The 2drx4 build, a Cherokee.

2drx4

Adventurer
As this build progresses, you'll realize a few things about me:

1. I change my mind a lot
2. I have no clue what I'm doing


So, onto the good stuff.


I acquired this XJ through a bunch of schinanigans. It belonged to a co-worker's girlfriend, and I had made some drunken deal that when she bought a new vehicle I'd buy this pile. Granted I'd never even seen it when I agreed to this. Being a man of my word, when I got the phone call I headed over with cash in hand.

Did I get ripped off? Uhhhhhhhhhh......

Not the worst looking from here.
P1010058.jpg



Swing out spare - doesn't interest me.
P1010060.jpg



Rockers were optional I guess.
P1010063.jpg



The B-pillar took a hit and is dented in, the door frame is twisted, and generally there's dings all over the place.
P1010061.jpg



The good stuff:

4.0L/AX-15/NP231. Not a bad combination. Personally I'm more of an AW4 guy, but whatever.
1990 - it's a renix, I understand it.
2drs, since I'm young and stupid.

The bad:

The rust, dents, dings, ugly paint.
Clutch slave or master is out.
Water pump MIA.
No AC, although I only want it for the pump. It's probably a good thing actually...
10 000 other things. Most of which contribute to the general unreliabilty of the rig.

My 'Plan' (like I really have one)
Build what I consider a 'mild' wheeler for extended camping/expiditions. I no longer live in an area where there is estabilished hard-core wheeling, and you can't do that alone. I'm thinking I will probably run about 2-3" of lift and some 33s, along with some body mods. The back seat and cargo area interior will be axed in favor of making enough space that I can sleep, and some storage. I'm planning dual batteries but haven't entirely sold myself on how they should be done. OBA is needed, and I will run a sanden style compressor out of convenience. I would like F/R winches, but do not have the cash right now, so they'll be a 'later' thing. However, the biggest emphasis of this build will ultimately be the reliability of the rig as a whole (more on this later).


So, the first order of business was to change the water pump and serpentine belt. The old belt got eaten as the water pump had played up to the point that the belt got thrown into the mechanical fan. I changed the lower rad hose while I was at it, the old one looked rough.

Serpentine belt shredded around fan:
P1010070.jpg


Since I need a new belt, I did the idler pulley delete. No sense keeping a useless pulley. Which I've had fail before, not a good thing, as the belt smokes off in about 30 seconds.

Reference picture of belt routing minus the idler:
P1010006-1.jpg


Part number for the belt (upside down so it's easy to understand)
P1010007.jpg



Started pulling out the interior junk. Found that the roof braces had de-bonded, probably as a result of whatever had hit the B pillar on this thing before. I think I'll just use some 3/16" bolts to re-attach it, and seal them with poly or something. I'm undecided, but definatly not going to bother replacing the roof to fix the dent.

P1010077.jpg



Rust, rust, rust...
P1010078.jpg


At this point I figured it was at least a solid starting point.
 

2drx4

Adventurer
Started pulling the rear bumper off... I said I didn't like the swing out - so off it came. I broke EVERY bolt that held it on. And while I'm sure you could just unbolt the bumper from its brackets, I was not interested in that game (torx). So I just cut it apart...
P1010086.jpg


Bumper removed, only snapped two of the bolts that hold the brackets on. Trailer hitch/boat anchor removed mostly - I had to cut one of the tabs off it as the bolt was not removable yet (still getting to that)
P1010088.jpg


I have to comment on who-ever the genius was that had installed this aftermarket hitch... Put some damn anti-seize on the bolts, I only broke 4 of the 5 that I removed (with the 6th still in place, as they installed it in a creative manner, I will remove it whenever I have more stuff out of the way). And that was after I heated them cherry-red with the torch.

Began the first of the sheetmetal mods... This part was all rusty, and really doesn't do anything for me. So, I butchered it off. Just the inital cut.
P1010089.jpg


Before you jump on how I cut all of this, I just went for it. Later I'll clean it up, I was just concerned with getting it out of the way for now.

View from inside... I'll weld in some 22ga or something in the hole.
P1010090.jpg



The pretenda-rockers had to go next... I'm going to weld in some 2x6x.188 in their place, I think.
P1010091.jpg


Mostly cut out in rough...
P1010092.jpg


All cut out. Other than the end there. I need to figure out exactly what my plan is there. I was going to use some MJ rear flares over the rear (cut and fold it), and see if that part was 'covered'. But that's kidna hack. I might just have to cut a bunch more out, and maybe patch it (heaven forbid).
P1010093.jpg



Took off most of the junk from the front that doesn't interest me... Vacuum bottle and horn will get relocated. There's more work to be done here, but not for tonight.
P1010094.jpg
 

2drx4

Adventurer
Did some more work....

This area had to be cut out... I was about half done at this point, all of it had to go. Oh yeah, there's a few cracks there, don't mind those, they're on the list.
P1010098.jpg



At this point I figured I was about done cutting this side. Yeah...
P1010095.jpg



I cut out the back of the uniframe rails to put my bumper mounts in (2x3x.188).
P1010099.jpg


Yeah, I cut that one very square... Shh. It will need to be opened up a bit more later, so I can fix that. The top shackle bolt extends too far and is in my way. Luckily it has about 20 threads more than it needs.

So I pulled it out, cut off about five threads, then ground the end to a bit of a point so it would self centre.
P1010100.jpg



Threw some anti-seize on and reinstalled. Plenty of clearance.
P1000064.jpg


(I know that's a picture of the other side, just imagine everything backwards if it's a problem)
 

2drx4

Adventurer
Test fitting the new rocker/slider. Looks like it'll work... Of course I had to cut way more stuff off.
P1000061.jpg


More test fitting...
P1000063.jpg


You can see how it doesn't extend too far back. More on that later...
P1000065.jpg


Capping the ends.
P1000067.jpg


Ugh. Was still dialing in the welder (haven't welded in 2 months), then realized it was spooled with crappy wire (I lend it to a friend when I'm at work). Of course, had I looked before I started welding, this wouldn't have happened. Anyways, I ground that part out and re-welded it.
P1000069.jpg


I cut the front of them on a 40* angle, then capped them too. At this point I was getting a little more comfortable.
P1000070.jpg


Ground smooth (same with the rear). Then I RO sanded the entire thing to promote paint adhesion.
P1000072.jpg



Shimming it all into place for welding...
P1000075.jpg


Welded most of it up. Had a minor, almost major, fire in the interior. Apparently this foam lights up really easy. Considering I was welding on the other side of the A-pillar when it lit off.
P1000077.jpg


Welded all around the top... Ain't done, but I was sick of welding. Thick steel to thin sheet it trying of one's patience. The welds vary from decent looking to horrible. I think I'm going to put a sealer of some sort over them anyways, so nobody will really see...
P1000078.jpg
 

2drx4

Adventurer
And then I started building both rear bumper mounts... Just some 2x3x.188 with some nuts welded in it. They aren't as hardcore as some people's, but I pick up 4 place on the uniframe per side, plus the 4 stock holes per side (other than the ones that have broken bolts in them, something to do sometime...) I used 1/2" GR8 hardware for no reason other than it fit the holes in the frame nicely, and GR8 has a nice plating on it so it doesn't rust as quick.
P1000079.jpg



Made the ears for the bumper mounts:
P1000080.jpg


In retrospect, those could have been made from a single peice, and it probably would have looked better. Ohwell, nobody sees 'em. Oh yeah, the new hardware is AN, I think AN6-11As, but whatever, I have lots of it and it'll work. I drilled through the stock captured nuts and will just put nuts on the back.

Of course, prior to this I figured I should remove the two snapped off stock bumper bolts. Welding a nut to them did not work. So I chose to drill them out. After dulling a lot of bits in a short period of time (I lack a bench grinder to resharpen them here, and have to do it at work), I tried using my nice lennox step drill since it has a carbide edge. I broke the end off. Swearing, lots of swearing.
P1000083.jpg


Anyways, welded one of the ears on.
P1000084.jpg


Other side.
P1000085.jpg


Main part of the bumper is 2x4x.188. I cut the ends at a 40* angle. RO sanded for paint adhesion, yada yada...
P1000086.jpg


Welded the caps on the ends, wasn't overly impressed with myself with the bead appearance, but the penetration was good. I ground them smooth afterwards anyways.
P1000087.jpg


Tacked it place.
P1000088.jpg


Keg stand! But not quite how I did them in college. Man do I ever have a ghetto shop, instead of a welding table I either use my trailer or whatever is around... Anyways, welding the bumper mounts on. You can see the shape of the brackets...
P1000089.jpg
 

2drx4

Adventurer
Got the other slider welded on. Well, half welded on. To the same stage as the other one anyways (good enough for now)
P1000091.jpg


Some of the welding went awesome, some of it was ugh.
P1000092.jpg


But I managed to get it to match the other side pretty darn well, even the slight angle they're on (they slope outwards a bit so water will run off) is the same. I have to say though, these were more time consuming than I thought. So much cutting stuff off, then putting them in place, only to pull them off and grind a bit off something else, and try again and again... But I think they'll be worth it.


Now, what I did that I do NOT like at all. Instead of doing the cut'n'fold on the rear wells, I decided to try something different. My reasoning was that I couldn't get as much clearance by just folding them as if I changed/removed the lip/pinch seam completely. Also, I had a rust issue, and I wanted to cut it out.

So, I did this.
P1000113.jpg


Basically I screwed it up so bad that I'm going to have to do some major surgery to fix it. I took 1x.125 flat bar and welded it between the quarter panel and wheel well from the inside. Then I cut off the pinch and ground everything 'flush'. My mistake was that I should have used much wider flat bar (2" or 2.5") or just done it with sheetmetal like a regular person. As it is, I've not got a properly shaped wheel well.

P1000114.jpg


I didn't even bother cleaning up the front because I'd realized it was screwed.

I'm pretty mad at myself. Normally I think about things enough ahead of time that I don't get in this situation.

But it's all for another time. I do 'tours' with my employment, and will be a long ways away for a while
 

StumpXJ

SE Expedition Society
Cool stuff man, I am currently building my tube front bumper and quickly realizing how much I hate uni-body's. Looking forward to seeing the rest. I really like the rockers and rear bumper mounts.

~James
 

JeepN95YJ

Adventurer
I can see one advantage of starting with a rusty Jeep....NO FEAR cutting it up to build awesome rocker panels and plenty of tire clearance!

Nice job. I hope to tear into the wife's WJ like that some day.
 

BigAl

Expedition Leader
Look'n good, keep the pics coming. I curious how the bottom edge of the door will go?:safari-rig:
 

2drx4

Adventurer
BigAl said:
Look'n good, keep the pics coming. I curious how the bottom edge of the door will go?:safari-rig:


It should be easy enough to make them fit. I need to cut about 3"-4" off the bottoms of them - which is rusty anyways. Then weld some new metal in the resulting hole in the bottom of the door.

If they don't turn out on the first try, I can always find more doors.
 

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