Birty Dastards Jeep Club
Tech Forum => Workshop => Topic started by: JamesH on February 17, 2013, 02:39:36 PM
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I've been threatening it for a while and it seems people want build threads so here's the start of mine.
The disclaimer is that for those who have seen my XJ before - it is not getting any bigger, no fancy coilovers or anything are being fitted and actually this thread could also just be called 'overdue maintenance'. The aim really is to fix some niggly problems and a few age and abuse related issues and end up with a simplified version of an XJ for offroading. It's still going to be road legal and able to drive to events if trailering isn't possible for some reason but I do plan to trailer mostly from now on just so I can do what I like offroad without journey home niggles on my mind.
Pics are better than words, this is what I've been doing today:
[attachment=2]
[attachment=1]
LPG system and underbody tanks removed, started the cleanup of 7yrs offroading and assembled a new stock petrol tank to re-fit.
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nice one James
got to do a similar thing to the ZJ
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:popcorn:
I'm looking forward to this. S'all looking reasonably sound under there James. :greggmo:
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After a bit more cleaning with a scrubbing brush (messy) it looks ok, nothing more than a few patches of surface rust where the lpg tank has rubbed a bit and along edges of sheet metal joints. I'm planning a good check then put a layer of underseal or similar thick paint on it all.
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James what shocks are you running on that xj?
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Bilstein 5150. The extra reservoir is just bling really but they are good shocks.
On closer inspection of the rear floor and rails I have found a few crumpled bits and a small <10mm crack/split. I was planning to reinforce the whole of the 'frame' part of the body anyway but now I'm completely focused on doing it. The years of banging down onto rock ledges and winching the rear round at funny angles has taken it's toll. Luckily there's very little rust under there.
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good luck with the overhaul
if you ever wondered what a naked rear end looks like
(http://pic20.picturetrail.com:80/VOL1608/6728117/23880266/398315503.jpg)
I reinforced my rear oh er
(http://i166.photobucket.com/albums/u106/dt00th/IMAG0818.jpg)
(http://i166.photobucket.com/albums/u106/dt00th/rearwinch7.jpg)
so i could do this
(http://i166.photobucket.com/albums/u106/dt00th/rearwinch19.jpg)
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I like naked pictures! Seeing the shock mount crossmember 'open' is good and shows me what I was poking my fingers into to try and clean at the weekend. Seeing that I might drill another access hole or two for cleaning.
Mine looks like it's been moving where the end of the towbar mounts are. So the rigid bit of the towbard has done it's job but applied all the pressures to where it finishes and joins the much thinner body. I'm not going overkill - I've got some 3.5mm steel and I'm hoping to add structure and support as much as possible.
What size box section did you fit into the end of the rails for your bumper mounts?
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looks like you got plenty of burns coming your way james. watch the chicken dont have ya she looks like trouble. its better weather for tinkering at least.
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hey lard leave the chicken alone it looks like an expert to me
james nice thread dood i must recap on mine more often
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box section in the chassis is 3mm thick x 100x45mm according to my records :greggmo:
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box section in the chassis is 3mm thick x 100x45mm according to my records :greggmo:
Cool. I was thinking the 3.5 and 4 mm stuff I have would do but all you ever see on Pirate is 1/4" box, plate, angle or somtimes even thicker.
My work area is like a farmyard at times but it keeps me entertained, I'll get them out the way for the welding :117:
Cleaning it up and then welding at funny angles is going to be fun - I can do pretty welds on a bench but they quickly turn to crap when sat under the Jeep but practice, practice, practice I suppose.
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Same here i hate upside down welding ..
Pirate4x4 always seem to be over the top with there 1/4" plate etc but then there are running 42" tyres up a cliff
I took my lead from the towbars and winch most use 4mm thick tube and 6mm plate .
The angle iron you see in the picture is about 8mm and was channel but its what i use the bolt the winch plate too the biggest pain is the fuel filler going throught the chassis
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Any tips on cleaning and treating the inside of the chassis / frame rails?
I think jet wash in all the holes on sides, top and bottom (the inside of the Jeep is stripped out) should clean it ok. I'm not sure about whether to treat the inside of all these voids or leave them as is and just try to clean them out a lot.
I seriously dislike waxoyl and other non-setting rust prevention coatings / treatments because in my experience they just trap mud and other crap on them and are really hard to clean - I'm thinking more along the lines of paint that dries hard and shiny and can be cleaned easily.
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for in the rails get hold of a drain cleaning attachment for the pressure washer - you can then feed it in a hole and along the full length and be sure that everything is cleaned out
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what he said :iagree: then what about por15 or a 2k paint
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I know it's the noddy version for plebs but I've got hold of a big tin of smooth black hammerite that is a no cost option so maybe that's the
best most likely route.
I've seen a 7.5m Karcher drain cleaning attachement that looks evil so I think that will definitely work, thanks for the tip.
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hammerrite works it just needs to be clean and dry to stick properly and if you have some then its a no brainer
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Often thought about all of the crap in the TJ chassis rails.
Can it do any harm to get something like the karcher drain cleaning doodad in there or is it best to leave alone ?
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I don't see how it can do any harm, unless the mud is holding the metal together. It might blast any paint off in there I suppose? Having it packed with mud has got to be pretty bad though.
I've alsways got on ok with hammerite on outside surfaces and because it's simple to apply it can be touched up ok too. I think a 2 part paint system would be harder and adhere better to the surfaces but I did get this fairly big tin of Hammerite for free and free is good at the moment. If it turns out to be a mistake I'll let you all know.
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Personally I would wash out what you can with the jetwash attachment then leave it at that, the chassis and floors on my xj have been through the wringer, I know the floors disintegrated after my Bala sinking it and leaving the wet carpets in for a year incident, but when some of the rusty floor was removed I could see quite well into the chassis in places and was as good as new so I think trying to get paint in there may just trap any dampness which would then maybe cause you grief, just a thought James.
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As promised, some more stuff in this thread.
A few parts are going into the build even though it's not getting bigger or changing dramatically.
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Most of the additions are a bit more 'farmyard' engineering, no laser cutting here :icon_rolleyes:
Some of the rear inner frame rail stiffeners / reinforcements
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dont diss farmers and farmyards dood
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I actually thought that - they are more capable of quality work than most. Maybe 'office worker' fabrication suits me a bit better :100:
Making it up as I go along but have been lucky so far with this approach. Drilling all the holes is a mind numbing task :die:
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keep up the good work
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Drilling all the holes is a mind numbing task :die:
its really quite boring
ill leave
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:hysterical: :hysterical:
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James you owe me £35 ..... drain clearing attachment for Karcher turned up yesterday so I can clean the inside of the chassis rails out on the TJ & its all your fault :003:
You can settle up at the breakout, no rush :icon_jook:
Shiold you need anything laser or water-jet cut give me a shout, got both at work :icon_winkle:
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water jet :icon_eek: :peekaboo:
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Ooh, I might take you up on the offer Gaz. How do you need the designs? CAD?
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Just a simple sketch will be fine with the dimensions you need.
Any missing sizes I'll get back to you, your sizes will be put into our cads / machine software & we can cut what you need.
Only problem is I think 3mm is the thickest mild steel we use (i.e. have in stock, but i'll check) although machines are capable of much more :icon_winkle:
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After a few hours tinkering in between bad weather and house chores I have decided that I'm not going rear winch - at least not at the moment. There's just no way to tuck the winch in far enough without moving the fuel tank or messing around with the hatch and I don't want a window box sticking out from the rear of the Jeep cos an XJ overhangs enough as it is. Now that's decided I can crack on with finishing off the rear end, I'll just reuse my old bumper with a few adjustments to tie into my newly reinforced frame rails.
Gaz, what I have in mind would need thick plate but the way I'm going at the moment my plans are changing a bit :icon_rolleyes:
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So James your a promiscuous 4X4'r!!! That is, you flirt with a rear winch (in most cases these days it's a given) and tease us with the results, when in reality a man of your caliber should be engineering a centre winch, get on with it!!!
Don't let me down....
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i sorta agree young jedi expected of you much is
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James, I can get the plate cut, gratis of course, to your needs not a problem, its having the material in stock to produce it from free as well.
However, what do you have in mind and or what size roughly, 6" x 10" ..... if you can give me an idea, I'll see what we have :icon_winkle:
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I'm struggling a bit with all the winch ideas - I just don't get the buzz out of winch challenges that some do. Sticking winches everywhere doesn't do it for me that much. I should really live in the US because I like rocks and other technical stuff and big flex.
I suppose if I move the rear axle back a bit, adjust the fuel tank...
(Gaz - brake caliper brackets, nice thick 10mm thick jobbies probably but not massive sheets needed to cut from. I can get done locally if not a possibility.)
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I looked into a centre winch mounted under the rear seats which would run rear would around a removeable snatch block and then to the front just like the foers vector system ..
but settled with the system I have now
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(Gaz - brake caliper brackets, nice thick 10mm thick jobbies probably but not massive sheets needed to cut from. I can get done locally if not a possibility.)
Will see what we have, rough size would be handy, do they need bending / forming or flat ?
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Between you bastids and Pirate I'm doomed, I was being sensible 24hrs ago :100:
Gaz - I'll measure up and PM you, should be flat plate only.
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that is some jeep on your last post james, i could just see jou driving it, got my rear winch finished last year, prior to the 1000 rivers, here are a couple of pics
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Glad you posted Frosty, I forgot about events like 1000 rivers - I can see a rear winch being useful there. Did you use yours a lot?
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avoid pirate as you ideas for modification will change drastically
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i've been thinking of a rear mounted winch as alot of the time you end up sticking the fount end in a ditch or a mud pool and need to back out but need a pull of winch to do it,
or just to pull jay out of the shit when he follows me :hysterical:
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Glad you posted Frosty, I forgot about events like 1000 rivers - I can see a rear winch being useful there. Did you use yours a lot?
hi James, the winch worked great, but we did have a major problem, look in frosty's jk for the full story. what is the next event for you, i have taken a new job in Kuala Lumur, so will be missing a few. frosty
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Yeah, I know about Derek's acrobatics - is he on the mend now? I'm missing a few events too this year. I've got planning to extend the house and build a garage so have really got to spend my money and time on that. I'm doing the Birty's breakout event 18/19th May at West Harptree and that might be it until later on in the year. I've also just moved jobs again so there's a lot going on.
I hope the KL job is good for you, I've flown through and thought I'd like to go back and my Dad has worked there a few times doing hotels and apartments - crazy heat and humidity and no regard for health and safety is all I remember him saying. I'll PM you to catch up more.
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Spent this weekend repairing the footwell of Dad's rusty workhorse XJ. It wasn't fun and definitely a reminder not to ignore damp carpets. I've added one pice below but it's hard to see just how hard it was to find good metal to weld to.
I did get the chance to get some frame stiffeners bent up for my XJ. 'Only' 3mm sheet but I'm hoping the bends and angles should give structure and strength to replace the Yanks all beef approach (we'll see :017:). More holes to be drilled then weldy, weldy, burns and swearing.
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More goodies turned up today
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Just a thought, if you still want any bits making, work closed all next week for easter shutdown :icon_winkle:
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More goodies turned up today
I give up. What's the hoop for? :017:
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Front suspension.......coilover support.......???
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Front suspension.......coilover support.......???
Twas my original thought, but James does not have a chassis!!!
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Ha ha :greggmo:
Glad I got you guessing. No coilovers going on and that's all I will say for now. More work being done in the next couple of days an I'll give you an update.
Gaz, no rush at the moment, got plenty to keep me busy - probably too much :icon_eek:
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Front suspension.......coilover support.......???
I also thought this, but only one of them. Stinger maybe?
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There's 2, just well packaged on top of each other. Jeepspeed is the big clue I will give you until I can post a pic of the finished product.
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Rear shock top mounts? What do I win?
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The opportunity to build it for me?
:003:
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The opportunity to build it for me?
:003:
As much as I enjoy working on other folks trucks (because I care much less if it goes wrong) I should probably get out and work on mine :banghead:
Oh was I right then?
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More goodies turned up today
I give up. What's the hoop for? :017:
Stinger bull bar ?? :017:
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Handcuff loop??
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Yep, Donk wins the prize. Probably not a massive benefit for me but something I've wanted to do for a while.
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:icon_super: :icon_super: :icon_super:
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Yep, Donk wins the prize. Probably not a massive benefit for me but something I've wanted to do for a while.
HMMM, So what does one weld too? Are you exo cage also in the planning?
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Now the obvious answer would be shock hoop but then James has told us this a boring (his words) non-coilover build so that can't be it, plus they normally come in pairs. So, maybe something to do with a spare tyre carrier mount? And one of those strange co-incidences, I recognise the flooring, I just dropped a knife on the kitchen floor and created yet another divit! :)
Cuffy
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Now the obvious answer would be shock hoop but then James has told us this a boring (his words) non-coilover build so that can't be it, plus they normally come in pairs. So, maybe something to do with a spare tyre carrier mount? And one of those strange co-incidences, I recognise the flooring, I just dropped a knife on the kitchen floor and created yet another divit! :)
Cuffy
Ahhh!! The log effect.
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Getting started. Will post some more pics tomorrow
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I'm basically building the frame part of the unibody / monocoque into a stiffer frame so that the body flexes less and holds up to the suspension movement I have and the increased weight hanging off that suspension. It also will give more solid mounts for bumpers and other stuff. The plan is to do the length of the Jeep on both sides and tie together with crossmembers and bumpers.
All this bird shit welding takes time though, I've only done the rearmost 350mm and got about 10x that to go.
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Bugger, welding gas ran out this morning. As I got it off Mick (Captain Cavalier) from another forum and he's no longer in his old job at Energas in B'ham it looks like I might have to bite the bullet and pay BOC some money and fill some forms in :icon_sad:
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BOC..... Have been using them since started the gluing ...... Ain't getting any cheaper what with environmental tax and shit.......
BUT Argoshield is better than 'pub gas'......... Unless you're a welding god or don't mind mega splatter :icon_twisted:
Good luck with the rest of the reinforcements......looking good......just the weather for a lie down on the cold concrete :icon_biggrin:
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Agreed that argoshield is much nicer to weld with, but can get pub gas bottle for 7 quid so cost wins for me and I'll live with the splatter.
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I've been using migweld universal which is like argoshield universal so I think I'll go for that. I would try and get my Energas bottle filled / exchanged but there aren't any stockists nearer than Leicester and there are two BOC places close to home and work.
WW - would you mind letting me know what you're paying? By PM if you'd prefer. I'm looking at a ghay little hobby 2l bottle for about £50 or a replacement for what I have now which is a bottle about 3ft tall.
...and yes, lovely weather to be lying on concrete and touching metal :icon_rolleyes:
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James, its worth asking BOC if they still do the Volkzone offer you may get some discount, Ive used nearly 3 of those 2L bottles in a year just tattin and making tube fenders. I paid about £18 for a refill. If the 2L turns out to be too small you can exchange it and move up a size, i think the X bottle is about 3ft tall, not all BOC do the 2L bottles.
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here's an option
http://www.hobbyweld.co.uk/?page=35
Or
Ebay
http://www.ebay.co.uk/itm/Argon-CO2-5-Welding-Gas-No-Rental-Contract-for-MIG-Welding-/330889658244?pt=LH_DefaultDomain_3&hash=item4d0a8f7f84
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I'll look out the paperwork tomorrow James....and PM you the details....
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Got the gas sorted, BOC size X bottle. Had to bite the bullet and open the account and pay the rental and all that.
Finished the rear reinforcements and got busy with the paint to make it all shiny (black). Hoping to get the fuel tank, skid plate and other rear stuff fitted up this week. Should then get some more interesting stuff for you all to look at. And a bit of axle blinging.
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All painted up, fuel tank in and plumbed, wired and fired up and revved for a bit to entertain the neighbours. Still loads to do but glad to have the engine running again.
Gained a bit of clearance, only back to stock but a gain for me having had an lpg tank under there for the last 7 years.
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Getting there James, btw the lpg kit is still in the shed, may get around to fitting it when the weather warms up :icon_rolleyes:
And those two pics would make a good spot the difference competition :icon_biggrin:
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On board air using air-con compressor - generally I have a plan but a few of the components are stumping me.
Can anyone help me source a 90 psi pressure switch (electrical to turn the compressor on and off)? Like the ARB compressors have screwed in them but not at ARB prices.
Second request is for advice and parts - I have a 12mm (maybe 1/2") input pipe and 15mm output on the compressor. I need to connect air line or suitable pressure hose to them. What's the best way to do it?
I'm feeling a bit like BD tonight and so would love a 'use these' and 'buy here' plus a weblink so I can just stop going in circles :icon_redface:
Sent from my MZ604 using Tapatalk HD
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Smilies obviously a bit on the piss using Tapatalk!
As well as the above if anyone can say here's good to buy inline oiler, pressure relief valve, gauge, and manifold/fittings that would be really cool and they'll get rewarded with beer, pies and jaffa cakes!
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I'm feeling a bit like BD tonight and so would love a 'use these' and 'buy here' plus a weblink so I can just stop going in circles :icon_redface:
Sent from my MZ604 using Tapatalk HD
we are becoming a peoples republic of two James :icon_super:
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James,
I use these guys, they seem to have everything and deliver quick:
http://www.airlines-pneumatics.co.uk/
Pete
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Try RS components.
Heres a link, they sell everything.
http://uk.rs-online.com/web/?cm_mmc=UK-PPC-0212-_-00_RS_Brand_Terms-_-Top_Terms_Exact-_-rs&gclid=COPq1djS57YCFZQZtAodoAgASg (http://uk.rs-online.com/web/?cm_mmc=UK-PPC-0212-_-00_RS_Brand_Terms-_-Top_Terms_Exact-_-rs&gclid=COPq1djS57YCFZQZtAodoAgASg)
Sent from my iPad using Tapatalk HD
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A weekend working on the Jeep but it seems only a little achieved :017:
A bit of an update pic below, still work in progress but the plan is taking shape.
Breakout coming soon :icon_eek:
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Looks well grown up mate.........Pirate Hardcore would be proud of ya :icon_super:
us Birtys will be keeping that info and pictorial how to for future use. :icon_twisted:
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HELP! - Does anyone have a 1/4" NPT tap they could send me by post ASAP? The ARB airline port uses this and I only have metric and some imperial taps and this doesn't match up.
A quick Google brings up expensive UK suppliers and chances are I'll never use it again.
Beers, jaffa cakes or cash waiting.
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how many TPI is that, may have one at work
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The ARB instructions just say 1/4" NPT pipe tap but googling it makes me think its probably 18 tpi as that seems to be the most common one. It taps a 7/16" hole.
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I definitely have 1/4 BSP but that is 19 TPI according to wikepedia. I do have a box of assorted strange size taps so will take a look Monday for you James :greggmo:
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I might just live with the ARB as an open diff until I get a cheapo one delivered from China. Let me know if you find one though
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James i've got an 1/4 ntp tap for arbs just need to find it
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or
http://www.ebay.co.uk/itm/thread-cutting-taps-NPT-1-4-1-2-3-4-job-lot-/360653219909?pt=UK_Home_Garden_PowerTools_SM&hash=item53f89b6845
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James, from memory, I'm pretty sure when I did my OBA many years ago, I just bought adapters from the company Pete mentions that allowed me to connect up ARB solenoids etc.
http://www.airlines-pneumatics.co.uk/ (http://www.airlines-pneumatics.co.uk/)
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James, from memory, I'm pretty sure when I did my OBA many years ago, I just bought adapters from the company Pete mentions that allowed me to connect up ARB solenoids etc.
http://www.airlines-pneumatics.co.uk/ (http://www.airlines-pneumatics.co.uk/)
its the axle end he is on about, i have one..but i don't...but thats another story...
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James, from memory, I'm pretty sure when I did my OBA many years ago, I just bought adapters from the company Pete mentions that allowed me to connect up ARB solenoids etc.
http://www.airlines-pneumatics.co.uk/ (http://www.airlines-pneumatics.co.uk/)
its the axle end he is on about, i have one..but i don't...but thats another story...
Mike's just a few posts behind I think, from when I was getting stressed with OBA stuff.
Mike - if you have any pictures of yours that would be good. No rush if they aren't at hand at the moment.
Sent from my MZ604 using Tapatalk HD
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James, my OBA setup is in a plastic box in the shed, which bits of the setup are you interested in.
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I plan to use my stock AC compressor. Not sure what you used but I'm interested in the connections to the compressor. Also the pressure control - i need max 105 psi for ARBs, the pre-oiler and post compressor filter to remove oil from air supply .
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OBA will be one of my next projects using the oem ac compressor, looks quite easy to do and with a bit of small blanking work inside the compressor, should be able to keep it oiled without the need of an oiler or oil extractor, and with a smallish tank should be able to rattle out more than enough pressure for a wrench as well as tyre inflation :icon_winkle:
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Are you sure about,105psi for the ARB...... I'm sure that I had to get a step down variable output valve thing for mine as I was told 50 psi for the ARB.......????
Got my complete OBA system from B.O.A.B..... Oz company but here in UK...... Pump is similar to that of a Lard Rover P38 suspension jobbie and feeds a 9.5 litre tank.......OK for tyres and a few seconds with a wrench......
Tis really for trail fixes of punctures and emergency stuff......If you want air tools n stuff the way to go is what IOM has........looks like a winch and weighs the same makes a huge noise but produces enough for the windy gun. costs like a winch too :hysterical:
Here's the site.....lots of stuff like nice tents........ Easy to put up :hysterical:
Www.BOAB.biz/
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My ARB install booklet says 80-105psi, I was going to aim for 90 for the OBA.
I'd be interested to see the modifications that mean no pre-oiler and filter if you have any details.
Also interested in the step down valve thingy you used WW. Running at 100-120 would give better air-tool and airing up power but would blow the ARB seals.
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Way too much to do before breakout, just taking 5 mins from working on it just trying to get mechanicals in place so it will go, stop and steer
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Step down variable thing came from BOAB as well....... Can't find it on their web site........but have a look at Break Out and will try to find the paperwork that came with it. system cuts back in and runs at 130 psi max....... So they tell me :icon_biggrin:
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Found it.....
Tis a BOAB Pressure Regulator.......
Set at 0.5 on their dial knob thing....... And according to the Installation instructions is 73psi
Was great with the ARB when I had one on the front......and so far has been great with the air free spool......
If that is any help :icon_super:
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Great stuff, will definitely have a nosey at breakout.
Have finally got both diffs setup (taken long enough :icon_rolleyes:)
Now realised the ZJ rear calipers for rear disc conversion have rounded bleed nipples solidly seized into them - deep joy, just what I needed :jpshakehead:
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I must have done something horrible in a previous life.
Thought I'd do some simple jobs tonight -filled the front diff with lovely fresh oil after the rebuild, nice new and painted rockcrusher diff cover, fancy loctite grey rtv sealant - leaking onto the drive. Next job, reconnect rear prop to diff - uj cap falls off, I slip it back on but feels funny I check no needle bearings slipped - broken needles and generally fooked. Just getting the prop lined up and the slip joint feels stiff so get the grease gun out, runs out (of course), put a new cartridge in and the damn thing nearly explodes, grease everywhere and now won't work at all. Think I'll tap the slip joint on the prop a bit, it absolutely solid, tried a bar, ratchet strap...no joy.
Oh well, may as well tackle those seized nipples on the rear calipers, clamp in vice after they've been soaking in penetrating fluid, get the grips on them, bastard things round off, I slip, bash my hand and scrape knuckles!
This is supposed to be my hobby and enjoyable, stupid f#ck1ng bastid Jeep, it's lucky it's not burning bright and illuminating the village.
:die:
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Oh well, may as well tackle those seized nipples on the rear calipers, clamp in vice after they've been soaking in penetrating fluid, get the grips on them, bastard things round off, I slip, bash my hand and scrape knuckles!
Nipple in vice, turn caliper by hand :icon_winkle:
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That was before I'd seen that tip :icon_rolleyes:
Knocked it on the head now
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Doh :banghead:
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I heated the last set of nipples on the oven before cracking them off.
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Look what I got :003:
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Ooh yeah, better news. That's got me in a slightly better mood.
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I must have done something horrible in a previous life.
Thought I'd do some simple jobs tonight -filled the front diff with lovely fresh oil after the rebuild, nice new and painted rockcrusher diff cover, fancy loctite grey rtv sealant - leaking onto the drive. Next job, reconnect rear prop to diff - uj cap falls off, I slip it back on but feels funny I check no needle bearings slipped - broken needles and generally fooked. Just getting the prop lined up and the slip joint feels stiff so get the grease gun out, runs out (of course), put a new cartridge in and the damn thing nearly explodes, grease everywhere and now won't work at all. Think I'll tap the slip joint on the prop a bit, it absolutely solid, tried a bar, ratchet strap...no joy.
Oh well, may as well tackle those seized nipples on the rear calipers, clamp in vice after they've been soaking in penetrating fluid, get the grips on them, bastard things round off, I slip, bash my hand and scrape knuckles!
This is supposed to be my hobby and enjoyable, stupid f#ck1ng bastid Jeep, it's lucky it's not burning bright and illuminating the village.
:die:
Hahahahaha
I know the feeling, when I got the jeep thought I add a nice lift with some MUDs and happy days!
How wrong I was lol
Regearing, brakes, adjusting this and adjusting that, fucked UJ's and nowy ball joints are fucked and when I drive over the smallest of bumps my fucking head goes through the roof lol..... Plus my MPG ..... Well we won't go there lol.
My misses says on the weekend lets go on a drive up breacon to walk the dog and says lets take the jeep.
Ok need to pop and get fuel, £80 later 140 miles down and she empty lol...... Gutted!
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Just to note it doesn't help not having LPG yet lol
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Slightly better couple of hours fettling, just could do without the biblical rain in this part of the world tonight.
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Will it be done for the weekend? Anything I can do to help between now and friday? Off work till monday.
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It'll be moving, steering and stopping for the weekend but my metal guys haven't got some bits done so no winch and maybe a bit basic inside. Gonna use breakout as a gentle run in for some parts and test run for mods.
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It's kind of ready for breakout, as a test drive / break-in and learning experience.
Donk or others, if you have a spare steering box bolt it would be a massive help if you could bring it to breakout :greggmo:
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No worries will chuck one in for you.
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Awesome, thanks :13:
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Catching up on Donks thread reminded me, were those plates ok James ?
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They fit but aren't yet fitted, I'll show a few pics when done. Thanks for them though, much better than 15yr old cast ally.
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No probs mate, just hope they were what was needed :icon_winkle:
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I give up, what are the brackets for? Only thing I can think of is steering box spacer. :017:
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I believe you are spot on mate :icon_winkle:
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Got a few bits done and went out for a test drive and found it won't rev past 3000rpm and feels a bit misfire-y and gutless beyond the initial low torque. I haven't investigated but am keen for ideas of stuff to check. All the ignition components are new enough and so is the upstream O2, I have an inkling it might be a blocked cat' so will try that first. Any other ideas?
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I had a blocked cat and it would backfire through my snorkel and try to cut out.
give it a shake and everything would be fine for a bit
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A bit of tinkering time today - more reinforcement plating made, drilled, shaped and test fitted. It's a slow process, aiming for Cheapfest though.
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Looks like a lot of works gone into that, I've got a bad patch on the TJs chassis..
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Slow progress
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Looking good! Reakon you'll have it done for cheapfest?
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Yes, this lost of jobs will be done for Cheapfest - it will never actually be finished :icon_rolleyes:
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Spoke to BOAB yesterday about OBA fittings and the reducer for a lower pressure ARB circuit and seem promising but the main guy isn't back until 4th September.
Is it worth going 8mm pipe and fittings over 6mm? I would think yes for the better airflow to air up tyres and run tools but anyone have other ideas?
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Got BOAB system......had it for years.......and then I got the ARB step down valve that is basically a tap to turn flow down...........works a treat and has never let me down.........was unused for 2 years when I got rid of original axles but now powers the air drum for the winch........at same pressure as ARB.......
I went 8mm from pump to air tank and then 6 mm to the delicate bits...... With my system I could bypass the valves and filters and step down thing and go full fat 8mm direct from the tank.....
But then your risking moisture rust and stuff.
BOAB market their stuff in Oz as a get you out of the shit system and get you home so you don't die in the outback........Tis quality stuff.........it ain't cheap though........ain't fast either.....
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I really never learn - event looming closely, I try and finish a few more bits than I should and stuff goes wrong :banghead:
I'll save myself some embarrassment by not posting pics but it's enough to say that the winch mount I was building for the 8274 is shite and I'm starting again :icon_redface:
So no winch at Cheapfest but it shouldn't hamper my beer drinking and jeep chattin round fires too much
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http://www.gwynlewis4x4.co.uk/page76.html (http://www.gwynlewis4x4.co.uk/page76.html)
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I've got an ok mounting plate, it's the fitting to the Jeep and getting to the finished vision I have that's the problem (with the limited skill, tools, time and cash not helping) .
On another topic, I finally got the pitman arm off to fit a dropped one to help with angles. Following a recent post I checked the alignment splines, see picture. The drop one is offset to the opposite way, presumably cos it's LHD part. Question is - will it make any noticeable difference? I don't have full lock either way due to tyres so I'm guessing not but don't have time to piss about changing pitman arms 5 times before the weekend
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I've got an ok mounting plate, it's the fitting to the Jeep and getting to the finished vision I have that's the problem (with the limited skill, tools, time and cash not helping) .
On another topic, I finally got the pitman arm off to fit a dropped one to help with angles. Following a recent post I checked the alignment splines, see picture. The drop one is offset to the opposite way, presumably cos it's LHD part. Question is - will it make any noticeable difference? I don't have full lock either way due to tyres so I'm guessing not but don't have time to piss about changing pitman arms 5 times before the weekend
Ahhh this old chestnut!! You need to look at moving the steering arm to a high knuckle.
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The steering arm is already onto a WJ knuckle which has a higher second point for draglink and the mount is flipped so it's on top. Track bar is almost flat and this pitman arm should just about restore drag link to being parallel with the track bar. I could increase the angle of the track bar but that's a bit backwards in my view.
At the moment there's some bumpsteer but not crazy, just something I'd like to sort.
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You will also find out that the drop pitman arm needs further work - if you don't you will kill a couple of track rod ends before noticing it.
The crank on the end of the arm is the wrong way - for a LHD.
It will need heating up cherry red and bending over - I tried, and failed - so ended up sending back to Llamm 4x4 and David did it for me.
Picture shows it - car is flat and steering straight - but joint is maxed out.
Took me 2 TRE before realising
(http://i219.photobucket.com/albums/cc124/mds-houses/jeep/cherry/DSCF1342_zpsdac2b678.jpg) (http://s219.photobucket.com/user/mds-houses/media/jeep/cherry/DSCF1342_zpsdac2b678.jpg.html)
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Good tip - I'll check mine when installed. As i have slightly different steering it could be better (or worse).
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Ok, a few updates. Pitman arm was a no go, the keyway spline was off centre the same as the stock one but in the other direction. Obviously for a LHD and confirms there is difference. The result was no r/h lock so ditched it and went back to stock and will lower the axle end track bar mount to compensate.
Cherry bomb fitted and noisy. Cat made into a hi-flow with the aid of a big bar :icon_winkle:. Bends and tube arrived from Jetex.
Winch mount re-worked to look less like a window box but not yet fitted (killed a grinder in the process but it served me well and it did abuse it).
New TPS fitted, cheap ebay one from US cos it got here quick BUT, still have really bad rough running.
Question - bad idle, really bad splutter / hesitation, TPS changed, no blocked CAT, crank and cam sensors replaced not long ago with Mopar ones. No fault codes last time I scanned but I didn't scan again today. Ignition components not old and v low miles on them. Won't rev above 3k rpm. Has moments of perfect idle but it's not driveable. Should I start looking at mechanicals? Compression?
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Replacement fuel pump fixed the running problem so I've moved on to getting stuff done to MOT it, mostly a decent handbrake.
As I posted in the thread about bad running, I've got Transit rear calipers with a lever type handbrake function. I planned to pair these up with Nissan 350z rear discs because they are the same 5x4.5" bolt pattern and same diameter and thickness as Transit rear discs.
Got both parts today and unfortunately the friction surface of the discs is too thin for the Transit pads, about 40mm and I need about 60mm for the Transit calipers.
Bit of an arse but I thought I should give an update to this thread. Now back to the online brake catalogues, I know Delk uses Defender front discs so I might give in and go this route if I can't find anything else.
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I have used rally design caliper brackets welded onto an axle tube end to mount sierra calipers before (salisbury) From experience its easier to source the disks first then calipers/brackets after.
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Stock XJ front discs almost work, I'll keep investigating.
The transit calipers look perfect, big, mechanical handbrake and replacements parts are cheap. I'll make the brackets after I get the discs sorted, it'll all come together. I've got re-drilled discs on the front so am happy to do this again if needed but correct bolt pattern would be nice.
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what rear axle you running? Looked at ford explorer ones yet?
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Chrysler 8.25. It seems rear discs that have a drum handbrake use narrow pads. The transit discs re-drilled would be an obvious match. Quite a few front discs will work too if the caliper will open enough to accommodate slightly thicker discs.
Delk, if you read this then pics of yours would be handy.
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There's a couple of types xj front disc with slightly different back space
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I've got some early discovery front discs that are solid, about 14mm thick and plenty of space for the transit pads. I'll have to redrill them and the holes will be on the edge of the hub opening but the metal is at least 10mm thick so I don't see this being an issue. Best of all, they are cheap!
I also fitted some shackle mounts to the front bumper so that's almost there too - pics of all this next weekend :greggmo:
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cool glad you getting there with it
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I just got home from Scotland so here is a quick pic. I will get some better ones later this week.
My wife would not be pleased if I went out and started taking the tires off the Jeep after being gone for four weeks. Especially since it looks like I will be headed back out over her birthday.
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Wheels off
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Excellent, just what I needed to see.
What bolt pattern is your rear axle - the studs look wider spaced than mine, or you have different discs with a smaller centre bore :017:
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5x5.5 to match the Hp Dana 44 front axle. The axle shafts are larger the stck Tj and came with standard and larger bolt patterns.
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That makes sense, thanks, this really helps. If you were to do it again is there anything you'd change?
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Not waste money on the Terafex kit with the little parking brake shoes.
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Can I ask why you didn't just fit the disk/drum setup off a KJ?
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It's the same set up and also used on the ford explorer. The little drum sucks and barely held when I was on 33's Let alone my 36's. Plus the little shoes don't last very long around muddy puddles.
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I've fitted a zj rear disc kit and it's shite, crappy drum handbrake and calipers that seize all the bloody time. The Transit style caliper with handbrake involve much fewer parts and are designed to hold a heavy vehicle so should be much better suited to a heavy Jeep on 35s.
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Finally it feels like some progress is being made. A few pics to make up for all the words and lack of pictures lately.
First is the trailer just collected, needing a good service but will be put to use for the house extension as well as towing the XJ.
Front bumper to fit a Warn 8274 has been taking ages but is now there. I fitted it so the winch is tucked into the grill and had to cut a section of the front crossmember out. The angle iron provides a bit of strength back and helps keep the wiring loom away from the winch drum.
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It still sticks out almost as far as my old ARB bumper but only in the middle and mounting an 8274 any further back would have needed major re-jigging of stuff. I could have used a smaller winch but where's the fun in that :greggmo:
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That is looking good mate :greggmo:
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Nice one thats well tucked in for an 8274 :icon_super:
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nice work
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:iagree: :icon_super:
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A few hours of tinkering getting it tidied up and MOT ready. Wired the winch and fitted rope, fairlead etc. Fixed a couple of blown bulbs and fuses. Fitted a new horn, Stebel Nautilus, loud :icon_eek: especially when you test it a few inches from your face!
Somehow that lot took a whole afternoon but at least it's progress :icon_biggrin:
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Curiosity and a grinder led me to find out what was inside my sills...
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Haha, and what was the result?
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Mud, rust and general nastiness. I've been trying for 10 minutes to load a pic but computer says no :011:
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Ouch, I was scared of what's in my sills already - you've just made it worse! What are you going to do with it??
If it's so bad that you can't keep it, I'll happily take the XJ off your hands for you :icon_winkle: :003:
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ya just gotta go with what I did to the ZJ cills.....
4"x4" 3mm square section.......... Jobs a good'un
MOT man was well impressed........ Now with a new owner........ The Brother in law .......and he's impressed :icon_biggrin:
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Yes, am doing 120 x 60mm 3.5mm wall box. Did you weld the whole length or do 'stitches'? I'm thinking a good number of inch-ish welds but not continuous, then seal the length with some sikaflex or similar. Was also wondering whether to add some support to the unibody rail like my old rock rails :017:
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Photo?
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Nice
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8yrs+ of offroading helped build that lot up. I cleaned out the areas being kept and sloshed hammerite all over it so hopefully will be good for a few years. The metal was actually still a decent thickness in most places.
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I did one inch stitches and alternated between each end and the middle then used 'seam sealant'
That I got from Frosts..... Tis pale greenish and is for covering exposed welds such as floors....sets rock hard after a few hrs
I was going to add 2"x 1" bracing but was advised not necessary....... I have jacked upon them and no movement and the doors still opened and shut..... :hysterical:
Time consuming old job tho.......and positional welding..........still not my favourite.
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Cool. Welding old metal upside down is the worst - makes me really appreciate the welding I can do on a bench with clean new parts.
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Progress. Welding with high amp and just touching the sheet metal seemed to work but took concentration :icon_eek:
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Very nice
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A bit of sealant and paint. I think I'll add some tube steps and trees sliders so they stick out more. Probably gained 2" clearance over my old rock sliders.
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Nice one, that was quick work...... !
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Amazing what can be done when you push work to one side for a bit :greggmo:
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this is one of the greatest threads on here, crack on James, good work :icon_super:
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lots of work going on here keep it up mate you should be proud of it
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shame the door finish lowers the tone.
upside down welding lapping into old metal is always a challenge
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is all good from here
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Ok, it's getting there. I've been doing lots of little jobs like winch cut-outs that take so much longer than expected.
A few pics of bits and pieces I've done.
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Do you think exhaust sticks out enough for MOT? I read that it's supposed to be enough to ensure gases don't enter the passenger chamber. I may have read too many regs :umn:
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Looking good James, exhaust should be more than enough.
I've got to do mine waiting on the cherrybomb to as the slash cut tail pipe has melted the rear spring bush :banghead:
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How it sits on the drive today. Still some bits to do but it basically works and is done for Breakout. After that a few events and then the next phase.
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Some more details will follow. The number plate is just for MOT and road use until I get a small or sticker one made.
It does deserve a polish and the sticky trim adhesive removing but in the list of priorities that has been pretty low
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Looks great roll on break out
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Shock hoops
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Dig the hoops. Where did you get the rubber boots?
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:iagree: that is cool
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:iagree:
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Morris Minor gear stick gaiters
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Nice one......you been having a go with a bender?
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Soo many comebacks ...... must resist :hysterical:
Back on topic, did the re-designed plates for the brake calipers fit without modding James ?
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Sorry bought that one......just had a clean start to the day...shower and all.
Have yet to engage smut mode :hysterical:
ARGHHH that's better.....normal service is resumed :icon_twisted:
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It was slightly unfair of me Jez, before noon does not normally exist for hippies :icon_super:
Ramble on dude :icon_super:
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Warthog kindly made those for me, I'm yet to play with a bender :icon_eek:
The brake caliper brackets were spot on after I'd given you the correct measurements :icon_redface: I'll do a bit of a write up on those when I get a chance to take some pics.
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Warthog kindly made those for me, I'm yet to play with a bender :icon_eek:
The brake caliper brackets were spot on after I'd given you the correct measurements :icon_redface: I'll do a bit of a write up on those when I get a chance to take some pics.
a parts list and a copy of the brackets please :003:
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Wow, tis all coming together James :greggmo:
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Put a functioning cat in before the cherry bomb, it's taken the edge off but it still sounds good. I forgot to say at Breakout that I've got Pacesetter headers so that might be part of the sound combination.
Got an ARB compressor installed, wired and plumbed today. Might still pursue an OBA system with compressor but this was easiest for getting the locker working.
I'll get some pics uploaded because I know that's much better than just reading what someone's done.
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(http://img.tapatalk.com/d/14/06/03/gy3apu3y.jpg)
Just for the guys that were at Breakout - both shackles fitted!
(http://img.tapatalk.com/d/14/06/03/e6yqutas.jpg)
Sat on the drive next to the stock one I'm breaking and robbing parts off (helps me remember that I don't need to go bigger)
(http://img.tapatalk.com/d/14/06/03/zysy5y4e.jpg)
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Looking good James :greggmo:
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:imwitstupid:
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Very nice. Indeed......
What's next ?
I guess any more and Tis a trailer queen :icon_twisted:
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I have plans but they're on hold now while I get the house extension (and garage) built. Just going to use and abuse for the rest of this year and try and stay away from Pirate.
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Ah yes Pirate ........king CJ and DoubleJ.........
The start of my downfall and decline into 'Trailer queen'! :hysterical:
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Did you cheat and grind the shackles :hysterical: That would have driven me spare and i would have cut them off :lol_hitting:
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No, just a carbide bit in the die grinder.
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pirate :banghead: :003:
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She looks very yummy :)
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Just for the guys that were at Breakout - both shackles fitted!
Hahaha, good work! :lol_hitting:
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Well, not much fun stuff to update but I have been tinkering a bit with maintenance type stuff and gave it a very good testing in Normandy with J33P.
The testing revealed a reluctance to start which I've now worked out is because there is no fuel pressure with the ignition on but it will start after a few turnovers and then there is the necessary 49psi. I'm guessing some kind of fuel pump issue cos it always is and it needs the tanks dropping to sort - typical.
There was quite a bit of banging around type noise coming from underneath when laning and driving on the road in France so I've fitted a new gearbox mount and levered the cat a bit further away from the floor - all seems ok on a quick test run.
I've fitted some manual seats in place of the electric leather originals to save some weight and provide simple bases if I want to fit buckets on the manual sliders. Even fitted a stereo :icon_eek:
A couple of pics of laning in France - possibly the XJ is slight overkill for laning but we did find some tricky stuff requiring lockers, hence the muddy pic.
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How much lift is on it, and what size rubber James ?
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6" lift and 35" tyres
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OOFFF. Thanks James. :)
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Quick update on the lack of progress and updates. Garage and combined house extension is taking loads of my time and all of my cash. On the positive side I will soon have a nice workshop to build things in. It's a mess still at the moment but there's an outline forming
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Not fair I want an indoor workshop :010:
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Get yourself a small .......or as large as will fit..... workshop woodburner........
Been using mine the last 3 days.......make life more tolerable.
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It's on my wish list :icon_winkle:
Once building inspector stops visiting it might get a radiator fitted as well.
The wish list is quite long - new welder, compressor and air tools, nice storage cabinets...
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Quick update - supposed to be working late but ended up looking at XJs with rear stretches (helps with the big arse overhang).
Also a quick pic of where the garage / extension build has got to so you all know why I've been so slack modding and driving the Jeep.
Seeing as I've just opened another Hobgoblin and logged into NAXJA this work business could get a bit delayed :100:
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I think cage building might be moving up the list after seeing this picture on FB
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Kevs CJ is another picture to confirm a cage or substantial roll bar of some description is an added bonus
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yup not the best day
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it amazes me why insurance companies increase the premium for adding extra safety to the car in respect to a roll cage, on the belief that it will encourage irresponsible driving.
Take a close look at a WRC rally cage if you have the chance, now those are a work of art. they turn a "production car" into basically a tubed chassis car.
As for design and type to fit that's a matter of opinion for the vehicle you have
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I've been looking at WRC cages because the XJ is more like one of them than a separate chassis Jeep / 4x4.
I'll build it myself but ideally would like another die for my bender smaller than the 2" one I have - just so I can use smaller tube where space is tight.
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Got 1.75 die and 1.25 if you want a borrow :icon_super:
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Will they fit my JD2 bender? I've still got to save for the fancy CDS tube :icon_eek:
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:icon_biggrin:JD 2also.
Got my CDS 1.75 from Metals4U online delivered to house at 4 metre lengths......cheapest way to buy them.......( but not cheap :jpshakehead:)
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Thought I'd check the XJ over before seven sisters. It turned into this...(http://images.tapatalk-cdn.com/15/07/18/6040dcd19016ca767806782fdb9b5625.jpg)
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Access panel for fuel pump
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That's a lot of work going on there.......
Dodgy fuel pump and sender syndrome!!?
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Dodgy pump so changed for new, then dodgy return valve thingy me bob so released all pressure when ignition went off, changed again but got fed up of dropping fuel tank, skid... so thought I'd try this.
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why not go racing tank in the boot ??
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Tis,what I did.....
Sent the pump and float down to the man so he could make it fit......
2.73 galls is a bit small but was running LPG at the time.....
Reckon 5 galls is enough for most events/.days
Unless you've got a manly v8 :icon_super:
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Hi James
will you be at 7s having done all this stuff
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That's the plan, looking forward to it.
All the jobs I've done and got planned and it will look exactly the same as before!
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That's the plan, looking forward to it.
All the jobs I've done and got planned and it will look exactly the same as before!
Nowt wrong with that