Jeep XJ Pop Top Camper Build

XJlimitedx99

Active member
Thank you for answering all of my questions. When it comes down to it, putting the top on doesn't seem incredibly complex. Its pretty straightforward.

One detail that I would definitely incorporate is a cage. I consider my XJ a wheeling rig first, camping rig second, so to me the cage takes priority. I really would like the cage to be external up the A-pillars and down the length of the roofline at the gutter (really could've used some protection at those spots last week when I got into a tree at an awkward spot on a trail). I have not quite envisioned a way to do that cleanly with a pop top.

The top would need to be carefully notched out around the tubes to fit tight to the roof and the tubes. Not impossible. The bigger obstacle I see is getting the canvas to play nice with a hybrid cage structure that passes from external to internal. There is space in between the fiberglass top and the canvas where the tubes could pass down through the roof and not interfere with the canvas attachment, but that seems it could get complex with up/down bends to make that work.

Just food for thought for me. I have about 25 projects on the Jeep that take priority over the top, so more of a pipe dream at this point. Maybe in a couple years.

I really like what you're doing with shock hoops by tying into the shackle mount. Keeping the suspension mounts rigid is frame design 101. Those shocks are awesome too. There's just something about leaf springs and bling shocks together that gets me going.

Check out this post in my build thread to see what I did with my shock towers in the rear if you're looking for some ideas. I always enjoy seeing other people's takes on similar projects.

edit: I have been following on YouTube. I appreciate the effort you've put in to film your work and make videos. I know that's not easy. People have told me I should get into that, but I don't know that I have the drive to put in the effort to make good videos. Good job.

I deleted Instagram off my phone awhile ago because It was a time-suck. Its nice not death-scrolling for awhile, but I do miss out on some good information like what you're posting over there.
 
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Thank you for answering all of my questions. When it comes down to it, putting the top on doesn't seem incredibly complex. Its pretty straightforward.

One detail that I would definitely incorporate is a cage. I consider my XJ a wheeling rig first, camping rig second, so to me the cage takes priority. I really would like the cage to be external up the A-pillars and down the length of the roofline at the gutter (really could've used some protection at those spots last week when I got into a tree at an awkward spot on a trail). I have not quite envisioned a way to do that cleanly with a pop top.

The top would need to be carefully notched out around the tubes to fit tight to the roof and the tubes. Not impossible. The bigger obstacle I see is getting the canvas to play nice with a hybrid cage structure that passes from external to internal. There is space in between the fiberglass top and the canvas where the tubes could pass down through the roof and not interfere with the canvas attachment, but that seems it could get complex with up/down bends to make that work.

Just food for thought for me. I have about 25 projects on the Jeep that take priority over the top, so more of a pipe dream at this point. Maybe in a couple years.

I really like what you're doing with shock hoops by tying into the shackle mount. Keeping the suspension mounts rigid is frame design 101. Those shocks are awesome too. There's just something about leaf springs and bling shocks together that gets me going.

Check out this post in my build thread to see what I did with my shock towers in the rear if you're looking for some ideas. I always enjoy seeing other people's takes on similar projects.

edit: I have been following on YouTube. I appreciate the effort you've put in to film your work and make videos. I know that's not easy. People have told me I should get into that, but I don't know that I have the drive to put in the effort to make good videos. Good job.

I deleted Instagram off my phone awhile ago because It was a time-suck. Its nice not death-scrolling for awhile, but I do miss out on some good information like what you're posting over there.
Right on!
Yep looks like lot's of reinforcements on your end as well.

Looked into the idea of a boxed rear shock mount - but in trying to fit all this under/around a bed platform the tube would keep a generally smaller footprint. Seconded on the endless list of projects - the camper build scrambled some effort away from the other tasks at hand (tubing/armor, adding swingout to the rear bumper, etc, etc) - slowly but surely it gets a bit of work and design here and there outside of work & life.
 

XJlimitedx99

Active member
Just came across this old thread while searching cage stuff. I thought his method of attaching the roof sliders (as he calls them) and the internal hoops was really cool and would work well with a pop top. I would probably add in some more triangulation, but something a bit different from what I typically see.
 
And we’re back - returning to some unfinished projects on the cherokee camper build.

With a little Jeep Speed inspiration the rear finally got some full-size shocks. King 2.5” x 12” Travel. Remote reservoir w/ adjuster clickers.

Since these needed to go through the floor to fit, it opened a whole new can of worms. How to keep the Jeep interior sealed from weather while allowing full travel/flex.

What started as a 3” hole snowballed into a new project when I saw just how tight clearances would be between the unibody and wheel wells. In comes the aluminum wheel well boxes.

These box out the shock space around the wheel well and allow for more than enough clearance with a clean package. They’re built around a Kenworth shift boot and bolt through the xj wheel well.



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Next up will be tacking (and later welding) all shock hoops and mounts in place, test cycling things and getting bump-stops and limit straps installed.
 
Got the lower shock mounts cut and welded today. These will tie into the leaf spring U-bolt plates on the XJ.

Few changes to how I want the shock hoops to fit in the rear of the Cherokee. Then will be ready to cycle the suspension and start working towards limit straps and bumpstops.

The hoops will be getting a cross tube as well to tie things together. Plan is to set the cross tube at the level of the bed platform.

Feels good to get some wrenching in - this thing’s been sitting for far too long.


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More little details while waiting on parts. Started cleaning up the leaf springs.

These were originally from a junkyard pull and never got the full service they should have. Rubicon Express 3.5” Superflex Full Leaf Packs (RE1463).

Prepped, soon to be painted.
 
Bushings came in from Barnes today. Rubicon Express doesn’t offer a poly conversion kit for the XJ / Cherokee springs so on to improvising with a DIY.

The smaller (shackle) side was easier to source with a common 1.5” OD poly bushing. The frame side was trickier, requiring a 2x3” outer dimension with 9/16” bolt hole.

Found this 2x3 DOM sleeve setup that pressed right in place. Went in great.

Happy with how these fit compared to the “OEM” style rubber bushings.


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Test cycling the xj suspension to check everything clears. Have the travel running a full 10” - with a ~1” down travel cushion to account for limit strap stretch, and a 1” up travel cushion at full bump. Keep the shocks happy for years to come.

Pictured above is fully stuffed - where things will sit at full bump on 33’s.

The install is turning out to mirror Jeepspeed suspension for the 1700 class.
12” shocks in the rear w/ king bumpstops. Looking forward to taking it through the desert whoops when all tied together.
 
King Air Bumpstops fitted and sleeved through the XJ rear unibody rails. The upper thread and schrader service valve stick just through the floorboards.

This is a set of 2” x 2” king bumpstops. Similar to a typical Jeepspeed XJ configuration.

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