xaza's 94 XJ Build

[xaza]

Latest update, been slacking a little but we have a lot going on around here right now.

[dscowell]

Very nice! I like how it's bolted to the bumper instead of welded. Most of the time I see people weld the cage right on to the bumper and I always wonder how they'll get there fender off if need be.

[xaza]

The fender will not be coming off again but the bumper may end up needing replaced or removed to pull the motor.

[Kurtis]

I've seen the work that's been done on your exterior OK I really like it he's done a hell of a good job I've been actually talking to him about doing a couple on the jeep that I have so it's turning out really really well

[xaza]

Work continues on the truck. He took a moment to get shock mounts moved while waiting for some more metal. If all goes well we should be hitting the trails soon. Expect I have 1-2 weekends of maintenance when we get it back and he expects to be complete soon.

[xaza]

Today is such a glorious day that marks the start of a bunch of work on my part. Truck is home and ready to get painted, thanks Aaron for bringing it home. I have shown quite a few pictures of the build process that Aaron provided me along the way, but not all of them! For the full 700+ pictures check out this link.
https://photos.google.com/share/AF1Q...JJcDhEM2U2MkZ3

[theluke19]

Paint?! I liked your color scheme!!!!!

[Rick]

awesome!!!

[xaza]

color scheme is staying the same, just making tubes and such black and few spots of white to repair from the welding process.

[Hypoid]

I look forward to seeing it in person! How much does all that tubing weigh?

[xaza]

Aaron estimates tubing to be about 400-500 lbs.
Put together my list last night of issues needing addressed before we take it out.
1 - Paint tubing, body panels and axles.
2 - Wire in and install light bar
3 - Replace worn u-joints and bushings
4 - Replenish spare parts tote
5 - Slip yoke eliminator and rear drive shaft
6 - Top off axles after applying teflon tape to plugs
7 - Move axle to 2" back, 3" cuts it close to rubbing on the back with no load, while loaded I expect potential issues
8 - Bed liner cargo area and reinstall interior that is being used
9 - Grease all zircs
10 - replace relay and reinstall switch for aux fan
11 - Diagnose and repair CB issue
12 - Repair hood latch again
13 - Check and tighten bolts ; can't forget to tighten meh junk; missing sway bar bolt (or take off swaybar)
Going to get started today on painting, with any luck we can complete that. Going to be very difficult to get some areas of the cage, so I am contemplating a roll on bed liner for it also. Thanks again to Aaron for the fantastic work.

[Brucker]

You are very welcome Cliff! Happy to be of service. It was wonderful working with you and your awesome family. Hope to get the chance to spend some time wheeling with you all in the future. Thank you so much for supporting a small local shop!

EDIT: don't forget to replace the missing swaybar bolt!!! I didn't see that on your list. And bedliner may be hard to use around the tubing. A decent trim spray gun works well, as well as regular rattle cans. Did you find the prep stuff you were looking for on the cheap?

[Brad]

Wow! Incredible work Aaron.

[xaza]

Decided to coat cage and fender armor in bed liner. It added texture and tied into the bumpers very nicely. Truck bed liner went on smooth. Scuffed, prepped and laid down. First time using so it isn't show quality perfect but we mixed with mixer regularly and kept texture fairly even. Had way too much bed liner mixed so did rear cargo hatch also.Will have to get some better pictures tomorrow.

[xaza]

Aaron I did find the prep stuff cheap, at Walmart. Prep pads were $1 a piece so I used a couple of them as well as rags and Mineral Spirits as recommended by instructions for bed liner application. Mineral spirits were like $5 and I had the lint free rags. Thanks for catching that sway bar bolt, it is on my list in my notebook but I missed typing it in. Editing it into original post.

[Brucker]

Looking good Cliff! Any chance I could talk you into shooting a photo or two of the top of the exo now that it is coated? And do you mind if I steal some of your photos to add into the rest of the photos I took?

[xaza]

Been busy getting truck ready to go. Got SYE installed with another drive shaft from Bill. Took truck to car wash and it drove good. Had some noise from rear brake but got it resolved.

While setting past several months truck had grown some surface rust. It wasn't washed after last trip out in February. Wire brushed it clean and touched up rubberized undercoating and paint. Truck looks much better now.

[Chris]

Damn Cliff (and Aaron) that's looking great!

[xaza]

My list is getting shorter!
1 -
2 - Wire in and install light bar
3 -
4 -
5 -
6
7 -
8 -
9 -
10 - replace relay and reinstall switch for aux fan
11 - Diagnose and repair CB issue
12 -

Got second coat of bed liner done today with a new hood release cable. Looks like I will have some dirt underneath truck next weekend!

[xaza]

Got truck out yesterday for a quick run.Had a great trip out and truck did very well. As usual there is a new list now to take things to the next level. Primary issue needing resolved is a cracked exhaust manifold, will likely replace with a JY one until I can get a header. Radius arm still hitting factory lower control arm mount, will need to clean it up more. Coil springs are crushed at the top, will be looking to replace them with a more solid spring. Need to replace e brake cables and lower radiator hose. With steering working so much better since Currie upgrade, going to change pitman arm back and see how it drives with things properly aligned again. Still getting noises from y-link, going to pull apart all bushings clean/inspect/grease and replace as needed. Had a last minute oops on Saturday that almost prevented us making it out, had to grind off some bolts for the axle end bolts. New t-bolts should be here this week to get those right. Some movement in leaf spring mount, going to box it in and reinforce it. Thinking about using the Rusty's but welding in instead of bolting and completing it out to fully box it in.
http://www.rustysoffroad.com/rusty-s...-brackets.html
Rear doors do not open enough to access back seat anymore, working on something unique to resolve this issue. If we can pull it off it will be extremely sweet. This will take months and some JY doors to pull off so don't expect this to unveil soon.

Here is my favorite shot from yesterday, shows driver side bump stop not doing it's job. Wheel was all up in the wheel well, drive shaft hit radius arm and coil spring over compressed