ride (especially when driving fast on the back-roads)

Thanks! Let us know how it goes. I was considering the Y-link for the same reason but I can't decide if it is really worth it. I look forward to your evaluation.

Glen

[OverlandZJ]

Main reason for going to the Y-link is the ride both on and off road.



Exactly why i swapped to longarms. I got in on a group buy on RE components and picked up the RE lowers, and reused my existing uppers, combined with Clayton's crossmember. I wasnt concerned about clearance as i dont wheel much anymore.

Now to pick up a set of Bilsteins and limit straps.

[IntrepidXJ]

Did you add your own mounts just to have a stronger attachment, or was it motivated by something else?


i raised the mounts on the axle 2.5" for better angles (same benefits of drop brackets, except with added clearance)

[IntrepidXJ]

Well, after spending 18 hours working on my Jeep yesterday with the held of Zach and Joe, we managed to get my T&T Y-Link suspension installed along with the T&T Stiffeners and Dana 30 truss. Also managed to get my RuffStuff 8.25 cover on and shaved the bottom of the 8.25 housing.

Here are some pictures from the day.

On the lift
http://myxj.net/g2/d/111665-1/IMG_0933.JPG

Welding the Stiffeners on
http://myxj.net/g2/d/111693-1/IMG_0947.JPG

I started myself on fire a few times ;)
http://myxj.net/g2/d/111691-1/IMG_0946.JPG

Zach doing some welding
http://myxj.net/g2/d/111717-1/IMG_0959.JPG

Front axle gone
http://myxj.net/g2/d/111727-1/IMG_0964.JPG

Ruffstuff cover and shaved 8.25
http://myxj.net/g2/d/111747-1/IMG_0974.JPG

T&T Dana 30 truss welded on
http://myxj.net/g2/d/111737-1/IMG_0969.JPG

LCA mount gone
http://myxj.net/g2/d/111755-1/IMG_0978.JPG

Hanging the front axle again
http://myxj.net/g2/d/111765-1/IMG_0983.JPG

[OverlandZJ]

Lookin good Randy!

I found issues with my D30 housing, i need to swap everything over to a new housing and have it trussed.

[over2land]

Looks good man.

What rear bumper is that?

[IntrepidXJ]

What rear bumper is that?

Custom4x4Fabrication for the 84-96 XJ

[over2land]

Custom4x4Fabrication for the 84-96 XJ

Cool, thanks.

Notice any vibes with it? How about on the freeway???

[IH8RDS]

Randy,
What gear did you end up going with in tour TC for the speedo? I am running 4.56's with 31" tires. I belive that is what you are running. I couldnd find it in the thread.
I ran the no-slip for a couple years in my 8.25, until I upgraded to an 8.8 and ARB. I had no issues with the no-slip and it was a good locker.