The official Xota build thread

[87xjco]

Xota build-up

I've been posting my daily progress on rockfrogs.org and I thought I would put the build-up here. Flame suit is on.

This will probably make both Jeep guys and Toyota guys cringe. But, I
rolled my XJ and I have some bucks into the Detroit locker and true trac
in the differentials, and since the motor and trans. run real good. I
decided to do this project. I could of picked up another XJ body cheap
but it is hard to get big tires on an XJ and I find myself needing a truck
for hauling often.
So my solution is to buy a Toyota cab and frame and use all the XJ
drivetrain and electrical.

Crazy? maybe. Cheap? hopefully.

I'll start with the XJ teardown.

Before the roll
http://i6.photobucket.com/albums/y224/87xjco/xjboulder2.jpg

The XJ was rolled on "Widow maker hill" above Boulder Carnage.
http://i6.photobucket.com/albums/y224/87xjco/Misc/DSC02750.jpg

http://i6.photobucket.com/albums/y224/87xjco/Misc/DSC02747.jpg


Used a sawzall to cut off the roof. I'll need to remove most of the dash to
get out the complete wiring loom and computer. The way the roof was crushed
in it would have been difficult. I will also probably use the console, front
seats, shifters, and who knows what else.

Engine is ready to come out
http://i6.photobucket.com/albums/y224/87xjco/Xota/10-10rtft.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/10-10lfengout.jpg


Pic's of the Toyota.

It is a 1987 Toyota. Prod. date 4/87.

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC02778.jpg

I test fit the engine in the engine compartment and the I-6 is very long for
this Toyota. It is going to take some work to get it to fit. The painted
outline may end up being a cut line for the firewall to gain clearance.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC02779.jpg


Started building the front frame rails.

The rails are 1/4" wall 2X3.
http://i6.photobucket.com/albums/y224/87xjco/Xota/rails.jpg

Cab is now off and I've started mocking up the Lt. Rail
http://i6.photobucket.com/albums/y224/87xjco/Xota/Lrailmock.jpg

Setting up the position of the lower c/arm brackets was pretty easy.

Once I knew how far back the engine would be in the frame by test installing
with the cab on, I made some temporary brackets and mounted the
trans. x-member in place at the same height as in the XJ. Then I set the
engine at the same motor mount height as the XJ. Then I measured forward
from the trans. x-member the same distance as the XJ had and mounted some
more temporary brackets for the lower c/arms to bolt to.

This way I know the front diff. is the same distance away from the transfer case
as it was in the XJ and I'll have the same oil pan clearance and when I put the
upper c/arms at the same height as the XJ, I'll have the same drive line angles.

Then I figured out the angle that needed to be put in the front rail and notched
and welded the rail and mocked it into place. There will be plating and gusseting
at the connection between old and new frame.

The drawing below shows all the measurements taken off of the XJ before teardown
and a basic drawing of how the Toyota will look.
http://i6.photobucket.com/albums/y224/87xjco/Xota/xjmeasurements.jpg


The rails have some interesting bends to fab.
http://i6.photobucket.com/albums/y224/87xjco/Xota/ltrailview.jpg

I will bevel the edges and then weld up this second notch.
http://i6.photobucket.com/albums/y224/87xjco/Xota/railnotches.jpg


I have the rails built and positioned where I want them
http://i6.photobucket.com/albums/y224/87xjco/Xota/rtrailview.jpg

Welded them to the Toyota frame. My vertical welds aren't coming out to good.
Looks like I'll have to grind it off and put the frame on it's side for many
of the welds.
http://i6.photobucket.com/albums/y224/87xjco/Xota/railtackd.jpg

Made some plates to reinforce the connection and welded one of them on
http://i6.photobucket.com/albums/y224/87xjco/Xota/rtgusset.jpg


I have my spring seats and track bar mount bracket in place now
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00021.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00019.jpg

Now with the springs in and no weight on the front it would be a good
time to bolt on the front shocks and extend them all the way out and position
the upper shock mount.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00022.jpg

[Jeffro600]

Thats what sucks about XJ's...being a uni-body design, you only get to roll it once! No body swapping here! Looks like you got your work cut out for you though...will be interesting to see how it turns out!

[RJsfun]

Incredible work! Great welding and fabbing! Simply amazing. Good job!

[Whitey]

There is so much damn talent on this board, it just amazes me! Good you have the know how and place to do this work. Your fab/art is looking great!

Can't wait to see the finished product.......next week. :D

[Ghettojeep]

A Toyotakee? Sweet.

[TubeWerx]

pretty original...not bad

[Digger]

[DEEP VOICE] Ooooohh Yeahhhh [/DEEP VOICE] Very cool morph... Can't wait to see the end result :thumbsup:

[cherokeeJim]

I think all of us XJ,MJ,ZJ guys have secretly wished we had a frame!!! I would like my XJ more if i had a frame under it.....Good job, send in picswhen done!

[luvmeye22re]

I personally dont like jeeps much, but I think that is a cool project. The only I-6 you see going into yotas are supra motors so its a pretty rare project. Looks like its turning out well, I hope to wheel with ya someday. I like how your making use of all the parts you possibly can, thats thrifty. Nice fabwork. Keep the pics coming :hail: You wont miss that unibody much trust me ;) . But please tell me the front axle is a D44 :tisk:

[isotel]

Sweet, Your Fab Skilz are pretty Sweet.. Its Sacrilege IMO.. But what do i know, im just a Chevota guy.. ;)

Jeepota - A new word is Born

[87xjco]

Thanks guy's.

I wish it was a D44 up front. But I fully expect I'll blow out the D30 and D35 and then it will be easy to go bigger.

[bfg35yj]

Way to get right back in the saddle....... Nice looking build....

[FJBen]

I think your fab and ideas are awesome beyond frugal...very cool...


BUT...WHY THE FAWK would you do this just becuase of the D30/35 axles??? I think this is the ULTIMATE turd polishing thread...


but anyways...killer work.

[87xjco]

I didn't realize until just now how tall the shock bracket will need to be. About 5 1/2" above the rail.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00023.jpg

[87xjco]

I think your fab and ideas are awesome beyond frugal...very cool...


BUT...WHY THE FAWK would you do this just becuase of the D30/35 axles??? I think this is the ULTIMATE turd polishing thread...


but anyways...killer work.

Well in the last year I put a detroit locker in the rear and a true-trac in the front and 456 gears in both. That's over a $1000.00 in parts that I don't want to throw away until they break. And once they break, it will be an easy upgrade. Besides it's a good running engine, trans. and transfer.

[EEJEEP]

I didn't realize until just now how tall the shock bracket will need to be. About 5 1/2" above the rail.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00023.jpg

I think you are going to need taller. Those springs can drop off the brackets some.

[zukatude]

While I totally admire your handiwork, you must be doing it just for the sake of making a unique hybrid.

IMO, the easier and more frugal process would have been to:
1) Remove all the glass.
2) Cut off all the top.
3) Put in a cage.
4) Add a lexan windshield (optional).

Now go wheel it like there's no tomorrow :D

[87xjco]

I think you are going to need taller. Those springs can drop off the brackets some.

True. i am intending to install some center tubes in the upper spring seats so those springs can't pop out. But I don't want the suspension to hang by the shocks either.

Could put on limit straps but I feel like I want something stronger. Any suggestions from the board?

[87xjco]

While I totally admire your handiwork, you must be doing it just for the sake of making a unique hybrid.

IMO, the easier and more frugal process would have been to:
1) Remove all the glass.
2) Cut off all the top.
3) Put in a cage.
4) Add a lexan windshield (optional).

Now go wheel it like there's no tomorrow :D

I thought strongly about doing just that. But I want a street legal vehicle with a working heater. It's my bad weather driver too.

Frankly I'd rather have a V8 and D60's. It would be easier to fit a V8 in. But money is an issue.

[87xjco]

Shock mounts are in place. Just need to add some gusseting. I set them so that the spring drops 1" out of it's seat when these shocks are fully extended. I will get new shocks that have another 1" to 2" of travel and I think that will be just right.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00025.jpg

[Twisted Digital Video]

Nice work! More PICS please!
J

[87xjco]

Finally, the front frame mock up is done. Just need to get the frame off the diff's and add some more gussets and do some more welding and some trimming. Then I'll clean and spray paint frame.
http://i6.photobucket.com/albums/y224/87xjco/Xota/ltside2.jpg

As you can see I just have the rear diff. bolted up to some temporary brackets. I will wait to do the rear diff. fabrication until I have all the weight back on the frame. But I think I will swap the springs side to side and put the long side in the front to get a longer wheel base.
http://i6.photobucket.com/albums/y224/87xjco/Xota/Reardiff.jpg

[Steven_Mc]

Looking Good! Keep it coming! This is good motivation for the buildup I'll be starting soon.

[Twisted Digital Video]

Nice! Keep up the good work! I need to get the door stop back in the shop to finish up the bedwork...the 4th coming video is taking up all my time tho..
J

[fatwreck]

Can I ask why you didn't just attach the upper control arms to the lower arms for a radius arm setup? It seems to me that you're going to get some really odd handling characteristics with short upper arms, long lower arms, and completely different pivot points. :shrug:

[87xjco]

Can I ask why you didn't just attach the upper control arms to the lower arms for a radius arm setup? It seems to me that you're going to get some really odd handling characteristics with short upper arms, long lower arms, and completely different pivot points. :shrug:

Hmmm. I hadn't really thought about that. That is how it was setup in the XJ and I never had any handling problems. But it would be better for articulation.

[87xjco]

Underside of the frame is done and painted
http://i6.photobucket.com/albums/y224/87xjco/FRAMEUNDER.jpg

[87xjco]

I am now able to bolt up the front differential. Since all 4 control arms are adjustable, I want to make sure it is centered and that the wheel base is even side to side.

Here is what I did;
1: First I leveled the frame
2: Then I found two holes near the rear of the frame that were in the same location on both rails. I tied a string that went from hole to hole and then I measured and marked center.
3: Then I did the same up near the center of the frame
4: Then I ran a string that intersected both those center points and tied it off on the temporary angle iron that is across the very front of the frame.
http://i6.photobucket.com/albums/y224/87xjco/FTALIGN.jpg
5: Then I tied a string across from each of the upper ball joint grease
zerks, then measured and marked the center.


6: Then I used a plumb bob hanging down from the center string and aligned the axle center with the plumb bob and then measured back from each ball joint zerk to a point on the frame that is equal on each side of the frame (I used the cab rear mount hole). Keeping the axle centered I used each adjustable upper control arm to set the distance equal on each side.
http://i6.photobucket.com/albums/y224/87xjco/RTALIGN.jpg

This should give me a front differential that has the same wheel base side to side and be centered with the frame. I'll use the lower control arm adjustments to set the pinion angle.

[bfg35yj]

Nice build.... I'm very jealous... I wish I could do a build like this...

If I were you I would Truss the front and rear axle's..... Beef them up a bit...

[87xjco]

Woo Hoo!

Engine is installed (hopefully for the last time) and frame work is all painted. Just need to do a little work on the spring seats (weld in some center tubes) and I'll put all the front suspension back together. Then I need to build a better transmission crossmember. And then... and then... and then...........
http://i6.photobucket.com/albums/y224/87xjco/Xota/LTPAINTED.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/RTPAINTED.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/RTRAILPAINT.jpg

[longboy]

Terry, do you do side work? IIRC, you're a body man, right? Or do you do more frame work?

[87xjco]

I run a bodyshop. PM sent.

[87xjco]

Suspension is all together except for mounting the steering gear.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00045.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00046.jpg

[87xjco]

Suspension is all together except for mounting the steering gear.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00045.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00046.jpg

Can I get the boards help.

I've been discussing this on jeepin.net. The angle on my UCA is pretty steep and even thought it is all the same as it was on the XJ and the XJ handled fine, I am worried about the geometry and the caster/pinion angle changing when the suspension articulates.

One idea was to mount the existing UCA's to the LCA's and having a radius arm style set-up. But I'm worried about all the stress that would be put on the 2 heim joints.

I'm considering getting longer UCA's built and mounting them lower on the frame.

Does anyone have any other suggestions?

[Digger]

I'd mount them to the LCA . remake the LCAs with larger hiems or jonny joint style ends

You will get much better flex and ride.

[fatwreck]

I would either do a radius arm setup....or make new longer arms and have them mount inside the frame rails about as far back as the lower arms.

I would also consider beefing out your current lower control arm mounts.

[87xjco]

..or make new longer arms and have them mount inside the frame rails about as far back as the lower arms.

I would also consider beefing out your current lower control arm mounts.

I like that idea. I was just looking at things and I'm not sure but, there may be room enough for that. I'm thinking of building some test links out of cheap pipe and brackets. Then I'll cycle the suspension up and down to make sure there's enough clearance everywhere before I have some built.

[05Willys]

Maybe i missed my answer somewhere in the link, but is it possible to put a yota frame under an xj...I know it seems a little strange, but my roommate plowed backwards off an embankment and tore his hitch off toward the front of the car. I think the frame is shot, but if we could use the frame as a mounting point and attempt a Chericota we may have a vehicle yet. :rolleyes:

[87xjco]

Maybe i missed my answer somewhere in the link, but is it possible to put a yota frame under an xj...I know it seems a little strange, but my roommate plowed backwards off an embankment and tore his hitch off toward the front of the car. I think the frame is shot, but if we could use the frame as a mounting point and attempt a Chericota we may have a vehicle yet. :rolleyes:

I saw an XJ in one of the magazines that the guy had built his own frame under.

But to do a complete frame under an XJ would really raise your center of gravity and hooking up steering column and other things would be difficult. I'd suggest cutting off the bottom of the uni-body frame channels in the rear and welding in some 2x3 square tube.

[87xjco]

11/4/05 - Cab is ready to set back on frame. I need to have cab in place to set up steering gear box and column and to run fuel & brake lines.
But it will come back off again later for painting etc...
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00048.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00049.jpg

[87xjco]

Thanks for all the advise from colorado4x4 members and others, I am going to change the UCA's to a different configuration.
http://i6.photobucket.com/albums/y224/87xjco/Xota/ucaedit.jpg
something like this

[ZJustin94]

that looks like a really nice shop you have there. where is it? I can't wait to see final pics!! good luck

[87xjco]

Cab is set on frame. 11/5/05
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00050.jpg

[87xjco]

that looks like a really nice shop you have there. where is it? I can't wait to see final pics!! good luck

Northglenn, It's big but kind of run down.

[87xjco]

I still have some work to do for clearance near the throttle pedal. I'd like to get about a 1/2" so I can put some heat shielding in.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00053.jpg

I couldn't really put the engine any further forward.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00055.jpg

[TubeWerx]

:drool: ok ok ok, well now that you've put the Toyota body on it, you've really won my heart!!:D Seriously impressed with your work! That's alot more work than what it looks like, and you've really come along quickly....and judging by all of the pictures you've been very precise and careful, looks like things are really lining up for you!?

[87xjco]

:drool: ok ok ok, well now that you've put the Toyota body on it, you've really won my heart!!:D Seriously impressed with your work! That's alot more work than what it looks like, and you've really come along quickly....and judging by all of the pictures you've been very precise and careful, looks like things are really lining up for you!?

Thanks Tubewerx. Sometimes I look at it and it doesn't seem like it should have taken all those hours and sore muscles. But there was alot of time consuming fabrication.

Maybe the rest will go a little easier.

[87xjco]

Yes it runs!!!! Just started it for a few seconds as there is no radiator in place yet. I hooked up the wiring to computer,
relays, engine, grounds, etc.. I just routed the looms over the fender thru the window into the cab and plugged in the column.
I set the fuel tank on the back & hooked up the wiring and hoses and ran a ground. I wanted to make sure it would run again and
that I didn't have any new problems I would need to figure out.

It started easily and fuel pump runs. Now i'll start running the looms where they need to go.
11/09/05
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00059.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00058.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00060.jpg

[87xjco]

I am Making some modifications to the brake pedal/steering column mount so I can use the XJ booster and column.
I was lucky that the brake pedal is in the right position to bolt up to the booster rod once the booster is bolted thru
these new hole positions.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00063.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00064.jpg

[87xjco]

I was able to use the old clutch master cylinder position and cut out a square that the engine harness can bolt thru to the interior fuse box &
harness. The Jeep brake booster is bolted up now also.
11/15/05
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00065.jpg

Fuse box on the interior side of the firewall.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00066.jpg

[Steven_Mc]

Sweet stuff man!! Keep it coming!

[87xjco]

Turned the XJ gas tank around opposite of how it mounted in the XJ and built a frame out of angle iron that bolts to the gas tank and to brackets that are welded to the frame.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00067.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00068.jpg

[sonofmayhem]

you are gonna need to change up your sig now! great job though :D

[87xjco]

The Xota is really getting freaky now!!
11/17/05
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00069.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00070.jpg

[Jason]

What was the reason for using a toy frame ? why not the xj frame with the toy body? And whats the xj front clip all about?

[87xjco]

What was the reason for using a toy frame ? why not the xj frame with the toy body? And whats the xj front clip all about?

XJ's don't have frames. They are uni-body. I wasn't able to find an MJ so...

[Jason]

oh duh sorry i'm such a friking retard lol

[TubeWerx]

:thumbsdown: dude, I liked everything up until now......the jeep fenders and Toy cab togethor look gay. Ditch that plan :tisk: Otherwise, seems like it's still going good for you.

[Jason]

:thumbsdown: dude, I liked everything up until now......the jeep fenders and Toy cab togethor look gay. Ditch that plan :tisk: Otherwise, seems like it's still going good for you.
yeah I still don't understand why on that either?:confused: gross

[87xjco]

:thumbsdown: dude, I liked everything up until now......the jeep fenders and Toy cab togethor look gay. Ditch that plan :tisk: Otherwise, seems like it's still going good for you.

TubeWerx & J:un, I respect your opinions but...
I'd like to hear some more opinions from the board.

It sure makes mounting and wiring the lights and mounting the radiator a lot easier.

[snurfer_2004 AKA Trevor]

I disagree with the haters. I think the fenders look pretty good. This rig is goin to be quite different than anything on this board, and why not make it obvious that there's something different. It'll look a lot better when you get a single body color. Keep it coming, way impressed

[EEJEEP]

TubeWerx & J:un, I respect your opinions but...
I'd like to hear some more opinions from the board.

It sure makes mounting and wiring the lights and mounting the radiator a lot easier.

Screw the opinions of the board. Build how YOU want to build it. After all, it is not the board that is going to be wheeling it, YOU will be wheeling it.

Plus my opinion counts more than anyone else anyway because I wheel with you all the time.

[nblehm]

:thumbsdown: dude, I liked everything up until now......the jeep fenders and Toy cab togethor look gay. Ditch that plan :tisk: Otherwise, seems like it's still going good for you.

x2

[Steven_Mc]

Have to say I don't really dig the fenders either. The lines from the fenders and grill don't mesh with the cab. Unless you plan to do a ton of body work to get them to flow together, I say ditch'em!

[87xjco]

Screw the opinions of the board. Build how YOU want to build it. After all, it is not the board that is going to be wheeling it, YOU will be wheeling it.

Plus my opinion counts more than anyone else anyway because I wheel with you all the time.

All good points Eric

[87xjco]

I disagree with the haters. I think the fenders look pretty good. This rig is goin to be quite different than anything on this board, and why not make it obvious that there's something different. It'll look a lot better when you get a single body color. Keep it coming, way impressed

x2

Have to say I don't really dig the fenders either. The lines from the fenders and grill don't mesh with the cab. Unless you plan to do a ton of body work to get them to flow together, I say ditch'em!

Thanks for your opinions!

[Bryan]

Can I get the boards help.

I've been discussing this on jeepin.net. The angle on my UCA is pretty steep and even thought it is all the same as it was on the XJ and the XJ handled fine, I am worried about the geometry and the caster/pinion angle changing when the suspension articulates.

One idea was to mount the existing UCA's to the LCA's and having a radius arm style set-up. But I'm worried about all the stress that would be put on the 2 heim joints.

I'm considering getting longer UCA's built and mounting them lower on the frame.

Does anyone have any other suggestions?

If I were in your shoes, I'd ditch the upper/pass CA and make the upper/driver CA longer as mentioned before. This configuration would solve your caster problem more completely than the radius-style arms and would eliminate the binding that comes from both your current config AND the radius style. Many competitive crawlers are using this config if you'd like to see pics.

[87xjco]

If I were in your shoes, I'd ditch the upper/pass CA and make the upper/driver CA longer as mentioned before. This configuration would solve your caster problem more completely than the radius-style arms and would eliminate the binding that comes from both your current config AND the radius style. Many competitive crawlers are using this config if you'd like to see pics.


http://i6.photobucket.com/albums/y224/87xjco/Xota/ucaedit.jpg


Do you think changing it like this is good then?

[Bryan]

It is certainly better for your caster than the radius arm style, but the problems arise wen your axle is fully articulated. If your geometry allows any caster change at all, when one side droops, your links will be forcing the axle to twist (or your UCA mount more likely).

Eliminating the passenger side UCA eliminates this binding, but still keeps your axle fully constrained. Try this: build only your driver's side UCA assembly first, remove your passenger UCA, and then drive it on and off road. Off road, you'll find that it flexes like never before. On-road, you might never notice a change. If you don't like it, you can always continue on and build your passenger UCA assembly.

[Yucca-Man]

Those XJ fenders might look a bit more reasonable on the Toy if you trim 'em to the bottom of the grill.

Either way, you've done quite a bit of work here - good job!

[Bryan]

pics of the setup I described... (thanks to GPSflyer :beer:)

http://motorcitymopars.com/images/carimages/Independance/DSC04392.jpg
http://motorcitymopars.com/images/carimages/Independance/DSC04335.jpg
http://motorcitymopars.com/images/carimages/Independance/DSC04457.jpg

[87xjco]

It is certainly better for your caster than the radius arm style, but the problems arise wen your axle is fully articulated. If your geometry allows any caster change at all, when one side droops, your links will be forcing the axle to twist (or your UCA mount more likely).

Eliminating the passenger side UCA eliminates this binding, but still keeps your axle fully constrained. Try this: build only your driver's side UCA assembly first, remove your passenger UCA, and then drive it on and off road. Off road, you'll find that it flexes like never before. On-road, you might never notice a change. If you don't like it, you can always continue on and build your passenger UCA assembly.

Makes sense and sounds like a good plan. Thanks

[lilgreenjeepyj]

Loose the XJ fenders just doesn't look right, and Im a jeep fan. Go with some yota fenders. Otherwise, i like it alot.

[Ford Prefect]

Nah, I would keep the XJ front, I like it. Gives it the taste of being your own, and everyone will ask, thusly giving you the chance to explain the cool project. Pretty nice, I hope that you will fab your own rear deck though. I think that yota boxes are a bad idea, but I have seen some really nice yota flatbeds

Best-o-luck!

Ford

[ZJustin94]

personally, i like the xj fenders on there. It gives it character. It'll look pretty nice once its all said and done.

[Sean Dogg]

leave the xj's!

[XJ_Newbie]

Damn Terry!
You are an artist.
I wish I had some knowledge to share, but I am getting there!
Victor

[Steven_Mc]

It is certainly better for your caster than the radius arm style, but the problems arise wen your axle is fully articulated. If your geometry allows any caster change at all, when one side droops, your links will be forcing the axle to twist (or your UCA mount more likely).

Eliminating the passenger side UCA eliminates this binding, but still keeps your axle fully constrained. Try this: build only your driver's side UCA assembly first, remove your passenger UCA, and then drive it on and off road. Off road, you'll find that it flexes like never before. On-road, you might never notice a change. If you don't like it, you can always continue on and build your passenger UCA assembly.

I'm just beginning to learn and comprehend the principles of suspension geometry... :hail: sounds like this would make it a sort of 3-link hybrid setup rather than 4-link? but why not attach the UCA, to the center of the axle, and then to the frame on both the passenger and driver side? I would think the setup you describe would limit travel on the driver side, but give additional droop on the passenger side? I could be totally off, but inquiring minds want to know! :hail:

[87xjco]

Well I've pretty much decided to put the XJ front clip on. I like the look and the originality.
Started attaching XJ fender to rear lip of Toyota fender.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00072.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00071.jpg

[flashover]

Looks good. I like the fenders, as long as they blend in well with the doors. Good thing your body work skills are better than mine.

[RJsfun]

I love it!
Great job, good work.
Keep the XJ fenders for sure. Having had many, many Jeeps over the years (including built XJ's) and the girlfriend always having Toyota's, I love to see the two combined.
You should put in an application to Spike Networks building block, or one to Monster Garage. You have some very good fabrication skills to go with your imagination.
I agree, it's your ride, build it how you see it.
Always looking forward to more progress/update pictures.

[wickedxj]

WOW WOW, keep up the great work, I think what you are doing is awsome weatehr Xj or yota fenders its sweet. i would pimp it thats for sure. i would also like to say this is one of the best write ups if seen on this board. Best of luck,
steve

[87xjco]

Thanks guy's for all your comments.

The transmission tunnel is mostly built now. Just have to do some spot welding from underneath when the cab comes back off.
11/23/05
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00073.jpg

Before tunnel was built
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00053.jpg

Trimmed some of the Toyota radiator support, the crossmember will be cut off once I build brackets to support the inner fenders.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00074.jpg

[sonofmayhem]

fawk it make it your own custom design where you like it and it gives you what you need and want!

[*Max*]

I think that this is bad ass keep up the good work man.

[87xjco]

The last few evenings worth of work to rebuild the floor area around the shifters so they would be mounted in the correct positions
to operate properly.
12/1/05
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00077.jpg
Also the heater box was modified to fit around the tunnel, I was lucky that there was enough clearance inside the box that I could cut
some of the box off and not effect the operation of any of the control flaps.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00078.jpg

[ksperle]

Sweet buildup and thanks for sharing your progress.

PS - I say keep the XJ fenders. With some body work I'm sure you'll make it look good and it will definately be original.

[87xjco]

The metal work on the cab is done (I think that was harder than building the frame) So I lifted the cab back off and cleaned
up all the welds and then primed the bare metal.
Then I applied seam sealer on all the seams, then I applied a layer of alum. backed adhesive sound deadener. Now it is ready
to get the firewall painted.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00084.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00085.jpg

[trailbuilt]

NICE work, but you have WAY too much time on you hands

[tysonxj]

Now would be a good time to do a rear main seal and anything else that is leaking on your Jeep drivetrain.

[Phazertwo A.K.A Brenden]

simply awsome

[87xjco]

Had the painter spray it for me this morning
12/5/05
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00086.jpg
http://i6.photobucket.com/albums/y224/87xjco/DSC00089.jpg

[RockRash]

This is the first time I noticed this thread. Great work!

What are you doing for your rear suspension? I assume that you are staying with leaves for the moment, but you may want to consider SOA with a track bar or even go to a buggy spring configuration in the rear.

You could always double triangulate the rear (as I'm sure that there are several formulas available for others on the board here) and go with coil springs.

Bobbed rear end? Exo skeleton? Front stinger?

[87xjco]

I kinda expected some flaming on this project.

Some of the Toyota guys think I'm crazy.

http://www.4x4wire.com/forums/showflat.php?Cat=&Number=817710&page=1&view=collapsed&sb=5&o=14&fpart=1

[sonofmayhem]

god, horrible, im a yota owner / fan and i think its awsome.

[Phazertwo A.K.A Brenden]

I have also conveted to yota in the last year. I would never have thorught of that, nor done it, but its still freekin beautiful work, and a great idea. To each his own eh?
PZ

[87xjco]

This is the first time I noticed this thread. Great work!

What are you doing for your rear suspension? I assume that you are staying with leaves for the moment, but you may want to consider SOA with a track bar or even go to a buggy spring configuration in the rear.

You could always double triangulate the rear (as I'm sure that there are several formulas available for others on the board here) and go with coil springs.

Bobbed rear end? Exo skeleton? Front stinger?

I'll keep the rear leaf springs until the D35 blows up. Then I'll upgrade and probably go 4 link.

[sonofmayhem]

I'll keep the rear leaf springs until the D35 blows up. Then I'll upgrade and probably go 4 link.

haha i may go that route when i get my truck back from the insurance lot(accident) the funny thing is no body damage, just the springs:D

[WhtJeep]

got any side shots of it after its painted. Im curious to see the XJ fenders on it looking all nice and painted

[87xjco]

got any side shots of it after its painted. Im curious to see the XJ fenders on it looking all nice and painted

Sorry, It's going to be awhile till I paint the exterior but I'll show the right fender build soon. Still got to finish bolting everything up in the engine compartment, install carpet & insulation, dash (it will be unique and time consuming), seats. Then I will probably set up the rear diff. before paint. Then there is still the exo-cage to do.

[RJsfun]

Sorry, It's going to be awhile till I paint the exterior but I'll show the right fender build soon. Still got to finish bolting everything up in the engine compartment, install carpet & insulation, dash (it will be unique and time consuming), seats. Then I will probably set up the rear diff. before paint. Then there is still the exo-cage to do.

So your talking about two weeks? :D
Just kidding, but you seem to have some nice time and a good garage/shop for your build. My CJ is "under construction" and has looked the same since about your first post. :o

[87xjco]

Some more progress since last post. Big milestone hit....
it drove itself out of the shop this morning! Put the cab back on and have been routing and
connecting wiring looms, pwr steering, radiator, shifter cable, brake lines.

http://i6.photobucket.com/albums/y224/87xjco/Xota/engine.jpg

The clearance around the back of the valve cover is not too bad considering.
http://i6.photobucket.com/albums/y224/87xjco/Xota/clearance.jpg

The windshield was removed and there is a lot of rust around it that I've started repairing, sucks!
http://i6.photobucket.com/albums/y224/87xjco/Xota/rust.jpg

I'm still haven't decided if I should leave the rear diff. back this far (111" wheelbase) or swap the springs back to having the
short side in front.
http://i6.photobucket.com/albums/y224/87xjco/Xota/reardiff.jpg

In all it's glory
http://i6.photobucket.com/albums/y224/87xjco/Xota/left.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/right.jpg

[Milo]

so are you planning on putting a exo cage on this one???? :D :D :tisk:

[SPY]

I kinda expected some flaming on this project.

Some of the Toyota guys think I'm crazy.

http://www.4x4wire.com/forums/showflat.php?Cat=&Number=817710&page=1&view=collapsed&sb=5&o=14&fpart=1

They just sound a bunch of haters! Do your own thing, it's more respectable.

[WhtJeep]

That looks SICK! I am jealous

[jeepn4evr]

That looks pretty sweet. Nice work. Anytime you wanna come work on mine for free you are more than welcome. I did have 1 question though. If you wanted a pickup & the Jeep drivetrain why not build up a Commanche? This is definatly unique & very well done, but would seem easier to put all the driveline under a Commanche. Just my $.02

[87xjco]

Firewall is pretty much done! Primed and painted the interior floor and firewall and then installed the rest of my peel
and stick sound deadener.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00100.jpg
Installed the heater box.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00101.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00099.jpg

This is what I used for sound deadener
http://www.b-quiet.com/vcomp.html
Also ordered some of this for the back panel of cab
http://www.b-quiet.com/ultimate.html

[sonofmayhem]

good stuff ive been waiting for some pics

[87xjco]

Well here is the final positon of the rear diff.
http://i6.photobucket.com/albums/y224/87xjco/Xota/rdifffinal.jpg
A little more forward than this temp. mounting
http://i6.photobucket.com/albums/y224/87xjco/Xota/reardiff2.jpg

[sonofmayhem]

gosh hurry up this is awsome.:D

[87xjco]

I've been doing a lot of details like fabbing fan shroud, bolting up air cleaner, fixing rust around windshield frame, etc.etc...
They take up alot of time but don't give me much to photo. The dash is almost in. Then I can get the windshield
installed. This weekend I found one good door at "pull-n-save" but still need to find & install a left door glass. Then I
can pull it out of the shop easier on bad weather days. Won't be too long until I go back to work on the front sheet
metal. Just got my carpet in that I ordered from J.C. Whitney and I'll have to install the SYE kit that I got from Porc soon
and measure for the driveshaft. So there's still plenty to do.

Air box and fan shoud are in place
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00103.jpg

Used the Toyota filler panel that has the defrost duct in it and welded on a couple of small brackets that could then bolt
to the Jeep dash. I'll have to fill the gap in between. Ground off all the rust around windshield and welded up a few places
where it rotted through. Then used some spray rust treatment before primer and paint.
http://i6.photobucket.com/albums/y224/87xjco/Xota/windshieldrepair.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/Dash.jpg

[Yota]

Wow. :thumbsup:

Staying tuned.

[mtn WJ]

I have browsed this thread since the begining and your progress is awesome. Nice work. Now that I see the XJ fenders and grill it all makes sense to me now. It will be a sweet truck when you are done with it. It seems that you can agree with or deny what others are saying as you like because it is your truck and your skills not theirs. Keep it up and lets see it on a trail someday.

[TubeWerx]

I have broused this thread since the begining and your progress is awesome. Nice work. Now that I see the XJ fendors and grill it all make sense to me know. It will be a sweet truck when you are done with it. It seems that you can agree with or deny what others are saying as you like because it is your truck and your skills not theirs. Keep it up and lets see it on a trail someday.

X2 on all of the above....

[Ink]

X2 on all of the above....



X3 or 4, really enjoying this!

[Twisted Digital Video]

Keep up the great work and we will see you on the trails before you know it! :beer:
J

[ThePagan]

Dang straight do it you way.. although I think the Toy Fenders would have been better.. lol.

- Shawn

[87xjco]

Thanks for all the positive support on this project!

Not much to report. Slowed down these last couple weeks. But windshield is in and got some 35s mounted up. Put on the used door. I will be working on getting the rear diff. brackets fabbed and welded in.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00109.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00110.jpg

[RJsfun]

That looks SO good!!!
I wish I could build myself a custom hybrid.
Maybe someday. Keep up the awesome work.
I like the steep hood angle. It takes away from the stock boxy look of the Toy and the XJ.

[OlBlueCJ7]

I like the steep hood angle. It takes away from the stock boxy look of the Toy and the XJ.

I bet it will help with visibility too - pretty cool! :thumbsup:

[Phazertwo A.K.A Brenden]

looking really sweet now that its going back togather!

[87xjco]

Brackets are all built for rear diff. Just need to finish welding underside.
http://i6.photobucket.com/albums/y224/87xjco/Xota/frontbracketdrawing.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00116.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00111.jpg

The rear frame is going to get boxed around these brackets and about 16" forward from rear bumper,
I will have a good mount area for rear hitch, then they will all be welded in and gusseted
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00115.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/Rbracketdrawing.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00113.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00117.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00118.jpg

[cheepin]

Coming along nicely.One ? though.Why did you mount the short side of the spring forward?You could have built a slider hanger in front and kept the spring the same height and the wheelbase the same.Just wondering.

[87xjco]

Coming along nicely.One ? though.Why did you mount the short side of the spring forward?You could have built a slider hanger in front and kept the spring the same height and the wheelbase the same.Just wondering.

The photo right above your post shows the angle of the frame at the front bracket. If that bracket is moved forward as it would be with the longer side of the spring forward, it drops down and the pinion angle goes the wrong direction. Since I don't expect the D35 to last too long, I didn't feel it was worth the work to reposition the spring perches.
Even though I did not achieve the best departure angle possible, I still have a very good departure angle.

[87xjco]

Now that the SYE kit is installed, I can have the driveshaft lengthened.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00157.jpg
This is a used front driveshaft from an XJ, it has the correct size u-joints on both the CV end that bolts up to the transfer case and the other end that bolts up to the rear diff. It needs to be lengthened 10" for my stretched wheel base.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00156.jpg
Driveshaft after lengthened. The shop picked it up this morning and brought it back this afternoon. Only charged me $115.00
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00158.jpg

[Yucca-Man]

I believe you asked me about the vacuum switch on the rear of the t-case in another thread (possibly another forum)...with a non-disconnect front driveshaft (D44, right?) you don't need that vacuum connector over the shift rail; you can use the blockoff bolt that should have come with the PORC SYE instead.

[Phazertwo A.K.A Brenden]

this thing is http://board.marlincrawler.com/Smileys/marlin/boobs.gifand thats really the only way to say it!

[EEJEEP]

I believe you asked me about the vacuum switch on the rear of the t-case in another thread (possibly another forum)...with a non-disconnect front driveshaft (D44, right?) you don't need that vacuum connector over the shift rail; you can use the blockoff bolt that should have come with the PORC SYE instead.

Nope it was me!

What exactly do you have to do to ditch the vacuum stuff? I swapped in a D44 last year, so I don't exactly need it. I basically just unpluged the vacuum lines and wire tied them up. I know I should have down something to the T-case side, but I didn't know what to do.

I didn't get a blockoff bolt with my JB SYE. Where does the bolt go?

[87xjco]

I got one in the kit. It is just a round threaded plug with the same size threads as the vacuum switch and it goes in the hole where the vacuum switch screws in. Of course the switch screwed in, serves the same purpose.

Keep in mind that the sensor that turns your dash indicator lamp on is activated by a switch up by the firewall that senses when vacuum is applied to the front disco solenoid through the transfer case vacuum switch. So if you eliminate the vacuum switch. The dash indicator becomes inoperable. Not a problem for you though with ARB.

[EEJEEP]

I got one in the kit. It is just a round threaded plug with the same size threads as the vacuum switch and it goes in the hole where the vacuum switch screws in. Of course the switch screwed in, serves the same purpose.

Keep in mind that the sensor that turns your dash indicator lamp on is activated by a switch up by the firewall that senses when vacuum is applied to the front disco solenoid through the transfer case vacuum switch. So if you eliminate the vacuum switch. The dash indicator becomes inoperable. Not a problem for you though with ARB.

Good to know. Take out the switch, put in the plug. (So, when are you going to sent the plug to me?? J/J :flipoff2:)

I am not too worried about the dash light. It didn't work all last summer!

[87xjco]

Good to know. Take out the switch, put in the plug. (So, when are you going to sent the plug to me?? J/J :flipoff2:)

I am not too worried about the dash light. It didn't work all last summer!

I do need to get together with you and get that die and I have to find the plug here. now where is that thing...

[EEJEEP]

I do need to get together with you and get that die and I have to find the plug here. now where is that thing...

I think I should be around all weekend. I may go to Pull-n-Save on saturday to look for some different reservoirs on the heep. I could swing by the shop or your house.

I could bring the bender, so you can see the design.

[mtn WJ]

Perhaps you have posted this but what do you plan to do for a bed? Original Yota bed or flatbed maybe. I am curious.

[87xjco]

Perhaps you have posted this but what do you plan to do for a bed? Original Yota bed or flatbed maybe. I am curious.

Flat bed with exo-cage

[mtn WJ]

Sounds cool. Any estimates on when you might have that thing done?

[DADA_JEEP]

a little late on this message, but i also like the steep hood angle, but are you going to be able to get the headlights aligned ok?

[87xjco]

a little late on this message, but i also like the steep hood angle, but are you going to be able to get the headlights aligned ok?

Yeah I tried them and had plenty of adjustability.

[87xjco]

Sounds cool. Any estimates on when you might have that thing done?

I'm shooting for April 1st. Appropriate day huh?

[87xjco]

Started making the front bumper. I need it built so I can trim the fender properly and then finish up the fender body work. First I made 2 bends in 1 3/4 x .120 HREW tubing and hung it by some temp. brackets.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00203.jpg
Then I made the 2 end bends.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00204.jpg
Then I trimmed the fender. This is a photo chop, that shows what the upper tube that will be added to the bottom will look like.
http://i6.photobucket.com/albums/y224/87xjco/Xota/CHOP206.jpg

[4runninfun]

you are freaking crazy! i like it! :D you have done an outstanding job putting this rig together. when you get out wheeling you should post up whether or not the steep hood line helps or hinders visability. i would think you could see a little bit better. but we'll see. keep up the good work!:thumbsup: :thumbsup:

[87xjco]

After upper tube tacked on
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00209.jpg
Needs a little work on the ends
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00210.jpg

[87xjco]

Got the rest of my 100' tubing order in.

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00212.jpg

I will probably start with rocker hoops and the front stinger since those are easy. But then I need to do the main hoop behind the cab and I'm a little worried that I don't have enough practice bending. I would hate to mess up on a long section of pipe.

[Steven_Mc]

Very Nice, the bumper looks great!! It's hard to tell, but I'd be curious to know if the nose with the jeep fenders and grill results in less nose overhang than the toy setup did. Keep it up!!

[87xjco]

So i said screw it and went ahead and bent the main hoop behind the cab. What a pain in the a$$ that was.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00213.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00218.jpg
Test fit after I bent the first two angles. If I were more confident with the bender I would have just started at on end and worked my way along the tube making each bend as I go.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00220.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00221.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00222.jpg
I am happy with the Final fit to the cab.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00224.jpg

[Phazertwo A.K.A Brenden]

looks pretty damn good if you ask me!

[byron4]

the only thing i dont like is the jeep front end. :flipoff2: but overall very very cool!

[TubeWerx]

this thing is http://board.marlincrawler.com/Smileys/marlin/boobs.gifand thats really the only way to say it!

kids got some good skills!

[sonofmayhem]

I totally missed the third page, so i got caught up. i think about doing a buggy or a go kart to build up some skill then i think about the time and money needed that i dont have!

Great stuff

[87xjco]

I've been working on a crossmember that the shocks mount to and helps stiffen the frame.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00239.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00240.jpg
The reason I cut out the original crossmember is so that I could store a spare under the flat bed. This is a 33" tire, plenty of room for my 35's.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00242.jpg
Should clear under the new bed that will be built off of the vertical pipe on the hoop
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00243.jpg
Rear driveshaft is in and I think the angles are good. Full droop position.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00238.jpg

[Phazertwo A.K.A Brenden]

looking sweet.:drool: How are you going to access the tire if its under the bed? Dosn't look like it will drop out? Trap door?

[87xjco]

looking sweet.:drool: How are you going to access the tire if its under the bed? Dosn't look like it will drop out? Trap door?

The back half of the bed will be on a piano hinge and I'll probably use 1" oak planks since I already have some. I think with enogh bracing it will work good.

[DADA_JEEP]

i was thinking slide out, that way if the bed is loaded you wouldn't have to unload the gear to get to your spare.....

[87xjco]

i was thinking slide out, that way if the bed is loaded you wouldn't have to unload the gear to get to your spare.....

Well I think there will be too much bracing and taillamps etc... for the spare to slide out. But you've given me the idea to have the bed planks slide or lift out. True if the beds loaded it would be a pain to get the spare out though.

[87xjco]

The frame for the flat bed is built and tacked into place
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00252.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00253.jpg

[Sean Dogg]

Wow, that thing's really starting to come together! Props!

[DADA_JEEP]

ok, now looking at how you have the flatbed, what is going to be in the way for the spare to slide out? tail lamps and such? couldn't you put that on a hinged framework, be much easier to have that fold down and then slide the spare out, would be trick too, everybody wondering where the heck your spare is, then slide it out......


then agian i overbuild all my junk

[2LoudDodge]

lookin nice. :)

[87xjco]

Finished the frame fab. and cleaned it up and painted it. Added a couple more supports to the exo-cage.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00267.jpg

This is probably all of the cage I will build for now. I am going to move on to the body work and paint before the rest of the cage gets built.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00264.jpg

[Hayes]

Wow, This truck is awesome! I like the Jeep front and Yota cab, can't wait to see what it looks like!!

[87xjco]

I have started the bondo work on the fenders. Even though I run a body shop, body work is not something I have much experience in. But here is what I did. I first laid on a coat of fiberglass filler. This is better than plastic filler for filling large voids. I have some that will be about an 1/8" thick (unfortunately). I didn't photo that step but I spread it on in an area a little smaller than the plastic filler you see here, and then used a long flat board with 36 grit paper to begin leveling out the surface.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00269.jpg
Some tools of the trade. Long board for large flat areas, medium board for smaller areas, dollie, body hammer, small wrench used as a straight edge for matching the fender contour to the door contour.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00270.jpg
After sanding with mostly the long board. Now it will get one more coat of plastic filler and I'll sand that with 80 grit. I probably should of welded the holes shut where the flares used to mount before now. But I'll definately do it before the next coat of plastic filler.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00271.jpg

[87xjco]

One more coat of plastic filler
http://i6.photobucket.com/albums/y224/87xjco/Xota/lfenderbondo.jpg
Now a coat of glaze compound spread to cover all the filler
http://i6.photobucket.com/albums/y224/87xjco/Xota/lfenderglazed.jpg
Glaze coat is sanded and fender is ready for primer
http://i6.photobucket.com/albums/y224/87xjco/Xota/lfendersanded.jpg
Fit the hood and it need 1 1/2" narrowed on each side
http://i6.photobucket.com/albums/y224/87xjco/Xota/lthoodtape.jpg
I will need to first cut out some of the understructure
http://i6.photobucket.com/albums/y224/87xjco/Xota/Hoodunderside.jpg
After cutting out the inner structure
http://i6.photobucket.com/albums/y224/87xjco/Xota/Hoodcut.jpg
I then fit and welded in some light gauge angle iron. Using a body hammer and holding the metal down firmly I folded the edge over onto the sheet metal.
http://i6.photobucket.com/albums/y224/87xjco/Xota/Hoodangleiron.jpg
Installed on the vehicle. Kind of wide gaps and a little uneven but good enough for the trail.
http://i6.photobucket.com/albums/y224/87xjco/Xota/Highhood.jpg

[Steven_Mc]

Excellent work! It's really coming together.

After all the work you're putting into those one of a kind fenders you are going to cry when that first rock reaches out to say hello. Any plans for an exo cage to protect all the work you are putting into the nose?

[87xjco]

Excellent work! It's really coming together.

After all the work you're putting into those one of a kind fenders you are going to cry when that first rock reaches out to say hello. Any plans for an exo cage to protect all the work you are putting into the nose?

Yep, it's getting a full exo-cage.

[flashover]

Lookin better everytime you put up pictures.

-Joel

[87xjco]

One more glaze coat on the rt. fender and it will be ready for primer
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00290.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00292.jpg

[RJsfun]

I don't see any windshield wipers?
Looks great! Are you going to be spending as much time on the doors/cab as you did with the fenders and hood?
That thing is going to look sweet when complete!

[Kirby N.]

Subscribing. Interesting build...

[JKTODD]

WOW-just discoverd the thread. This is way better than Monster Garage, OCC, Biker Build Off, etc... This has given me inspiration for a build that I have in my driveway. Thanks. My aspirations are tame compared to this!

[87xjco]

Thanks again everyone for your support!

Fenders and hood have been primed and then the fender edges and the hood underside and the Lt. door edges have been painted.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00302.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00300.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00301.jpg
I'm going to be test driving it so I have the lamps wired and mounted on a temporary bracket.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00303.jpg

[87xjco]

Update:

I drove it around quite a bit yesterday (25 miles)and it drove real good. Seems to be lighter than the XJ was as I have more power now with 35's, than I did with 33's on the XJ. I still have a lot of details to finish and the rest of the exo-cage that will add weight but......

All and all I'm real happy, it was a little scary to start driving on the road after such an extensive build. Before I drove it I put it up on the hoist and checked every bolt and hose and wire from end to end (and I found a few loose ones).

All the things that were going thru my head like, are the welds strong enough, did I have the rear diff. lined up square, did I mess up the front suspension geometry and am I gonna suddenly have uncontrollable death wobble, etc...

But basically it drove just like it used to as an XJ, it just got a lot more people staring at it with confused looks on their faces.

So.... soon I'll do an easy trail run and see what happens. Wish me luck!

[Steven_Mc]

Absolutely amazing! Looks excellent! Good Luck on the finishing process! :hail: :hail:

:beer: :beer:

[JKTODD]

I would have loved to see it at the MNG on Saturday.

[byron4]

never thought i would see the day when a jeep and a toyota mated. very cool. great work!

[kPs]

I am real impressed man:thumbsup: That thing is sweet and I can't wait to see how it does on the trail:beer: Good Luck!

[Jefe]

it's amazing how fast you've gotten to where you are. Some people it would take a year or so to do. Looks great man!! Let us know how the first trail exposure goes!!

[Dan Corley]

Very nice job! Look forward to seeing the finished project! Also sent you PM about your exobed. Thanx, Dan

[87xjco]

PM sent

[kemosabee]

Awesome build!

[aspencop129]

Unbelieveable! I just found this thread and am totally impressed :hail:

Great work and even better creativity:D Keep up the good work......what is the final color gonna' be?

:beer:

[87xjco]

Body work on the left rocker is happening
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00307.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00305.jpg
Ready for bondo
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00306.jpg
First coat is fiberglass filler that I'm just starting to shape
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00308.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00309.jpg

[flashover]

Please tell me that you are going tobe putting some kind of rocker and fender protection in your cage. You are doing far too much body work to risk it getting smashed up. NICE work.

[87xjco]

Please tell me that you are going tobe putting some kind of rocker and fender protection in your cage. You are doing far too much body work to risk it getting smashed up. NICE work.

Oh yeah. I agree, way too much body work that I don't want to do again. The exo will be built to protect all that.

[87xjco]

Awhile ago I posted the 1st photo and said that I would be moving the UCA's and I would post pictures. Here they are as promised.
http://i6.photobucket.com/albums/y224/87xjco/Xota/ucaedit.jpg

What do you guys think of the position?
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00313.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00312.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00310.jpg

[sonofmayhem]

So whats the final Color? im freaking out here!

[87xjco]

Rocker is primed
3/13/06
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00322.jpg
Rt. cab corner is repaired and primed and also welded the holes where the Toyota nameplates were mounted
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00323.jpg

[Steven_Mc]

It's coming along nicely! What's the final paint color going to be?

[87xjco]

White, cage & grill & bumpers will be black.

[sonofmayhem]

nice........

[trailbuilt]

All this work, dont you think you should of re sealed that motor and trans when it was out? Nice work. Its cool. NO one else is going to roll up on you on a trail and have a cooler xjyotazilla...

[87xjco]

All this work, dont you think you should of re sealed that motor and trans when it was out? Nice work. Its cool. NO one else is going to roll up on you on a trail and have a cooler xjyotazilla...

Yes, I am bummed that I didn't while it was out.

[87xjco]

This photo, Rt. door is pretty beat up and I'm running low on time for finding a good used one. So I decided to replace the outer panel.
http://i6.photobucket.com/albums/y224/87xjco/Xota/Beforeskin.jpg
After skin is installed.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00329.jpg
Inner edges of Rt. door and jambs on the cab are masked up for paint.
3/15/06
http://i6.photobucket.com/albums/y224/87xjco/Xota/Ljambtaped.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/Rdooredging.jpg

I'm getting stoked. Now that the door edges and door jambs are painted, I don't have much to do to get ready to paint the outside. Just have to weld up the 20 screw holes that dumb a$$es have drilled in the cab back panel, then prep everything and it's ready to paint.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00328.jpg

[sonofmayhem]

yeah my pass. door is dented to hell too.. good luck with the paintin'.

[shimniok]

I am in awe. Jeep + Toyota = Joy :D

[87xjco]

Prep work is done, just need to mask it and get it into the booth.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00335.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00338.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00337.jpg

[Ski_freak]

Lookin good :beer:

[zillacon]

Let get to the squirtin! I want to see some shiny paint. Then Al can come over and put some Teal pinstripes on it with some chrome ad-ons.

[sonofmayhem]

http://i8.photobucket.com/albums/a30/Sonofmayhem/camaro.jpg
AT least its not turning into this.:flipoff2:

[jeepn4evr]

What the heck is that?:eek: & why would anyone do that. :shrug: Looks like a Camaro front end grafted to a Nissan pickup. Thats just wrong.

BTW the Joy Toy is looking good. Nice Work :hail:

[87xjco]

3/21/06
It's finally in the booth, it's been ready since yesterday morn. but the painter has been busy with shop work. That was a long day yesterday and this morning.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00343.jpg
I left the windshield for the painter to mask since it takes some skill to mask the moulding edge. I would have preferred to have the windshield out or at least the moulding off, but on this Toy. cab the moulding clips fit under the glass so they get installed together.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00345.jpg

[Phazertwo A.K.A Brenden]

COME ON I WANNA SEE IT PAINTED!!!!!!!!!!!!!!:bounce4:

[87xjco]

Special thanks to Jamie Divos for the excellent painting.

A little wet sanding and polishing done. I'll get more photo's after I get some stuff put together

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00352.jpg

[RJsfun]

Nice!!! That looks great!
I like how the bevel in the mid/lower part of the door flows into the fender. With paint, it looks like it came made that way.
Can't wait to see it in the magazines!!!

[shimniok]

Lookin' good! :beer: Definitely mag cover material if you ask me -- maybe you should add some bright like flames and crap tho to flash it up a bit and cinch that mag cover :D

[87xjco]

A little more put together now
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00353.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00354.jpg

[RJsfun]

Nice!!! Can't wait to see the exo and tube bed on.
Curious, what is it registered as?

[longboy]

Nice!!! Can't wait to see the exo and tube bed on.
Curious, what is it registered as?

as a Toyorrokee?

[87xjco]

Nice!!! Can't wait to see the exo and tube bed on.
Curious, what is it registered as?

Even though my old plates are on it, I use our depot plate when I drive it. I am going to have to go thru the process of getting it titled as a home made and I don't know what that will do to insurance.

[RJsfun]

You are basically using the Toyota frame and cab? I say transfer all Toyota VIN plates to it and keep it registered as a truck.
Registering as a home made SUCKS, especially if you want to get it on the road. The inspection program is very detailed, but I don't think you would have any problems hooking up what they want with all your fab skills.
The biggest headache is wait time.
Good luck.
Hopefully you can name it after yourself.

[Sean Dogg]

Dude! That looks amazing! All that body work paid off, it looks factory!

[Phazertwo A.K.A Brenden]

Freekin Insane!

[87xjco]

Bed is on, sorry for the big photo, but it distorts some when I resize it.
http://i6.photobucket.com/albums/y224/87xjco/Xota/Painted%20view/DSC00355.jpg

[OlBlueCJ7]

THAT is gorgeous. You should be proud! :thumbsup:

[Sean Dogg]

I really like it, it can still be kept pretty functional with that bed on there. Looks awesome.... but needs more toob!

[janice]

just wanted to say weve been watching your build for a while and just wanted to let you know that it looks feakin awsome nice work

[longboy]

Just saw this thing at lunch, and the pictures don't do it justice. It is absolutely sick, brah! :beer:

[87xjco]

Thanks Janice and Longboy and all the Colorado4x4 peeps for help and support:beer: :beer: :beer: :beer: :beer: :beer: :beer: :beer: :beer:

[REDLYNER]

That's hot! Any updates on the interior?

[87xjco]

Not much happening there for awhile. I'm concentrating on getting it ready to do some mild wheeling next weekend and I probably won't get to the interior until after that.

[87xjco]

Shameless posing
http://i6.photobucket.com/albums/y224/87xjco/Xota/Painted%20view/DSC00362.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/Painted%20view/DSC00363.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/Painted%20view/DSC00361.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/Painted%20view/DSC00364.jpg

[Phazertwo A.K.A Brenden]

dude, thats just hot!

PZ

[cheftyler]

Wow...that is crazy! Nice Job!

[RJsfun]

I think I just blew a load in my pants. WOW, it looks so good all together. Can't wait to see some real action shots!

[2LoudDodge]

Looks really good. Nice touch on the bed. I like it.

[JKTODD]

BRAVO-STANDING O FROM ME. You know, with your skills this could become a side business for you. Take wrecked Toyotas and graft all kinds of front ends to them to make capable little, reliable crawlers. You could put on front clips of Mercedes SUV's, or Lexus or anything for that matter.

Cheers :beer:

[sonofmayhem]

where be the sliders? that looks so fawking cool man, i really like the way it looks, kinda like a mj or somethin.

[Jason]

I have to say you did a bad ass job and very good workmanship. The body work was flawless. but the front still wierds me out....i can't get past the lines.

[Alpine Spirit]

DUDE!!!! That THING IS SWEEEEEEEEET!

[Jefe]

Shit hot!!!

Nice work, looks like a brand new truck thing. Very impressive!

side note: you should see if you can get those wheels rebalanced with the weights on the inside not only for looks, but to keep them from getting pulled off on the trail.

[Steven_Mc]

Amazing! Looks great!

[kPs]

Holy cow! Like many others I am very impressed! you definitely know whats going on!:beer: :beer:

[zjRyan]

May as well add one more comment to the list of accolades...VERY nicely done. I'm sitting here wishing it was mine. Definitely magazine caliber, even more so once it gets exoed.

[TruckinT]

Didn't think I'd like the cherokee clip and fenders till I saw the finished job, HOLY FRANKENSTEIN!!! You've got some vision my friend, well done!:hail:

[creeperjeeper]

I love how unique that rig is. nice job on how you took two different world's and made them one. It would be like puting a chevy & Ford together. My consion hates cherokee's with a passion and own's a yota himself. I sent him a copy of the final product and told he can't talk shit about this cherokee. Any way keep the creative juices flow and come up with another crazy project. Nice work!!!!!!!!!!!!!!!!![]llllllll[]

[87xjco]

Thanks again for all the positive comments on the build

Carnage...
So like a dumba$$, I try to take this line on the ledge
http://i6.photobucket.com/albums/y224/87xjco/Chinamans%204-15-6/9.jpg
Heard that loud bang noise and had this
http://i6.photobucket.com/albums/y224/87xjco/Chinamans%204-15-6/91.jpg

The rest of the run went good
http://i6.photobucket.com/albums/y224/87xjco/Chinamans%204-15-6/1.jpg
http://i6.photobucket.com/albums/y224/87xjco/Chinamans%204-15-6/3.jpg
http://i6.photobucket.com/albums/y224/87xjco/Chinamans%204-15-6/7.jpg
http://i6.photobucket.com/albums/y224/87xjco/Chinamans%204-15-6/4.jpg

[Steven_Mc]

Nice pics! Bummer on the U-joint.

[Guammy]

It looks even better in person. I got to see it today and Terry does awesome work.

[87xjco]

Starting to build the rest of the exo

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00434.jpg

[JKTODD]

Looking good. Did you have a spare axle on Chinaman's? I blew out my short shaft side on 21 Road. I carry an extra set of axles now. I liked the way it performed at C.O.R.E.

[87xjco]

I had spare D35 shafts, so of course it was the D30 that had problems. But I was able to take off the hub with the outer stub still in it and remove the inner stub. Then I stuffed a rag in there and put the hub back on and drove it.

But I now have most of the front axles for spares. So I'm sure I'll break something different next time.

How's your rig after CORE? Any damage?

[87xjco]

SCORE!! - front & rear dana 44

http://i6.photobucket.com/albums/y224/87xjco/Xota/Dana%2044/DSC00440.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/Dana%2044/DSC00439.jpg

They are out of a 88 Waggy.
I plan to put full Detroit lockers front and rear with 4.88 gears.
I'll leave the drum brakes on the rear. i already have new 6 hole steel wheels. I'll use the Warn hubs off of the 83 waggy I bought.

So I have to build front coil spring perches and control arm brackets and I will probably rotate the knuckles.

I don't think I will do alloy or heat treated axles. ( when they break, it's alot more expensive and spare stock ones are cheap).

[TubeWerx]

I am very impressed with your final outcome! SO clean and thought out. Beautiful job! :thumbsup:

[JKTODD]

Ummm-not to be a smart ass or anything but didn't you start this whole project because of the money that was invested in your current axles? The 44's will be better though. It's just a shame to have to build axles all over again. What's in the front Dana 30 for a locker? I may want to buy it. I wasn't overly impressed with my TrueTrac. It worked but having to hold the brake and give gas at the same time got a little old.

[87xjco]

Ummm-not to be a smart ass or anything but didn't you start this whole project because of the money that was invested in your current axles? The 44's will be better though. It's just a shame to have to build axles all over again.

Well I don't know if it's the reason I started the project. But maybe one of the main reasons I used the XJ platform as a builder (also the 4.o and aw4). But I always new there would be a day when I would have to upgrade axles. It does suck to loose that investment. Even if I am able to sell the old axles to someone, I'd be lucky to get 1/2 of the investment back.

And you know, when your at Chinamans, and you really want to try the left line at whales tail, but worrying you'll blow an axle so bad that you won't be able to drive home, and start thinking about the expense of that. And when I'm pretty sure I won't make it with just the true-trac up front. It tends to push me to upgrading sooner.

What's in the front Dana 30 for a locker? I may want to buy it. I wasn't overly impressed with my TrueTrac. It worked but having to hold the brake and give gas at the same time got a little old.

It has a true-trac, that's better than no locker but, I was disappointed also. It's nothing like a Detroit no-spin for traction.

[87xjco]

I am very impressed with your final outcome! SO clean and thought out. Beautiful job! :thumbsup:

Thanks TubeWerx, and all the peeps who have posted. It's great to get the feedback.
Terry

[JKTODD]

Dang-I was hoping that you had a Detroit or even a Lock-Rite I could steal-I mean buy from you. I need to see it now that you starting tubing it out. Cheers :beer:
Todd

[Jefe]

Dang-I was hoping that you had a Detroit or even a Lock-Rite I could steal-I mean buy from you. I need to see it now that you starting tubing it out. Cheers :beer:
Todd

Not trying to Hijack....

but if you want a cheap and easy locker up front, try an aussie locker.

[87xjco]

Lower bars of the cage are on. Took a run thru Boulder Carnage 5/13/06.
http://i6.photobucket.com/albums/y224/87xjco/Carnage%205-13-06/DSC00466.jpg
http://i6.photobucket.com/albums/y224/87xjco/Carnage%205-13-06/Ob1.jpg
I also added some boat tub style skid plates that give the rockers alot of strength and protection and I already broke them in good.
http://i6.photobucket.com/albums/y224/87xjco/Carnage%205-13-06/DSC00487.jpg

[sonofmayhem]

NICE! Im gonna either drop in a d44 this summer or do a TC kit. but im gonna take some of your ideas if you don't mind!:D

[87xjco]

Feel free to use what you want.

[Vinman]

been followin this thread, and all i can say about this rig is WOW, saw it drivin today on federal @rocky's goin north, i passed ya in my 4runner(no top, cab exo, maroon) when ya turned off federal. you have truly created a very nice rig, it looks even better in person than in the pics! Nice job! :beer: :beer: