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battery tray looks like a nice piece of kit

With the bushings in place is was FINALLY time to start putting things back together. My old bolts were all in pretty rough shape, I soaked them in Coca Cola (yup, seriously) and then used a dremel wire wheel to clean them up but they still looked pretty gnarly, so I ordered new ones. The...

After upgrading the threaded rod in my "press" to 7/16," I still ended up breaking the rod after getting the bushings about 3/4 of the way into the leaf spring eye. You can see in the image below that the eyes were a little small and they were deforming the outer metal ring of each bushing at...

I applied the Eastwood Internal Frame coating tonight on the rear 2/3rds of the uniframe. I was glad I bought two cans because I used them both completely. It made an awful mess but I had a full coverall suit on and plastic over my garage floor. The green over-spray isn't great looking on the...

Jswanson and Anak, thanks for the insight. I'm going to use both pieces of advice. Regarding the "receiver cup" on the bottom side of the make-shift press, I think you're absolutely right, Anak. I was going to drill out a hole in a piece of hard wood and hope that would nest against the leaf...

I started pressing the leaf spring bushings into the leaf springs tonight. I started with one of the smaller bushes; greased it up and used some 3/8" threaded rod and a stack of washers to fashion a makeshift press. The press worked well even though I was deforming the large washers under...

Thanks JSwanson. I'm trying to pick away at this but haven't had much free time at my disposal. Last weekend I only managed to wire-wheel a few spare parts. Afterwards I hit them with a rust converter and primed them tonight. I'm painting the shackles, gas tank straps, rear axle brake line...

Great looking XJ, well done. I'm about to start installing the same suspension kit from DPG. I wasn't planning to do any fender cutting but your jeep has me thinking twice about those flat bushwacker flares. I'm planning to try and keep mine looking relatively OE but those flares are pretty...

Pleased to report that the morning after the Chassis Saver looks like it is living up to its billing. I spent about ten minutes under the Jeep this morning with a warm and fuzzy feeling. I reinstalled the penultimate exhaust bracket and it really shows the difference: I had covered most...

I think I called Mark (at Detours) when I ordered my Backbone and I asked about the Tailbone at the same time. He acknowledged that it was discontinued but was willing to make one as long as I was willing to wait. It took a long time (months) but he came through for me. I got lucky with the...

These two are responsible for the downtime between my projects and they're also the ones who I hope benefit from all this Chassis Saver work! Finally, with the Chassis Saver complete, I can start putting things back together.

I never planned to paint the undercarriage when I first started in on this project, so while I had gone to the car wash beforehand, it was too dirty for paint. Last night I rolled out some sheet-plastic in my garage, put on a raincoat and went to town with some soap and degreaser: I needed to...

So I kept finding rust. Nothing too bad but evidence that I needed to do something to stop it or risk the jeep deteriorating beyond the point that I felt like I could save it and/or bother spending any more time and money on it. This spot where the unibody frame meets the rear is a good...

Anybody have a good way to rotate a photo after uploading? Some of my iphone photos orient themselves correctly on my computer/phone and then up sideways when I upload and post them.

I started regularly applying PB Blaster to all the necessary bolts in the days leading up to the project. The U-bolts came off with a sawzall and the leaf spring bolts were so frozen that I ended up using my jack stand to lever on the end of my breaker bar. It worked but I pumped the jack with...

At some point this past year I swapped out the alternator but just swapped in a like-kind unit, which isn't very exciting like suspension replacement... This jeep only has 66k on it, but the suspension was all original as far as I can tell and was spent. I ordered a 2.5" OME suspension lift...

So when you don't install the spare tire carrier and live on a small island, you think its ok to drive around without a spare tire, even when you go camping in the winter, miles from the nearest real road and guess what happens? It was pretty cold and windy this particular night, so we pulled...

My wife and I had identical twin boys last year, so you can probably guess why this thread hasn't been updated. I've been chipping away at Marge slowly and while she doesn't currently have a rear axle, she's in better shape than she has been in a long time. Last summer I did manage to install...

Sportsmobile West just put out this video:

Thanks guys. I like the plaque idea too. Where does one get the plaque key-chains? I found a thread about them on DefenderSource. Is that right?