expo xj on a budget

[IronRoberts73]

Well I got a little done today with the rain. Picked up new motor mounts to kill more rattles and clunks and installed a push bar on the front I bent up from 1 1/2" tube. I also stripped the door trim and painted the rockers with body armor bed liner spray bombs.

 

[IronRoberts73]

I got everything painted with bedliner and reattached this weekend. And during the process noticed a major mistake by the PO the left rear flare was mounted on the right front lol. I slowed hopefully stopped a few leaks by tightening a load of Tcase and other bolts.
Now im working out a design for my storage unit in the cargo area. Incorporating both 120V and 12V outlets air and water connections and covered storage for tools recovery gear and parts.

Cheers!

 

[IronRoberts73]

Well I managed to tear up my AC joint in my shoulder so I have been off work since last week, but I have been able to do a lot of cleaning and some of the interior work. I started by pulling the headliner and recovering it with some cheap black Jersey material from jo annes. Next was cleaning up all the accumulated dust and trash from under the seats and around the interior panels.
I wanted a place to Stowe my tools gear and other maintenance supplies I started by pulling out the rear cargo mat and using some cheap totes to set the height of the cargo deck. Next I cut a cardboard template to fit tight side to side and from the rear seat back to the tailgate. I used 2x3 studs for the framing and turnbuckles to secure it to the floor I then used the template I cut earlier to layout and cut the cargo deck from 5/8" plywood. After I test fit the parts I covered the deck with black auto carpet from wally world and secured to with #14x 1 1/2" wood screws. I then secured 8 tiedown rings around the perimeter and mounted my fire extenguisher to the top. I'm almost finished with the interior upgrades that I can handle one handed, next on my list is mounting and wiring up my inverter for 120ac and 12vdc plugs and setting up the OBA tank regulator and air lines.

 

[IronRoberts73]

 

[IronRoberts73]

I hope this weekend i can install my new steering stabilizer I ordered a dual kit from rustys off-road to hopefully kill the last bits of my death wobble. I also picked up my 4 gallon air tank for the OBA setup yesterday it's a RV air tank used for the air over water pressure system. Down the road Ill be able to plumb a onboard compressor into it but for right now it will just be filled by my shop compressor as a holding tank. Plans are to mount it inside the frame rail and run the lines up into the rear cargo area to the gauge and quick connect for filling and use.

Cheers!

 

[IronRoberts73]

Well its been a couple of weeks since I posted a update work has been crazy we moved into a new house and my weekend expos project has turned into my DD. I have started making a few steps toward setting it up though with small projects I can finish in my limited free time from work kids and moving.
At this time I have finally killed the DW with pretty much a fully rebuilt front suspension and steering.
I installed a temporary fix for the lift to level it out while I'm loaded with all my gear. Rustys add a leaf and a small lift block. I also installed a cheap cobra 19xd cb and a 48" ratshack antenna tuned with my dads trusty old rf meter from his CB days.
I also ditched the thrashed oem shocks and installed a set of rustys hydro shocks with much more travel. The shocks were the factory installed units and static they were at their extended limit.
I wanted some better tunes for my hour commute to and from work so I installed the pioneer head unit replaced the door and soundbar speakers and added 6x9s to the load deck in back. Then I installed a kicker 10 inch comp sub wired through a cheap Dual 400 w amp and stuffed the sound bar and the 6x9 boxes with fiber fill.
I stared removing the factory roof rails and picked up the material to build a full length roof rack similar to a baja style I saw on a xj years ago. It will have 2 forward facing 2 45* forward facing lights and 2 rear facing work lights along with the spare mount hilift shovel and axe.
I have already installed a main battery disconnect switch for safety and security so it was easy to build a aux battery system to run the 1k Watt inverter and extra 12v outlets. In using a 10 watt solar panel that will be mounted underslung beneath the roof rack to protect it tom limbs and road debris and running it through a controller to keep the aux battery charged and to protect it from discharging past the safe point.

 

[IronRoberts73]

It's been a while since my last update. Sine our last installment I have finished the roof rack installed new bearings crush sleeve oil seals and lube in the rear. just in time for the clutch to take a dump. Apparently the PO had the tranny overhauled and didn't bother to turn the toasted flywheel. Causing the flywheel to eat the clutch disk and start a hellacious chatter and slippage. Luckily my father in law drives a wrecker he towed it home for me and I started tearing into the trans. I decided while I had it on the ground I would strip it down and replace gaskets seals and anything showing signs of wear. Good news is everything looks new in the trans I figure while its down I'm going to take the time to clean tighten and check everything I can. So far I have cleaned and re painted the trans, transfer case, crossmember, control arms, and rear axle. Today I finished the engine oil leaks with a pan gasket and a valve cover gasket. I also replaced the water neck gasket and checked the thermo. Still waiting on a throw out bearing and a pilot bearing before I can reinstall the tranny and I need to order the ujoints for the front driveshaft. Honestly if all goes well I hope to be finished with it by next weekend then it will be out to the ranch for a shakedown run.

Pics following soon.

Cheers!

 

[IronRoberts73]

The freshly cleaned engine compartment with a quick coat of paint on the valve cover.


My almost finished AUX power panel I still need to build a cover for the wiring and fuses.


I installed some wire shelving as protection from shifting gear breaking the glass and as attachment points for small items.


The condition I found the transmission crossmember in no wonder i had a vibration in the driveline.


My solution, Not for the weak of heart *grit your teeth squint and pump the jack check the straight edge hope the strap dosent break*


Starting my $55 roof rack


Managed to bent mirror image offsets for the top rail.


Starting to look like something.


All loaded up and waiting for transmission parts.


Cheers!

 

[Mekcanix]

Very nice, looks like you got it all figured and planned out nice job

 

[Nathyne]

love it! need to remember to borrow an emt bender from work and make myself a roof rack like that! only worry for me is the fact that the pipe is galvanized not too healthy to weld did you do anything to take the coating off?

 

[IronRoberts73]

I sanded back the joints a little but also wore a nosh mask that stuff can give you a nasty headache and nausea. EMT really welds clean with my el chepo harbor freight mig.

 

[xjman88]

Nice xj man. Makes me really miss mine. Nice budget mods. Ive built my zj grandy on a budget as well. I see your Marine Corps sticker. Thanks for your service. Us vets seem to have great ideas for our builds. Again nice build and i plan to follow it.

 

[Eaglefreek]

Looking good. Are you an electrician? It usually takes quite a bit of experience to make bends like that.

 

[IronRoberts73]

Xjman88 I was a medical discharge from boot (destroyed my knee) so I couldn't serve but my son is in his 4 week of boot at MCRD San Diego. Thank you for your service.

Eaglefreek I have been in the electrical field for close to 12 years most recently as a I&E tech I run stainless steel pneumatic and hydraulic tubes among other things for the oil and gas industry. Think fuel and break lines from hell lol.
Thanks for the complements gents I cannot wait toget her back on the road.

Cheers!

 

[ox4mag]

It's looking great! By the way, I just noticed you're in Houston. Whereabouts are you? We're in The Woodlands and it's always great to meet fellow 4x4 adventurers.