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Old December 3rd, 2011, 09:13 PM   #61
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Love how much cleaner the engine compartment looks with out the factory harness running all over it. One unfinished item may be the clearance around the radiator cap. That looks like a finger slicer if your hand slips.
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Old December 4th, 2011, 05:32 AM   #62
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Originally Posted by 1x1_Speed_Craig View Post
Nice progress, John.
Thanks

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Originally Posted by GREASYHANDS View Post
Love how much cleaner the engine compartment looks with out the factory harness running all over it. One unfinished item may be the clearance around the radiator cap. That looks like a finger slicer if your hand slips.
It's not quite as bad as it looks there, but I don't like it either. I will be doing something with it.

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I didnt pay too much attention to your gauges,I want to go back and study your build Better,it deserves it,again beatiful job.
Here's how the instrument cluster turned out.


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Old December 17th, 2011, 08:42 AM   #63
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Finally finished merging the two harnesses. Everything turned out great and I even fixed the radiator cap opening for you Greasyhands :)

The only thing left on the wiring is to figure out the O2 sensors, looks like a change from my 2005 harness to my 2004 harness. I also have to dig my speed sensor out of the t-case adapter, it broke in half somehow.





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Old December 29th, 2011, 09:46 AM   #64
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Finally some progress...

I think I mentioned before that I didn’t want a cowl hood, so I could not use the truck intake and swapped in an LS1 intake (7” shorter). On the trucks the alternator sits high and to the left of the TB. I cut the alternator/PS bracket down and made a new bracket that put the alternator lower and outboard so I could still service the PS pump.





I had a slight miscalculation when I made my alternator bracket the first time and it ended up being 2” too high. So, I redid it where it should be. I like it a lot more now.





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Old December 29th, 2011, 09:48 AM   #65
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Rear brake upgrade has been on the list since I did the axles last winter.

Worn drums and blown wheel cylinders… wonder why I couldn’t get any brake pedal.

Started with this.


I have been gathering parts for the rear disk brakes for a while.



I used caliper brackets from Ruff Stuff, Chevy ˝ ton calipers/pads and Ford rotors - it went pretty well.



Not a lot of room to work with since I narrowed the axles to XJ width.


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Old December 29th, 2011, 09:50 AM   #66
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ACOS were not on my list of things to do, but a friend upgraded his front to some King bumps and I stole them from him It was one of the easiest upgrades ever, it took about 15 minutes per side.

Stolen parts – 70 bucks is like stealing…


Called JKS to freshen them up a little.


Started with this.


Cut off the bottom and tap the washer.



Done.

Last edited by John D; December 30th, 2011 at 04:56 AM.
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Old January 3rd, 2012, 04:02 PM   #67
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A ton of work for a small update. I have been looking at front stiffeners for a while and haven't been satisfied with what I found until T&T came out with these.



I have also had a set of HD Offroad mid-stiffies sitting in my garage for nearly a year, so I finally put them on along with the T&T units. I will eventually do something between the coil mounts and the bumper.

I have heard of a few different methods for getting the undercoating off and the uni-rails prepped, but what worked really good for me was a wire wheel on a 4.5" grinder and then a light touch with a flap wheel.




I back-welded three 1/2" nuts on each side aft of the t-case cross member for future use. Probably just use it to mount a skid for now.



I also cut of the coil mounts from my front axle and put these Ruff Stuff mounts on. The old ones were too far forward after I stretched the front 2". I added a second hole here for future use too.



Coils sitting where they should now.

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Old January 3rd, 2012, 04:14 PM   #68
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Damn, my pants got a bit tight.
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Old January 3rd, 2012, 11:53 PM   #69
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wow john, your doing a lot to it this winter.
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Old January 4th, 2012, 05:48 AM   #70
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wow john, your doing a lot to it this winter.
x2!!!!

I wanna get down there and check this thing out. But I dont think I will be able to. Because, I'll walk away with jeep and garage envy.
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Old January 4th, 2012, 06:36 AM   #71
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idk if i've missed it or not but on my old XJ when i cut the rears out what i did was after removing the flares took a cut off wheel and but divets in the fender up until where the inner fender meets the quarter panel (aprox 1") then after that i rolled the cuts back into the inner fender. doing this strengthens the cuts so they wont seperate. also i installed TJ rear fender flares onto the front and rear for extra tire coverage and for just a different look.

sorry don't have any during pics. only after.


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Old January 4th, 2012, 06:38 AM   #72
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it wasn't the best looking job but this was my first jeep i ever modified. later on i cut off the folds on the flares to make them look like flat flares and sprayed them with satin black to make them look better
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Old January 4th, 2012, 06:38 AM   #73
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thought you'd also like this
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Old January 4th, 2012, 06:41 AM   #74
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best picture i have of them on the front.

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Old January 4th, 2012, 08:49 AM   #75
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Im pretty sure hes already cut like that. He's looking to go farther. IIRC
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Old January 4th, 2012, 12:57 PM   #76
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Damn, my pants got a bit tight.
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Old January 4th, 2012, 12:58 PM   #77
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wow john, your doing a lot to it this winter.
Every winter... use it six months, work on it six months.
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Old January 4th, 2012, 01:02 PM   #78
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I wanna get down there and check this thing out. But I dont think I will be able to. Because, I'll walk away with jeep and garage envy.
Come on down anytime, you need to come look at my cage anyway.

Maybe Walt will give you the beer he owes me to bring down with you
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Old January 4th, 2012, 01:09 PM   #79
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idk if i've missed it or not but on my old XJ when i cut the rears out what i did was after removing the flares took a cut off wheel and but divets in the fender up until where the inner fender meets the quarter panel (aprox 1") then after that i rolled the cuts back into the inner fender. doing this strengthens the cuts so they wont seperate. also i installed TJ rear fender flares onto the front and rear for extra tire coverage and for just a different look.
Thanks for the ideas, but I am not a huge fan of the TJ flares on an XJ - just my personal opinion.

I don't think I am going to need to do that much... for now.

I moved the rear axle back 1" and I think I can get away with not getting too deep into the sheet metal. I will need to limit the up-travel of course, but it's do-able. If I have enough time this winter I can come back to it.

Before



After

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Old January 4th, 2012, 02:37 PM   #80
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Come on down anytime, you need to come look at my cage anyway.

Maybe Walt will give you the beer he owes me to bring down with you
Sounds good!!!! I can check out our heep and drink Walt's beer. Sounds like an ideal day
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