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Thread: SynergyXJ Re-Build

  1. #21
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    Default Re: SynergyXJ Re-Build



    Misfire DTC trackdown conundrum

    I'm delayed on this post, I know ya'll were on the edge of your seats. I went through a crazy chase of about 8 trouble codes and finally tracked down the cause of the misfire. 10 days ago, I could have walked you through the details, but I'll save it and say the misfire has been solved.

    Other rig updates:
    - The truck is running pretty well but having some heat issues under sustained load, such as big hill climbs and high speeds. I hope to resolve that by replacing the 15 year old, likely clogged, radiator with a 3 row performance one or something.
    - The new lift is not flexing in the front as much as I expected. More research will be conducted.
    - Edit: dieseldoc tells me they'll break in and partially because I don't have much weight in the front. I believe it.
    - After running my fiberglass fender flares for over 8 years, I decided to go fender-flare-less and took them off.
    - I made some new square steel tube rockers.
    - x44 (my off road data software) is coming along well.

    Fabrication posts coming soon!

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    Default Re: SynergyXJ Re-Build



    2x5 Square Tube Rockers
    Fabrication Pictures!

    My first set of rockers were puny and needed an upgrade, then the stock rocker panels began rusting out.



    Cut it open... Yup, there's more rust. There was even mud in the passenger side.




    I got some 2"x5"x1/8" wall square tube and welded caps to the ends. I debated a thicker wall and decided on 1/8" and adding 1/8" angle to the outer corner, so it's light but thick where it needs to be. The discs to the left were welded to test out my new Millermatic 211. It works!



    ...welded the tubes in...


    ...


    Painted and rubberized:



    I didn't end up welding the angle on. It's still way better than it was. These ones aren't rusted through! There were a bunch of holes where cables mount that could allow water in from the inside in case of flood into the area between the passenger area wall and the rockers (stock design), so I'm planning to fill that with expanding foam. That should displace potential water and prevent future rust.
    ___________
    Engineer - Artist - Innovator
    Instagram: @jeepstream
    2000 XJ Chop Top Sport & 1992 XJ Backup Rig

  3. #23
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    Default Re: SynergyXJ Re-Build



    schemin'
    ...color scheming...

    Oh yeah, I should have posted this earlier! Here's the inspiration for the color scheme of the suspension and steering components:
    (found from Googling "cherokee steering components" or something - http://www.cherokeeforum.com/f2/fron...ponents-53018/)






    This way if my spotter doesn't know the parts names, they can say "your sea foam blue thing is on a rock" and I'll know it's my drag link. I've even started thinking of colors as "drag link blue".
    ___________
    Engineer - Artist - Innovator
    Instagram: @jeepstream
    2000 XJ Chop Top Sport & 1992 XJ Backup Rig

  4. #24
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    Default Re: SynergyXJ Re-Build



    Front "Bumper" and Transmission Cooler

    I put bumper in quotes because it's really more of a winch mount than a winch mount bumper. It's just two 3/8"x4" plates to extend the frame and some 1/4"x2" steel angle to mount the winch. My goal was to get the winch as high and tight in as possible to retain as much approach angle as possible. Recently, my fabrication projects have been totally in my head, no sketch or anything, but I did CAD this up in SolidWorks to see how tight in I could get it. Of course, some front grill trimming is needed to get it really in there.

    After burning some tranny fluid (and being able to recognize that smell), I put a transmission cooler in as well. Since I was trimming the grill, this was the time to do it. Project double up.


    Pseudo Test Fit:





    SolidWorks Model:




    I tried to take a picture while I was plasma cutting, but it was hard.





    Here are the "frame extenders" - 3/8" plate plasma cut to size. This will bolt to the frame then eventually be welded. You'll also note the shackle holes. I stacked up some scrap 3/8" plate on both sides for a total of 9/8" thick, then drilled a 1" hole.





    Shackle Test Fit (excess 3/8 plate will be trimmed)





    All welded up and transmission cooler is partially plumbed. I may route the hose differently, I dunno.




    Then I painted the winch and bolted that mug on.
    Jah Winch! (we be tuggin ya irie, mon)



    And then I didn't take a good picture when I was on the trail testing it. But I will take a good picture.



    The winch has been on for almost a week and has been involved in 5 recoveries between 3 trucks. Seems like it's still snowy on the trails.
    ___________
    Engineer - Artist - Innovator
    Instagram: @jeepstream
    2000 XJ Chop Top Sport & 1992 XJ Backup Rig

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    Default Re: SynergyXJ Re-Build



    Looks good Evan.
    So is this a secound winch? Or is it te one from the back, repurpoused?

  6. #26
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    Default Re: SynergyXJ Re-Build



    Looks great Evan Its a complete rebuild from the last time I saw your XJ, lift,tires new rocker,bumpers

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    @EKXJ87 - Thanks man! I've been meaning to hit you up, let's run a trail sometime soon.

    @dieseldoc (et alia) - This is the winch from the back. I was tired of that thing sticking out the back of my rig, catching rocks, finally bent the fairlead up some. I have a better angle with it in the front, but I may move it back to the back after I chop the top (the back hatch was the limiting factor keeping the winch out and low).





    Approach Angles - 54 to the winch mounts and 65 to the stock front without stock bumper, a substantial difference! I'm not sure where it would have been with the stock bumper, but I would guess it would be pretty close to the 54 mark.
    ___________
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    Instagram: @jeepstream
    2000 XJ Chop Top Sport & 1992 XJ Backup Rig

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    Default Re: SynergyXJ Re-Build



    CHOP THE TOP should I dare ask what your plans are?
    I'm about 99% done with my XJ changes for the year so I'm ready to run some trails once they open.

  9. #29
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    Default Re: SynergyXJ Re-Build



    Engineers always have the most detailed build threads. Nice welding!
    ___________
    _O IIIIIIII O_

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    @Paul - Haha, yeah we do (see below). We're also more likely to include CAD drawings. Thanks!

    @EKXJ87 - Plans? Ha! I'm going to draw a line and cut then figure out what to do next.


    In all seriousness, I have put a lot of thought into the project. Although most of the process will be a do some then figure out what to do next, I do have grandiose ideas for the whole thing. Off road utility and organization are at the core of the development.

    Reasons to chop:
    - Rear passenger quarter panel area keeps getting smashed and needs body work anyway
    - Inside/Outside area [electronics inside / spare tire & gas outside, etc.]
    - Future electronics projects are dependent on the above
    - Reduce back top corner area that hits things
    - Room to raise gas tank (clearance and access, integrate skid plate)
    - No back hatch -> the rear winch can go back without sticking way out the back
    - Rear window being closer results in increased viewing angle
    - The back hatch is the only part of the XJ I don't like (aesthetically)
    - I currently have the time available for a consuming project and I'm totally obsessed with build projects, I don't even have a choice. I HAVE TO!

    General Plans:
    - Move the back hatch up to the C pillar and weld in place, retaining rear window and wiper
    - Remove ~3' of middle of headliner
    - Partial cage around and above the new truck bed area (on the way to a full cage)
    - Trim quarter panel area, taper in
    - Move lights horizontal and more centered, use recessed LEDs
    - Raised floor above raised gas tank
    - Spare tire mount above gas tank
    - Equipment and air compressor boxes


    Status Update: I have everything out of the rig, back hatch off, rear windows out. Probably cutting tomorrow.

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    Default Re: SynergyXJ Re-Build



    Under the knife again....
    not like we can go play much....
    All the north trails are snowed in still.

  12. #32
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    @dieseldoc - best wishes, man, we'll get out and play soon.

    Winch Control Hijack [part 1]

    You have probably noticed those boxes on the top on nearly every winch out there. You may not have noticed that I've never had a box on mine. I dislike them for no legitimate reason, perhaps aesthetics. My box was inside the trunk in my last rear-winch setup.

    With the new front winch setup, I have no idea where to put this thing. It's way too big to fit anywhere in the engine compartment and I really don't want it anywhere outside. I planned on putting it back in my electronics area, but then I'd need three 10 foot runs of 2 ga wire. So I opened it up and the actual contactor is about 1/5th the volume of the enclosure. Just mounting the important part will be much easier. Then while I'm at it, might as well hijack the controls!


    Small relay in a big box:



    Mounted the relay on the top of the firewall:



    Control connector on the top of the grill, easy to access near the winch:





    Next plans (part 2) are to wire a winch control center on my dashboard. This will include an in and out push button and the receiver for the wireless remote.



    Status Update: I have started cutting and welding the chop top! Pictures coming soon.

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    Default Re: SynergyXJ Re-Build



    Its amazing how mqny floks dont relize they can have remote in cab controls.
    the relay/solinids is what hadles the heavy loads....
    you will like in cab controls for sure.

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    Shweet! I envy your solid works talent.
    ___________
    1990 Jeep Comanche

  15. The Following Member Says Thanks to dscowell For This Post:

    SynergyXJ (May 25th, 2015)

  16. #35
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    Default Re: SynergyXJ Re-Build



    Chop Chop!!

    I started chopping! Big things. I'm pretty stoked on how it's coming out.





    Wanna see something crazy? When you plasma cut steel backed by fiberglass insulation, this happens.

    crazy stuff

    I put the insulation in 10 years ago. It seemed like a good idea at the time. I tried to get it out before cutting, but apparently some was still in there.


    Trimmed up the back hatch and welded it in:


    Cut scrap slivers to weld in the gaps




    More to come (lots of work left)....

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    Looking good man.
    I sure hope you have a bucket of water around when you plaz.....hate to see you burn up.

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    @dieseldoc - Do you mean water to put out fires ignited by shooting vaporized steel at flammable things behind the cut? I've never really had issues with fires before this project and this time was because I had an asphalt based sound dampener on the sheet steel and that stuff flamed like a small flame thrower - literally 2 foot flames. I've never seen that before with plasma. I kept a spray bottle around after seeing that.


    Chop Update

    I mentioned this back passenger corner always gets nailed into obstacles. So I cut it all out. Cage tube will go in this area.




    Cut a chunk of roof out to close up the back. I'm not sure why so much of the hatch got cut off, but we'll fill it in.




    I took it out on the street today! I'm at least a week or two from completion, but great progress.

    ___________
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    2000 XJ Chop Top Sport & 1992 XJ Backup Rig

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    This is awesome! Can't wait to see the finished product. A little off topic, how do you like your Cooper tires? I need to replace my duratracs soon and I've been thinking about those- I met a Ranger at McInnis Canyons that ran those on her truck, she had winches front and rear and a highlift on her trailer that looked like it had been to war. She said those tires were the best she had ever run, both for the nasty mud out there and winter streets.
    ___________
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    Default Re: SynergyXJ Re-Build



    I was going back to ask about your tires too, are they the ST-MAXX MT?

    great job on a very useful, practical, well-thought-out build too!!!
    ___________
    "The mountains are calling, and I must go."
    -John Muir


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    Armored, Locked and Ready for Rocks

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    Default Re: SynergyXJ Re-Build



    Nice comp cut work there Evan.
    ya I was talking about fire prevention.
    It looks good man.
    One of the better looking comp cut and cab cuts I have seen on an XJ.

    We hope you are finished soon so we can get out and wheel.

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