97 XJ Build

[SByota]

I started working on reinforcing the bump stops, shock mounts and front end in preparation for paint and final assembly. I cut of the bottom of the stock bump stops and sleeved them with 1.75” DOM. The new bump stop tube runs up into the engine bay and is attached with a 3/16” plate. I will tie the new bump stop tube into the top of the shock mount. The new bump stops have nuts welded (pictured) inside them for short urethane snubbers. I will use prothane coil inserts with a UHMW rod inside as the actual hard stop.
I cannot wait to be done welding on the thin galvanized sheet metal, it’s terrible to work with.

 

[SByota]

Got one side all done. Other side is about 3/4 done.

 

[SByota]

It's coming together slowly. Got the SYE installed and t-case back installed. Fresh paint on the trans cross member and my fabricated transmission mount.

Started on the driver side motor mount. I love having my mini fixture table. Makes measuring stuff like this so easy.

Picked up a new toy. $200 for a very basic 3-1 mill/drill/lathe machine. It was never used and was still covered in grease from 1994. It is so nice to be able to face off tubing to make it square. I wish I would have paid attention better in High School shop class. I'm learning as I go.

 

[SByota]

Worked on the driver side motor mount plate today. The stock ones are only held on by 3 bolts and are prone to failure. I am also going to raise the motor up 1/2" to help with track bar clearance at full bump. Also had a little garage elf with me.

 

[SByota]

Driver side motor mount done and installed. I made a really stupid mistake and somehow lost an inch when I located the through bolt holes on the motor plate side. Should have measured 4 times I guess. I was able to fix it, but it didn't come out as clean. At least its done.

 

[SByota]

Every once and a while I get one just right. Passenger side motor mount almost done.

 

[Smileyshaun]

Amazing fab work and attention to detail , can't wait to see how this turns out and seeing it out adventuring

 

[bubba68]

great job love all the fab

 

[SByota]

Motor mounts all done and installed. Of course the second one was WAY faster than the first one. Started on the double shear for the pitman arm. It's all tacked up ready to be burned in. Ran out of time today and had to get ready for work.

 

[XJackal]

That is impressive stuff your turning out , following your build. After seing how you beefed up the lower control arm mounts may do the same was planing to box them.

 

[Nomad00XJ]

I just inherited an XJ and love seeing everyone building these up as overland rigs. Even though it's a pretty basic vehicle I really love mine. Great build, and envious of your fabrication skills!

 

[SByota]

Exhaust is all done and. The OEM system was rusted out and done. It was also tiny!! as small as 1.5" in places. It's all 2.5" now with a cheapie Summit Racing "race bullet" muffler, which is basically small glasspack. This was my first time doing exhaust, I'm pretty stoked on how it came out. Front axle truss and gears are next, the I can do final assembly on the front.

 

[Nomad00XJ]

That looks great! I'm looking into exhaust as well and haven't been able to find the entire system in 2.5". I think I'll have to go to a local shop and have someone with a pipe bender and welder to connect the pieces I can find online.

 

[SByota]

Got the new exhaust installed for real. Started painting stuff and getting the front end prepped for final assembly. It feels good to be getting somewhere.

 

[SByota]

Front axle is DONE! I built a full truss and added plates to the upper "C's". Welded out all of the link and shock mounts, threw in a set of 4:88 gears with all new bearings etc. This was my first time doing gears, it was and experience for sure. Lots of trial and error, swapping shims over and over again. Ended up super happy with the pattern and with backlash at .008". I would be able to do it so much faster now! Next step is putting the front end together, feels good to make progress.

 

[SByota]

Starting to actually put stuff together. All the time I spent mocking everything up is paying off.

 

[Nate 5303]

Looks great man, good job!!!

 

[SByota]

Got an free driveshaft for the front, bummer is that it was 2" too short. I have a lathe, welder and some basic metal skills.... let's see if this will work. Chopped the slip yoke, made a sleeve out of DOM and got it to .003" from perfectly true. It only has 3/8" of plunge from bump to droop. Also had the best helper in the shop working on the front end.

 

[SByota]

Spent some time doing final assembly on the front end. It looks so pretty all clean and fresh. Anti-Seize has an amazing ability to get on EVERYTHING!! I looked like the tin man when I was done. Also burned in the rear leaf spring plates/lower shock mounts.

 

[SByota]

One step closer! This is the first project I have had where I actually have every single part to get it road worthy. Just need more time to finish it. Front end just needs calipers, coil springs and some fender trimming.