Let's hear what everyone has to say on building an XJ.

2 door 91 XJ 5 spd purchased for $1,800 Cdn (~$1,200 US)

Budget for mods was $2,000
Already spent:
$50 for tremclad paint job
$150 for a set of 32" tires
$50 for wheels
$200 for axles with 3.55 gears (stock was 3.07)
$200 for winch bumper (already have a winch)
$100 for 2" spacers, add a leaf, and ZJ coils
Already have CB, recovery gear, fire ext, tools, etc.

That leaves $1,350 for more mods.

What does everyone think would be the most useful way to spend it?

I am debating a roof rack, Bushwacker flares, axle truss and a lock-right.

good set of rock sliders also doubles as a step in to the vehicle.
spare tire.
good jack.
place to store the spare and jack such as roofrack or rear carrier. or just throw it in the cargo area.
good set of offroad lights.
service manual.
get a rubbermaid cargo box and buy all the oils required for your vehicle to run. motor oil. transmission fluid also doubles as transfercase fluid. gallon of coolant. power steering and brake fluid. ujoints for EVERYTHING. both driveshafts. tarp so that you dont get dirty when you have to work on the jeep in the field. decent set of tools and wrenches in adition to what you have at home. those should stay in the box at all times.

im sure i am missing something but i just worked 12 hours and mowed my yard.
enjoy jeeping!!

My rockers are a bit rusty anyway, so I was thinking of cutting them out and welding in box steel.

quote:

---

Originally posted by Chris S:
My rockers are a bit rusty anyway, so I was thinking of cutting them out and welding in box steel.

---

Thats a good idea, and while your welding box the uni-rails with 3/16" plate. What rear axle do you have? If its a D44 throw a Lock-Right in it, if its a D35 you may consider a Super35 kit with a Detroit locker. A good t-case skid is a must if you do any rocks at all, XJ's T-cases and totaly exposed and being that tey are a cast aluminum case it will shatter at the sight of a rock being to close. Cut and fold the rear 1/4 pannels and gain about 12" of clearance, then buld a bumper that wraps around. For the rear I would ditch the add-a-leafs and get some full packs....get some Dakoda leafs, cut the eyes off the main leaf. Then remove all the leafs from your XJ main leaf and put the dakoda leafs under it. It should give you 4-4.5" of lift and flex quite well. Cut the rear lower shock mounts off and weld them where you wont smack your shocks all the time, then build a cross-member where the top of the shocks can bolt on to. For the front axle cut off the lip right above your LCA's, when you flex it will it your control arm with greatly limits your drop.

Lots of good ideas there, thanks.
Already got the AAL so I'll try it out.
Found some used skids on NAXJA so those are on the way.
Also got front Grand Cherokee V8 coils today to make up for the winch & bumper weight.

Rear is a 35C, hence the need for a truss.
I can get an old 44 cheap, but the rebuild would take a big chunk of my budget. No place to work on stuff like that at home.

Trying to figure out where to cut the rear panel behind the tire. There's a piece of galvanized sheet in there at an angle. Do I leave it or cut above it? Don't want to compromise any body strength.

Any pics or install of the upper shock mount crossmember?

Doubt my front flex is enough to need to trim the LCA mounts, but I'll keep an eye on them.

1/4 pannel: http://community.webshots.com/photo/144876356/144876737fJRJDf

the best way to do it is cut the back, fold the front under and tack weld it in place. I cut bent mine right at lower edge of the angled part of the body.

lower shock mounts:

http://community.webshots.com/photo/107946507/107946875MTLvuT

quote:

---

the best way to do it is cut the back, fold the front under and tack weld it in place. I cut bent mine right at lower edge of the angled part of the body.

---

Lots of room, but it looks kinda chopped. On a rig with an exo who cares, but this is also my work delivery vehicle. I'm thinking either angle the cut so it starts lower and rises, or extend the bumper closer to the tire.
Either way I think I will wait to see what kind of rear bumper I can find.
Thanks for the pic.

rear shock tower: http://community.webshots.com/photo/107946507/107946987fQiIDX

The rear came out very clean to tell ya the truth. Just because it has an exo cage dosent mean Im not extreamly persistant on having things done right. Lets just say that it looked factory original, and BTW that was my daily driver

quote:

---

Originally posted by RENEGADE:
rear shock tower: http://community.webshots.com/photo/107946507/107946987fQiIDX

---

Is that just bolted to the bump-stop extensions?
Looks easy enough to fab.
Better fix the rust holes in my hatch floor before I cut the exhuast that short though.

quote:

---

Originally posted by RENEGADE:
The rear came out very clean to tell ya the truth. Just because it has an exo cage dosent mean Im not extreamly persistant on having things done right. Lets just say that it looked factory original, and BTW that was my daily driver

---

Maybe it's just the angle. it looks odd with the body under the doors and behind the flares being at such diferent heights. If the flash wasn't lighting up the undercaraige it probably wouldn't be so noticable

quote:

---

Originally posted by Chris S:

quote:

---

Originally posted by RENEGADE:
rear shock tower: http://community.webshots.com/photo/107946507/107946987fQiIDX

---

Is that just bolted to the bump-stop extensions?
Looks easy enough to fab.
Better fix the rust holes in my hatch floor before I cut the exhuast that short though.

---

Yea, its bolted to the bump stop extension. The extensions are welded to the unirails wich are plated with 3/16"

Got a roof rack
Also decided to buy a D44 and put it in instead of the 35C, so that's another $250 gone.

Ren how much lift and what size tires are on the xj? I found a 90 and mama wants to build so she can chase me.

I had a RE 4.5" lift with 1" coil spacers up front. Be sure to get the full packs for the rear...I got the add-a-leafs and they started to sag withn 2 months so I replaced them with full packs from RE. For tires I was running 33x10.50-15 BFG M/T's on factory TJ 15x8 Canyon wheels (5.25" backspacing) this was an excilent set up that worked VERY well with minimal trimming needed, however you will have to adjust the steering stops to keep the tires from rubbing on the LCA's.


....I miss my XJ ....but I just wont get rid of my YJ!