Project Silver XJ

[RedJeepster1]

Figured it's time to start a build thread to keep all this in one place. Picture heavy.

Purchased in November last year for about $150. Pretty clean shell. Ian took the drivetrain for his 4wd swap in his green XJ and I kept the shell to build as a rust free Jeep.

Didn't really start working on it until late July early August this year. Plan is to have it at Rocktoberfest the first weekend in October. Started ordering parts for it months ago. 4.56 gears, IRO full length stiffeners, 3.5" IRO military wrap leafs, 3.5" RE front coils, bolstering shocks, Clayton 3 link drop out crossmember, Clayton front truss, WJ knuckles and brakes, GM tre's, JJ's, heims, DOM... bunch of other stuff, been collecting for months.

35" treadwrights on JKR wheels. Hand mounted them one day after work. Now I can say I did it, but I think next time I'll bring it to the shop.

Started with frame stiffeners in the rear. Pulled the rear axle, springs, shocks, bumper, and ground all the undercoat off. Then ground the frame clean to accept the stiffeners.

Stiffeners welded on.

Once stiffeners were done, I cut the stock shackle boxes out and set up my shackle relocation. Final angle seems pretty good. This is with 200 lbs in the trunk.

While this was going on I have been collecting parts for the front suspension. Johney joints, bushings, TRE's for the steering, heims for he track bar. DOM for the links and Clayton crossmember and truss.

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[RedJeepster1]

Saturday I pulled the drivetrain that I will be using in he silver Jeep. 4.0 with 210k and AW4 and NP231 with 357k from my red Jeep. That Jeep has been very reliable while I have owned it so although the drivetrain is high mileage, I'm not too worried about it. Swapped two rear axles and pulled the drivetrain in about 6 hours. Had lots of help and everything had been out before so it went pretty smooth.

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[RedJeepster1]

Sunday I started my SYE install but stretched a snap ring. Last night I picked up a 21 spline transfer case from my neighbor that he was going to scrap, pulled it apart and reassembled my 231 with the SYE. All sealed up, just needs the yokes torqued when I put it in the Jeep.

Also spent a little time prepping my front axle for the front truss. I think I am happy with the fit at this point but I still have to trim the cast mount a little more so I have a nice area to weld. I have new lower control arm mounts and sprig perches to go on also before I weld the truss in place.

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[XJ-Maki]

there's no thumbs up so I'll give you the big clap  :applaud:

this is what every XJ owner wishes they did from the start

 

[YJScrounge]

Nice job, lotta work going on there...

 

[gorilla_skater]

Definitely a clinic in how to build an XJ. Great work so far Jeremy!

 

[A new level]

Can't wait to see this in person. Your doing hell of a job!

 

[redjeep]

Good Job!  Nice write up!!

 

[gorilla_skater]

Are you going to use wheel spacers/adapters for the JK rims? I was thinking of going to JK rims.

 

[RedJeepster1]

Are you going to use wheel spacers/adapters for the JK rims? I was thinking of going to JK rims.

Yup, I'll be running 2" spacer adapters. I needed to jump to 17" wheels to clear the larger WJ front brakes and I got 5 JKR wheels for $125. I also always liked the silver JK wheels on the silver XJ's, so it was a no brainer.

 

[BrokenXJ]

Silver XJ's are the best ones.

 

[gorilla_skater]

Cool, are you running 35's? I have this theory that a 35" tire on a 15" rim is just about the limit to be able to balance them well enough to run at highway speeds. That's why some companies don't even bother making 35x12.50-15. Just a theory.

 

[RedJeepster1]

Yes, rims are 17x7.5 and tires are 35x12.5R17 Treadwright Guard Dogs. Got the tires on a sale for less than $850 for 5 shipped to my door.

 

[harryhood]

How the heck did you mount all those with just tire spoons. I just about killed myself trying to change my rims. I got one tire fully remounted and could only get the first bead on the other three on. I had to bring them to a shop to get the outer bead on.

 

[redjeep]

How the heck did you mount all those with just tire spoons. I just about killed myself trying to change my rims. I got one tire fully remounted and could only get the first bead on the other three on. I had to bring them to a shop to get the outer bead on.

You need to make a tire machine that goes in your receiver hitch.  Pretty simple and works AWESOME.  Makes Boggers go on like Butta

 

[blackjeep02]

Is there anything Terry can't answer?

 

[RedJeepster1]

Mounted them up with two tire spoons and a bottle of soapy water. I think the 5 tire's took a little over 2 hours.


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[YJScrounge]

been changing tires by hand my whole life...

 

[XJ-Maki]

never had a problem doing LTB's and Q's by hand, wonder if they're easier bc of bias ply or 15" or just lower tolerance mfg from interco?

 

[XJ-Maki]

Are you going for a low COG build? What are your plans for fenders/flares?

Noticed you went with the no lift version of the shackle boxes and only 3.5" coils