Rebuilding the XJ

[flashover]

My XJ has served me well over the past few years. I had an RE 5.5 lift on it with 33" BFGs, but I think it is time to move on.

Before
http://flashover4x4.com/BlueXJ/before

Now that Ryan's POS buggy is out of garage, we can get some work done on mine.:flipoff2:
The long term plan is to build it capable of competing in W.E.ROCK stock class. I don't plan to be competitive this season, as I just don't have the budget to do everything it needs, but hopefully I can run most of the 07 season and maybe one or two this year.

First step was to strip everything it doesn't need. Ditched the heavy front bumper and rocker guards I had along with the doors and the lift gate. After everything was off, the body was sitting noticibly higher. Ever after a cage is put on, I think it will end up with a bit less sprung weight than before. (Unsprung is a whole different thing :D

http://flashover4x4.com/BlueXJ/no_doors

We cut off the stock rocker sheet metal and replaced it with 2x6x.188 box tube. That will give it a bunch more strength without any loss in clearance. It is also wide enough that the cage can be mounted to it.

Ryan cutting off the old sheet metal
http://flashover4x4.com/BlueXJ/rocker_removal

The aftermath
http://flashover4x4.com/BlueXJ/cut_rocker

All welded up
http://flashover4x4.com/BlueXJ/rocker_new

It is welded to the sheet metal below the doors and the pinch seam underneath. I'm still working on how to tie it in to the "frame"

Progress will probably be slow, as I am doing things as money allows, but it will get there.

-Joel

[74BuckinBronc]

Cool, I thought you were crazy using 2x6 there until I saw you were using it to tie into a cage. So it'll be an exo cage? Thanks for the pics of the rocker opened up, I've wanted to know what it looks like behind there!

J.D.

[flashover]

Yeah, it will be an exo. The rule say body panels have to be reasonable straight, and I just don't think I could keep them that way with an internal. It wouldn't matter so much if they were easily replaced, but that dang unibody takes a lot of work replacing panels.

-Joel

[74BuckinBronc]

How far does the 2x6 stick out past the rockers and did you but it all the way to the seam? Just trying to get a feel for what someone would use if you weren't doing an exo.

J.D.

[Jeffro600]

Man, your brave welding with goggles!! Bet youve got one hell of a sunburn huh?? :P

[cheepin]

Man, your brave welding with goggles!!
He is cutting with a plasma torch.:rolleyes: Please read before replying.:flipoff2:

[Jeffro600]

He is cutting with a plasma torch.:rolleyes: Please read before replying.:flipoff2:

lol, my bad....i just saw sparks and what looked like a welding torch! :D

Still though....doesnt a plasma cutter put out alot of UV rays too??

[flashover]

The 2x6 sticks out about 2 inches from the body. It is butted all the way up to the pinch seam.

Plasma does put out a bunch of UV. That's why proper safety equipment include the shade 5 cutting goggles you see him wearing.

-Joel

[formatt]

Joel.. what ever happened to that XJ you and ryan were working on a year or so ago?.. with the competition cut rear.

[Jeffro600]

Plasma does put out a bunch of UV. That's why proper safety equipment include the shade 5 cutting goggles you see him wearing.

-Joel

What about the rest of his face then??? :P Last time i checked, UV rays are pretty hard on your skin!

[flashover]

Matt,

I got such a good deal on the rockwells I picked up, I decided to build bigger than the XJ would allow. The body work was taking a lot more than I really wanted to do, and a buggy was better suited for the parts that I had. So, in one afternoon, with a sawsall and the plasma cutter, the XJ was cut up into 2'x2' pieces to take to the scrap yard. The rockers for this are the same ones that we had built into the old one.

Ryan

[formatt]

... So, in one afternoon, with a sawsall and the plasma cutter, the XJ was cut up into 2'x2' pieces to take to the scrap yard....

seriously ryan... nobody makes me more nervous around cutters and torches than you two. I need to swing up there some afternoon. I'm not too far south of you guys.

[flashover]

C'mon up. The more the merrier and we usually have plenty of cold :beer:

[flashover]

Finally got some more work done. Things have been a bit hectic around here lately, but hopefully we'll have more time soon so progress should get faster.

So far we have gotten the rear hoop, the a-pillars, b-pillars, windshield cross bars and the hood bar on.

http://flashover4x4.com/BlueXJ/cage1.JPG

http://flashover4x4.com/BlueXJ/cage2.JPG

http://flashover4x4.com/BlueXJ/cage3.JPG

There is still a bunch of tubework to go, so no comments about more triangulation, it will get it soon enough. :flipoff2:

-Joel

[87xjco]

Another cool flashover project to watch. Nice!1

[jdogg4]

Another cool flashover project to watch. Nice!1

thats what I was thinking. It never gets old because they always have something cool cooking over there.

[DADA_JEEP]

just a guess, no more doors?

[jdogg4]

just a guess, no more doors?

O no no doors. Those just get in the way of falling out and it looks cool.

[Clod Hopper]

Going doorless on an Uni-body vehicle is a real risky idea. You loose alot of structural strength. Haven't you heard that XJ's fold in half when doorless? Course the tube may help that somewhat.






:flipoff2: . It is looking great!

[DADA_JEEP]

Going doorless on an Uni-body vehicle is a real risky idea. You loose alot of structural strength. Haven't you heard that XJ's fold in half when doorless? Course the tube may help that somewhat.


this is what i was thinking, don't the doors give some of the rigidity?

[strom911]

I have angle iron along the unibody frame rails and run without doors. I have tweeked the unibody and then had it bent back and welded some more angle iron to the unibody that did not have any. I will argue that there is no structural integrity in the doors. When i tweeked the unibody, the rear doors as well as the front did not close very well at all. I guess my question is, how does a door latch keep a unibody straight? I don't think that it does.

[jdogg4]

they might keep it from folding like a taco but ya your still going to tweek the body with the doors on. Maybe not as bad but still put that jeep in a body tweeking position with or with out doors and it's going to happen.

[87xjco]

this is what i was thinking, don't the doors give some of the rigidity?

Only if you have the windows up

[DADA_JEEP]

Only if you have the windows up

ok, now you're screwin with me........

[jdogg4]

ok, now you're screwin with me........

O no it's true really.

[flashover]

I know that the thing will collapse without the doors. That's why they're sitting in the basement. They don't actually have to be attached to add strength. They just need to still be in your possesion. Maybe it only works for me because I have mastered the powers of The Force. :flipoff2:

Just wait till you see the final cage. It will have more rigitity than any XJ I've ever seen. The a-pillars are already tied it to the original door hinges.

-Joel

[Alpine Spirit]

SICK!!!!! Keep the updates coming

[flashover]

Got a little more done yesterday. The winch tray and shackle tabs are done. The winch tray is made from some 4x6x5/16 structural angle we had laying around. I know it's a bit excessive, but we have 20 feet of it to use up. The shackle tabs are the ones that Rokmen sells. Glad I got that big welder. I think I was pushing well over 200 amps into those things. Welder didn't even get warm.:D The brackets going back to the frame are 1/4 plate and tied in with 7 bolts on each side. I'm also gonna fully weld them to the frame. I still need to add a plate filling in the bottom between the frame brackets and and some protection around the headlights. I don't know how much I'll get done today with the snow, but hopefullly soon.

Sorry for the bad pics. My camera doesn't really like the dark.

-Joel

http://flashover4x4.com/BlueXJ/winch1
http://flashover4x4.com/BlueXJ/winch2

[87xjco]

I like that cage design up front, I may have to steel that from you when I finish my cage!

[flashover]

Got a bit more tube in yesterday after work.

Added door bars and a brace up to the main roof bar. Also added a cross bar between the two sides. There was some interference with the door bar and the factory B-pillar, but a little custom bodywork (big ball peen hammer) took care of that.

http://flashover4x4.com/BlueXJ/side1
http://flashover4x4.com/BlueXJ/side2

Also got some rear bracing in

http://flashover4x4.com/BlueXJ/rear

Hopefully we'll get a lot done today. It will be the first full day we've had to work in a long time.

-Joel

[angrygoat]

SICK XJ...

I cant wait to get that far on my stuff.

[cheepin]

Sorry but That thing is UGLY!I just hate exos!Maybee it will look alright when finished.

[RockyMountain4x4]

I had no probs at all with my unibody, and your cage looks way stronger than mine....

http://motorcitymopars.com/images/carimages/Independance/DSC04467.jpg

[Jeffro600]

I had no probs at all with my unibody, and your cage looks way stronger than mine....

http://motorcitymopars.com/images/carimages/Independance/DSC04467.jpg

Now thats freakin sweeeeet!! :thumbsup: :thumbsup:

[flashover]

Got a couple more tubes in today.

Roof is finished
http://flashover4x4.com/BlueXJ/roof1.JPG

More interior bracing
http://flashover4x4.com/BlueXJ/interior1.JPG
http://flashover4x4.com/BlueXJ/interior2.JPG

Thanks all for your kind words. It's been a kinda slow process, but it's coming along.

-Joel

[74BuckinBronc]

It's been a kinda slow process, but it's coming along.

...nicely!

[flashover]

We decided we need to start working evenings now, or it won't get done in time.

We got the interior bracing finished up.
http://flashover4x4.com/BlueXJ/interior3

There are 7 tubes going into each node. Having a Pipmaster makes those joints SO much easier.
http://flashover4x4.com/BlueXJ/node

We also got most of the rear tubework done
http://flashover4x4.com/BlueXJ/rear1
http://flashover4x4.com/BlueXJ/rear2

-Joel

[98XJDMB]

wow, thats going to be one solid XJ!

[formatt]

Joel.... are you modifying the exhaust at all? I've heard that the fumes can be REALLY bad without the rear hatch.

Looks really great so far!... you and ryan definitely do nice tube work!

[flashover]

Right now the exhaust is cut off at about the rear axle. That was just because it was banging on the shackle and the back mount had torn itself off. I hadn't even given much thought to fumes yet. With all the doors off, hopefully it will have enough air flow that it won't be bad, but I guess I'll find out pretty soon. We still don't have a trailer, so I'm gonna drive it all the way to Moab in May.

-Joel

[Steven_Mc]

We decided we need to start working evenings now, or it won't get done in time.

There are 7 tubes going into each node. Having a Pipmaster makes those joints SO much easier.
http://flashover4x4.com/BlueXJ/node

-Joel

That is going to be one heavy biatch!! Looks good!! :thumbsup:

What is a pipemaster?

[flashover]

That is going to be one heavy biatch!! Looks good!! :thumbsup:

What is a pipemaster?
http://vansantent.com/images/pipemaster_group.jpg

http://vansantent.com/images/pipemaster2.jpg

A pipe master creates the profile of your notch using a bunch of pins. It really has made life much easier on these complex pieces. On my buggy, some of the three or more tube junctions really looked like crap, but with the pipemaster on this one, they are much better.

As far as weight goes, with the interior stripped out, no doors, and no hatch, we are hoping the cage does not bring it too much bast the stock weight.

Ryan

[Jeep-in-dna]

Ryan, can you give a link to the pipe masters web sit or maybe where you got those. I saw them on pirate a while ago, and since I'm too cheap to buy a red star I can't search for that thread anymore.

Thanks,
Matt

[flashover]

Tricktools.com (http://vansantent.com/pipemaster.htm) They are also a Pirate vendor.

[Steven_Mc]

http://vansantent.com/images/pipemaster_group.jpg

A pipe master creates the profile of your notch using a bunch of pins. It really has made life much easier on these complex pieces. On my buggy, some of the three or more tube junctions really looked like crap, but with the pipemaster on this one, they are much better.


Ryan

Wicked, definitely going to have to pick up one of those!

[flashover]

We got a lot done this weekend, but not much that makes good pictures.

The seats are in
http://flashover4x4.com/BlueXJ/seat.JPG
http://flashover4x4.com/BlueXJ/seat_brct.JPG

We also got the front skid on.
http://flashover4x4.com/BlueXJ/front.JPG

The spring perches are mounted on the rear axle. Just need to mount shocks and it will be ready to go.
http://flashover4x4.com/BlueXJ/rear_axle.JPG

Ryan started grooving the tires while I cut down the runflats for the hummer rims. I've read plenty of things saying to be careful when cutting them, or you'll light the magnesium on fire, but I did it with the plasma and had no big problems. The only issue was when I got a burning magnesium spark on my lip. It lit my beard on fire and left a nice little hole in my lip.:eek:

That's it for now.
-Joel

[charliealter]

i am lovin the thread! i can wait to do this with my grand cherokee. keep the great pictures coming!

[flashover]

I had today off, so I got a bit more done today.

I finished welding up the spider gears.
http://flashover4x4.com/BlueXJ/spiders.JPG

I also got the rear shocks mounted. I'm just reusing the crappy shocks I had before. When I get some more $$, I'll get some good ones and mount them vertically through the floor.
http://flashover4x4.com/BlueXJ/shocks_mounted2.JPG

I also finished up the grooving on the tire Ryan started yesterday. Only three left to go.
http://flashover4x4.com/BlueXJ/grooved.JPG

[98XJDMB]

Ryan started grooving the tires while I cut down the runflats for the hummer rims. I've read plenty of things saying to be careful when cutting them, or you'll light the magnesium on fire, but I did it with the plasma and had no big problems. The only issue was when I got a burning magnesium spark on my lip. It lit my beard on fire and left a nice little hole in my lip.:eek:

That's it for now.
-Joel

Ouch... i think thats what people say to be careful about. Burning a hole in your lip with magnesium sounds like a problem to me :eek:

sounds like somone wasn't wearing a proper facemask :tisk:


:P

[flashover]

sounds like somone wasn't wearing a proper facemask :tisk:
:P

Funny thing is that I tried to wear a full face sheid, but it wouldn't fit over the cutting goggles. I think the real solution would have been to cut them when it wasn't so dang windy. :D

[flashover]

The man in brown brought me more stuff today. Now I don't have any excuses for not getting the suspension done.
http://flashover4x4.com/BlueXJ/parts.JPG
-Joel

[Steven_Mc]

The man in brown brought me more stuff today. Now I don't have any excuses for not getting the suspension done.
http://flashover4x4.com/BlueXJ/parts.JPG
-Joel

Looks nice! Are those Evolution Heims?

[flashover]

No, just 2.5" Johhny Joints. I sure hope I don't end up needing Evo joints. I'm hard on my junk, but not that hard.
-Joel

[flashover]

We got started on the front suspension today. In order to get the lower links to clear the tires and frame they have to bend in two planes.

Ryan figuring out how to cut the pieces.
http://flashover4x4.com/BlueXJ/link_draw.JPG

In order to get the round Johnny Joint shank into the box frame, a section of DOM was braced and welded to the plate.
http://flashover4x4.com/BlueXJ/link_interior.JPG

Link clearance against the tire.
http://flashover4x4.com/BlueXJ/link-tire.JPG

I really don't suggest building links like these. There is 11 hours of work for two people in just those two links and they aren't even welded yet. They should work, but I think there is probably easier ways to accomplish the same thing. These are also extremely heavy. The top and bottom plates are 3/8, and the sides are 1/4. Each link weighs about 50 pounds.

-Joel

[OlBlueCJ7]

Ryan figuring out how to cut the pieces.
http://flashover4x4.com/BlueXJ/link_draw.JPG


Wow, you guys REALLY need CAD. :p

That's a beefy link. Nice work! :thumbsup:

[flashover]

We have AutoCAD, but I am not all that great with the 3 dimensional stuff. 2D, let me at it, but this was a little beyond my ability.

Ryan

[Trango]

Those links are pure crazy. Awesome!

[Phazertwo A.K.A Brenden]

We have AutoCAD, but I am not all that great with the 3 dimensional stuff. 2D, let me at it, but this was a little beyond my ability.

Ryan

Drawing it on paper is 2d too:flipoff2:

I have solid works and cad (student editoins stuff, but works the same) I wouldn't mind helping you out!

PZ

[flashover]

We only put in 13 hours of work on it yesterday, but we got the front suspension finished.

The bends in the lower link work out great. There is about 1/2 inch clearance between the link and frame at full compresion.
http://flashover4x4.com/BlueXJ/links_side.JPG

The panhard bar and draglink are within a degree of each other at ride height and the panhard is 7/8 inch longer than the draglink. Shouldn't have too much bumpsteer.
http://flashover4x4.com/BlueXJ/links_front.JPG

The draglink clears the panhard by about an 1/8 at full turn.
http://flashover4x4.com/BlueXJ/steering_clear.JPG

It certainly won't be done in time for our trip to Moab, but I think it will be done enough. Just have to get the axles geared, rebuild the axles, setup brakes and do a little wiring.

-Joel

[Rex Ashton]

Holy Monster Links, Batman! :eek:

Keep the Pics comin' :cool:

[kerndogg]

that is the wackiest set of control arms ever, wacky but way cool, is it just dom that has been boxed?

[flashover]

No, the only tube is right at the end so that I could weld the threaded insert in for the Johnny Joint. The rest of the link is just plate. The top and bottom are 3/8, the sides are 1/4
-Joel

that is the wackiest set of control arms ever, wacky but way cool, is it just dom that has been boxed?

[MtnRunner]

Looks like a set off a Trophey Truck rear...very beefy.

[flashover]

Front's on:bounce: :bounce2: :bounce: :bounce2: :bounce: :bounce2:
http://flashover4x4.com/BlueXJ/front1.JPG

We got the rear slung too and realize that the caliper brackets interfere with the spring plates:mad:. Hopefully we'll get that rebuilt tomorrow.

Also got the battery relocated behind the passenger seat and all the wiring run.
15 hours of work today, time for bed.
-Joel

[OlBlueCJ7]

RockRash (Bob) and I saw your truck at Anderson's yesterday, but couldn't track you guys down to say hi...

Lookin good!

[rockfrog]

Why even run shocks if you are gonna have them at that angle, they will do basically nothing. If you need longer shocks I have basically a new set (4) of Rancho RS9000 99012 p/n that are for sale. let me know.

[flashover]

Why even run shocks if you are gonna have them at that angle, they will do basically nothing. If you need longer shocks I have basically a new set (4) of Rancho RS9000 99012 p/n that are for sale. let me know.

I will get longer shocks and mount them right eventually. For now, they fit there without cutting holes in the body and building shock towers. This is just to get me by until time and money allows something better.
-Joel

[flashover]

Rear axle is done except for running brake lines. Front is done except assembling one hub. It's sitting on it's road tires now.
http://flashover4x4.com/BlueXJ/1.JPG

F250 brakes are huge. They should stop this thing pretty good.
http://flashover4x4.com/BlueXJ/brakes_frnt.JPG

-Joel

[Wally]

Nice Job guys :beer: can't wait to see the final version...and of course the trail pics :D

[flashover]

After some interesting manuevers to get at the wiring, the dash is buttoned up. I think the blood is finally leaving my head.
http://flashover4x4.com/BlueXJ/2.JPG
-Joel

[sonofmayhem]

NICE! gotta love those tires. great pics as well.

[jdogg4]

I just got to see the buggy driving through town on saturday. I happend to be in windsor driving to the folks house ans saw it on main street there. Looking good looking good.

[flashover]

Thank jdogg. It finally drives. That was it's maiden voyage to Napa, Sonic, and the beer store. I'll get some pics up tonight.
-Joel

[satan]

Just for fun - run it through a truck-scale... The weight-to-power ratio has gotta be amusing! I wanna see (more) pics!

[flashover]

Radios and brakes (line lock and proportioning valve) are mounted between the seats.
http://flashover4x4.com/BlueXJ/3.JPG

Found out that the space between the seat and a panel in the back is sized perfectly:D Unfortunately, that space is now taken up by an axle shaft rack.
http://flashover4x4.com/BlueXJ/4.JPG

Front flexes great. Brake lines were limiting, but those are now moved.
http://flashover4x4.com/BlueXJ/5.JPG

Rear still doesn't flex for crap. Maybe I'll link it next winter.
http://flashover4x4.com/BlueXJ/6.JPG

Sorry, no wheeling pics till after Moab.
-Joel

[sonofmayhem]

Awesome, good to see it done now get on with that buggy! j/k

[flashover]

I drove it to work today. It drive great other than a bit of a shimmy at about 50mph. It cruises at 68mph quite well, but doesn't really like going 70. It'll be a long drive to Moab, but it'll make it just fine.
-Joel

[sonofmayhem]

My yota did the same thing, and at 80 as well.

[matthew.quimby]

Looks friggin awesome. Nice color btw. Gives me hope for my 94 XJ.

[4Lo]

I've seen those 33s before....

Looking good man! Can't wait to see Moab pics.

[flashover]

Other than the drive out and back, the rig performed great at Moab.

Golden Crack
http://flashover4x4.com/BlueXJ/7.jpg

Comp are at BFE
http://flashover4x4.com/BlueXJ/8.jpg

Overall, the suspension is quite a bit more stable than it was before and the flex up front is great.

Found a few problems. The lack of limit straps caused a shock mount to tear off the axle. The 14 bolt really needs to be shaved. It was hanging up on everything. The unbalanced flex between front and rear gets a little awkward. The Goodyears suck, even heavily grooved. They just don't hook up at all and they are chunking something fierce. I guess I should expect that from a $30 tire. I really need a front locker. It'll take a little time, but it should be pretty easy to get all the little things dialed in.
-Joel

[Jefe]

Looks great. Saw you down at the shell station while I was getting gas. I think you guys were getting a couple bottles of anti freeze.

[flashover]

Yeah, the CJ that was with us overheated and puked a bunch of coolant about a block away from there. Just one of many problems that week.
-Joel

Looks great. Saw you down at the shell station while I was getting gas. I think you guys were getting a couple bottles of anti freeze.