Project RottenBottom

[xj_man_646]

Well, I'm gonna start up a build thread for my new Cherokee. I have re-named it 'Project RottenBottom' because...well...you'll see. Its not done yet, but more to come on that later.

I purchased this from NativeXJ:


1994 XJ, 4.0, ax-15, 231, 4.5" Rustys lift.

The plan:

• 4x3x3/16 channel subframe
• Hidden 3 link up front
• 2x6x3/16 retangle tube crossmember
• 2 1/4" x 3/8" DOM lower links
• 1 1/2" x 1/4" DOM upper link/panhard bar
• 2 1/2" forged JJ's all around the lowers
• 5/8" bolt x 3/4" shank chromoly heims for the upper/panhard bar
• Retaining the leaves out back
• 4.5" Rustys leaf packs
• 1.5" TnT UBE's (U-bol eliminators)
• 1.5" XJ shackles, relocated with new shackle mount
• Swapping the Waggy 44/AMC-20 from my previous Jeep.
• Get it done between this weekend (12-8) and next weekend (12-15). This, in reality, did not happen. It was a valiant effort, but small setback after small setback (parts delays, issues with random stuff, etc) has since caused the Jeep to be incomplete as of 1/3/08 when I had to leave it for the final time. More on that later.

Got off to a decent start so far...the project took quite a turn when, during disassembly we noticed carpet showing through the floor at the front spring mounts. This got us thinking about the rest of the interior.

Went to see how badly the rust had taken its toll. Here is what we found (after some poking around):


Previously mentioned spring mount:


Passenger floor:


Driver floor:


At this point, the plan to do just suspension went out the window. About 80% of the floor is going to be replaced. Stevie (VTJeepCJ84) ordered a bead roller today (was planning on it for the winter anyway) and I paid for 2 day shipping so he can start the floors. He worked on re-enforcing the spring mounts today, while I worked on the rear shackle hangers...until we ran out of welding gas

Cleaned up the area around the springs


Trimmed/cleaned up the stock shackle hangers


What a diesel burning heater, and lots of grinding does to a small garage


Stevie working hard...or is it hardly working. I don't know which



Spring reinforcement done



Shackle hangers well on their way. I have the lower plates and all the tabs made...but with no welding gas I can't exactly finish the job.


Taking my first stab at welding in anything but small practice beads since High School


Could be better, but I need to practice a bit more. I don't think its going anywhere


Hangers all done


Bit more welding. Its meh...oh how I wish I could lay a bead like Timmay Maybe after I practice more I will get somewhere near that caliber.


Hangers going in


First try at unweighted shackle angle. Its been changed since, just a smidge.


Slid the rear axle under, mocked in the new UBE's and pinion angle, then burned it home. Here it is in primer


UBE's


New yoke and diff cover courtesy of Stevie's bent AMC20



Wire brushed and painted the shocks.


Yayz. Yes, I know its really tall...I did not anticipate it to end up this tall. My plan is going to be to replace the 4.5" packs with some 2-3" packs once the Jeep actually moved again. I would like it 1.5-2.5" lower. Might have to get a shorter shackle too.


25* shackle angle sitting on the ground.


While I started the unibody sleeves, Stevie continues on his floor quest...




Cutting 6' of 4x6 rectangle to form 4x3 channel with nothing but a grinder sucks. Took me quite awhile, but only burned through 2 cutoffs.



Cut and marked for the rosette welds



Welded up and in primer. Drilling those 1" holes took forever, as did getting a hold of welding 3/16 to the unibody. Most of the welds are far from pretty, but I am confident in saying that the actual weld is fine, and is not going anywhere


More floors...FWIW...this is basically all Stevie has been doing up until I left on 1/3


Now came the most dreaded part of the build...in my mind anyway...the front hidden 3 link + panhard

Out with the turd


In with the fohtee fo


Mocked up, and burned in the new coil buckets


LCA brackets...I have far too much time into these, and this is not how they ended up looking. I had to cut the top off completely to clear the coil bucket. This is the 3rd set I made...




That is just about where I left. No pics of them, but I also made the brackets for the UCA, and the frame end LCA mounts. This is also where I left the build completely, due to time. Stevie is kind enough to get it rolling, finish his floors, and is going to tow it up to MTU for me next month come winter carnival.

This is what the x-member ended up looking like after a bit of modification to clear the driveshaft


Stevie's welds


Can kinda see where the UCA is going to be in the passenger compartment. I don't care about passenger comfort...they don't have to ride with me. I don't think it will end up being TOO bad, as I think the UCA bracket is going to be shortened once final ride height is determined, and the geometry is double checked/modified.


And thats it, for now. I will update this thread more as Stevie gets some more work done. Thanks a bunch, Stevie...couldn't have done it/be doing it now without your help/resources

[Timmay]

Super duper.... That looks a lot better than I thought it would, for real.

[xj_man_646]

Originally Posted by Timmay

Super duper.... That looks a lot better than I thought it would, for real.

Thanks dude, I can't wait to see it done.

[Timmay]

Agreed. Towing my XJ to the shop today made me think long and hard about going to the steel yard for 2 sheets of 16 gauge. To be honost, I think I might do it in the morning.

[GWhiteXJ]

Ohhhh lookin good man! Excited to see the final finish! BTW your beads dont look that bad.

[xj_man_646]

Originally Posted by Timmay

Agreed. Towing my XJ to the shop today made me think long and hard about going to the steel yard for 2 sheets of 16 gauge. To be honost, I think I might do it in the morning.

Doooo eeeeet.

[xj_man_646]

Originally Posted by GWhiteXJ

Ohhhh lookin good man! Excited to see the final finish! BTW your beads dont look that bad.

Thanks

[VTJeepCJ84]

Originally Posted by xj_man_646

Thanks dude, I can't wait to see it done.

you and me both

[MBood82]

needs more cowbell

[xj_man_646]

Originally Posted by VTJeepCJ84

you and me both

[JeepXJ3]

Looks great James! So this is what, the 3rd build thread on the same Jeep?

[xj_man_646]

Originally Posted by JeepXJ3

Looks great James! So this is what, the 3rd build thread on the same Jeep?

2nd, noob.

[JeepXJ3]

Originally Posted by xj_man_646

2nd, noob.

haha

[xj_man_646]

Originally Posted by JeepXJ3

haha

I could call this the first since there is no record of the one I put up before this

[6DoF]

Stevie FTW!

[xj_man_646]

Originally Posted by jeepnski

Stevie FTW!

Give me no credit? Die in a fire!

[jeepkid05]

Looks good so far. Your welds are looking good, only gonna get better with practice

[xj_man_646]

Originally Posted by jeepkid05

Looks good so far. Your welds are looking good, only gonna get better with practice

Thats my hope! I want to buy my own welder this summer...should yield good amounts of practice

[VTJeepCJ84]

Originally Posted by xj_man_646

Give me no credit? Die in a fire!

you did do the frame stiffeners all by your lonesome.

if you're lucky i'll get my happy *** out there tomorrow night and get something done. I spent tonight playing with my slow azz computer.

[xj_man_646]

Originally Posted by VTJeepCJ84

you did do the frame stiffeners all by your lonesome.

if you're lucky i'll get my happy *** out there tomorrow night and get something done. I spent tonight playing with my slow azz computer.

and the shackle mounts, and the preliminary crossmember, and all the brackets until you modify them.

[bbaCJ8]

Originally Posted by Timmay

Agreed. Towing my XJ to the shop today made me think long and hard about going to the steel yard for 2 sheets of 16 gauge. To be honost, I think I might do it in the morning.

What are you doing now?

[Timmay]

Originally Posted by bbaCJ8

What are you doing now?

I don't know, what are YOU doing now?










Ialreadyknow

[mudin1]

HURRAY NOOB!!! It looks like it had 4 wheels so you accomplished something!

[6DoF]

Originally Posted by xj_man_646

Give me no credit? Die in a fire!

i never said i didn't give you ANY credit.... i just said that stevie built your jeep

[bbaCJ8]

Originally Posted by Timmay

I don't know, what are YOU doing now?










Ialreadyknow

Not exactly hard to figure out what I'm doing.

I was thinking a new floor in yours but why would a '00 need it?

[fatwreck]

Wow....I can't believe you're building that. I think I would have thrown it in the garbage with that much rust.

I am impressed with the progress though. It may turn out to be pretty nice afterall.

[xj_man_646]

Originally Posted by jeepnski

stevie built the floors of your jeep




up to when James had to leave

fixed, fukkass

[xj_man_646]

Originally Posted by fatwreck

Wow....I can't believe you're building that. I think I would have thrown it in the garbage with that much rust.

I am impressed with the progress though. It may turn out to be pretty nice afterall.

Well, it was a cheap XJ that ran. Huge steps over the one I had.

[BMFmike]

20 to 1

[zjwrekkr]

not enough empty beer cans : rusty floor boards

[Timmay]

Originally Posted by bbaCJ8

Not exactly hard to figure out what I'm doing.

I was thinking a new floor in yours but why would a '00 need it?

In a way i'm doing a new floor. My XJ is rust free.

Basically i'm cleaning this garbage up by replacing the swiss cheese with nicely bent 16 gauge.

[bbaCJ8]

Nice.....I'm sure it'll look like a whole new rig once you're done with it. I'll update the Scrambled thread in case you're curious of some of the details of the frame crap.

[Timmay]

Originally Posted by bbaCJ8

Nice.....I'm sure it'll look like a whole new rig once you're done with it. I'll update the Scrambled thread in case you're curious of some of the details of the frame crap.

That's the point. This isn't going to just be another hacked up XJ, that looks like a hacked up XJ.

People are actually going to wonder if it's from China or something. It's going to look good and finished. None of this exposed sh1t. I'm actually sort of going for a rig to show off my skills, if you catch my drift. I've got some really extensive plans for that back area. Everyone I explain them too is usually like What? Cooolllll man.....

You'll see.


Looking forward to that update.

[bbaCJ8]

That'll be funny with an uber detailed, clean inner 'cargo area' and every body panel smashed in. It'll still show off the skills so whatever works...

[Timmay]

Originally Posted by bbaCJ8

That'll be funny with an uber detailed, clean inner 'cargo area' and every body panel smashed in. It'll still show off the skills so whatever works...

I cut off all the smashed panels. The front fenders and half doors are the only thing left. I'm pretty sure they are getting fixed before paint.

I'm going to take my wheelin down a notch and play smart with this rig. When I get out of school i'll be starting on my buggy.