The latest prodject

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So now that the t-case was in place to where I wanted it--it was time to build the cross memeber--those who know my work will reconize this setup :awesomework: I really like it and have used it many a times

 

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And since that big chuck of alum. is just sitting there--I figured I would give it a little METAL to rub on :flipoff:

This is what I got sone tonight

So tommorow I will drop the crossmember and t-case out. I have a little more trimming to do and then toss the works back in for good :awesomework:

 

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Awesome work, Crash! I really like the front shackle hanger and the rear spring pocket idea. I've got your webcam saved in my tool bar, I check your shop out from time to time, been watching you work on this one.

Thanks randy--its coming along nicely and I have been trying out some new ideas on this rig that I have been wanting to use for a while now. Another stalker eh

 

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Well joe came up today and brought a few goodies. I also told him to bring up his 42's so---of course we JUST had to put them on..:awesomework:

I think joes jaw dropped once they were put on :redneck:

 

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So the next step was to remove the new cross member and t-case to seal the t-case to the tranny and remove a tad more sheet metal ---yup a lil more messy time :redneck:

And while it was out I got what needed to be painted all painted up :awesomework:

I got lucky with the fuel lines--just a little bending and they popped right back into the stock holding fixtures

 

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And figured it was time to get the shifter assy done up. For now I am leaving the stak case shifters alone and only bent the doubler shifter enough to get it thru the floor--will fit the shifters to joe once the floor is done and a seat back in.. I had to notch the floor behind the origional shifter hole and under the floor to clear the stak case shifter/shifter rods. Plus I had to slit/bend the floor at the new hole hole (showed joe a little trick :awesomework: )

So since the t-case was now in the weight distribution was done which means I can now do the rear shackles. My setup ended up being right on the money for the shackle length and started building and they are almost done...

 

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Ok I got the rear shackles all done and the back of the rig painted up..
Is there anything better than huffing paint fumes..:redneck:

 

[Grey Fox]

Very nice work with some great ideas. I may borrow your front bumper design. Way cool. I wish I could weld like you. Cheers, Kim

 

[Scott Mine]

Awesome Work

Crash, I have to admit you do some great work there.

 

[The Real CJ8]

Just wondering if you are using TIG or is that all MIG I know my MIG welds dont ever look that good
And bless the plazma cutter (DROOL)
joel

 

[crash]

Grey fox---Go ahead

Thanks scott

And The Real CJ8--Its mig--I have a tig but I rarely use it until I get a nice dedicated tig box then I will use it more but I have alot of years doing this stuff so I have had alot of time to practice,lol...

 

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So I went and started digging thru boxes and figured since joe put the new pump on a while back--I figured it needed the other parts thrown at it. Found a real nice mounting place for it--worked like a charm :awesomework:

 

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So I got tired of tripping over the boxes of wiring harness's--so what the hell I thought to myself--lets see what kind of mess I can make--and a mess I did make(granted it was only a small mess-but be asured it will be a bigger mess here soon enough :redneck: )

So I was able to pre-wire the front clip. One thing I fought with was where to mount the fant control do-hicky thing a ma bob. There was just no place that it would easily fit--to where it was somewhat protected from water. Well as you can see its up high--only damn place I could find.

 

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Ok so I went thru the stock wranger wiring harness and trimmed out all the un-needed stuff(2.5 harness). There are a couple circuits I left that I might use but for the most part that parts done.

Here is the bundle of crap I yanked out of it.

And here is the wiring harness that came out of his XJ that I will now make a massive mess with

 

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OK--Just kinda putting my way thru it.
Here is the cleaned ecm side of the harness. You can see I left the bulkhead connector on the harness for now.

Freshly tossed in ecm harness. Time to get the bulkhead connectors outa there...

The 4 cylinder map sensor was in the middle of the firewall--I didn't like it there so I reworked the bracket and moved it to drivers side of the firewall where the edge of the tunnel is.. And you can see that the bulkhead connectors are now gone. Looks much better.

And got the line locks mounted also.

 

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Ok I am still poking my way thru the wiring. My main goal is to retain the wiring structure of the XJ for ease of diagnosing any future component problems. But here is the relays all done except I have to move one terminal into a different cavity.

Here is where I put the ignition module and the small fues block. The only thing I changed from the Xj structure was I added fuses and broke the power sources up a little since the XJ used fusable links.

I also cut/modified the stock diagnostic ports bracket and mounted it to the battery holder.

I mounted the main junction block and started making all the positive cables. Just need to do the negative cables and I can start checking what does/doesn't work

 

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Ok I got all the ground cables done..

 

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For future usage's I went ahead and pre-wired wires in the wiring harness so joe won't need to dig into it. All wires go to under the dash for ease of use

For kicks I thought I would goof around a bit. I had to replace the amber bulbs but looks like all works. I also stole (he he he) jacks winch controler again and checked the winch and yup--that works perfect too..

 

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I also had to remove the cooling fan to run the wiring from the motor to the controler. But here is how the engine wiring turned out. Its now 98% done(couple small things left)

 

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So I got the big mess I made cleaned up--and started going thru the boxes that joe brought up for the rig and the brake master fell and landed on my fott. I figured that was a sign,lol. And as stated the brake master bolted right up.

I had to do 2 things to make it an easy bolt up. The first one adjust the push rod---that was an easy turn deal. The other was I had to dimple the brake booster to clear the latch rod for the cap on the brake master.

As you can see its pretty close and still rubs the booster but its "acceptable".

I also dug out the radiator hoses--had to do a little trimming on them but they went right on..