Calgary Jeep Association
4x4 Related Groups => Build Ups => Topic started by: Waytec on March 09, 2010, 05:29:36 PM
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So this is a big one I have been keeping a build on other sights for some time now and am have it hear as well.
Here it is as a nice little baby the day I brought it home. The guy I bout it off almost did not sell it to me. He asks me what I wanted it for. I responded to drive and go camping in. He goes good I don’t want it chopped up and bush beat.
(http://i306.photobucket.com/albums/nn279/waytec/jeepstock003.jpg)
The next day RE 3.5 and 31” Pro-Comp Extreme MTs ;D
(http://i306.photobucket.com/albums/nn279/waytec/jeep002.jpg)
(http://i306.photobucket.com/albums/nn279/waytec/jeep004.jpg)
(http://i306.photobucket.com/albums/nn279/waytec/jeep009.jpg)
Later that day. I had to :o
(http://i306.photobucket.com/albums/nn279/waytec/jeep006.jpg)
Radio for com’s
(http://i306.photobucket.com/albums/nn279/waytec/jeep007.jpg)
Next to carry the spare and high lift a roof rack made from material I scavenged from scrap metal at work. It was funny how all the pieces where found in the bin and where the perfect size and length already.
(http://i306.photobucket.com/albums/nn279/waytec/April262008041.jpg)
I was not going to go with a bumper and winch right away, but the deal of a century came up so I could not refuse.
(http://i306.photobucket.com/albums/nn279/waytec/April262008039.jpg)
After a meeting with a log
(http://i306.photobucket.com/albums/nn279/waytec/May032008PresadentsAsult041.jpg)
Sliders where in order
(http://i306.photobucket.com/albums/nn279/waytec/EdmontionOct052008027.jpg)
(http://i306.photobucket.com/albums/nn279/waytec/EdmontionOct052008025-1.jpg)
I found having the spar on the roof made the rig to tipsy. A swing out is not in the budget right now so, inside the spare goes on it own rack.
(http://i306.photobucket.com/albums/nn279/waytec/14.jpg)
(http://i306.photobucket.com/albums/nn279/waytec/wheelrack1.jpg)
Stay tuned next is an on board air system and I have bent my front stock track bar so a heavier one is on order.
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The On Board Air is done. I was able to fill two 2.5 gallon tanks from 0 to 130psi in about 2 minutes and air up my 31 x 10.5 for 10psi to 30psi in 45 sec with checking pressure 4 times.
The pump came with the XJ. I modified the existing A/C compressor; I used 2 2.5 gallon tanks in the rear, and -6 signal brad hose with reusable fittings to get the compressed air from the pump to the tank. The compressor is not internally lubricated so I hooked up a small oilier I got from Home Depot.
Thanks Trevor (Immortal) for the use of a heated Garage and your help.
A dash switch for power. The green light comes on when the pump is on.
(http://i306.photobucket.com/albums/nn279/waytec/WAYTECOBA025.jpg)
The compressor modified to except the inlet and output of air. All the wiring is now in loom and is nicely secured.
(http://i306.photobucket.com/albums/nn279/waytec/WAYTECOBA022.jpg)
(http://i306.photobucket.com/albums/nn279/waytec/WAYTECOBA023.jpg)
I used a relay to control the power from the switch, battery and pump.
(http://i306.photobucket.com/albums/nn279/waytec/WAYTECOBA008.jpg)
I found the perfect spot in the floor to drill a hole to get the hose from the underside into the cab. The carpet was cut in the spot already.
(http://i306.photobucket.com/albums/nn279/waytec/WAYTECOBA017.jpg)
2 tanks mounted with all the hardware.
(http://i306.photobucket.com/albums/nn279/waytec/WAYTECOBA018.jpg)
(http://i306.photobucket.com/albums/nn279/waytec/WAYTECOBA020.jpg)
(http://i306.photobucket.com/albums/nn279/waytec/WAYTECOBA019.jpg)
;D
The system is set up that I throw the switch in the cab green light comes on to remind me that the pump is on. The pump starts pumping. Once it the pressure in the tanks gets to 130psi the pressure control cuts the pump out. Once the tanks get down to 100psi the pump will cut back in. I figure I should be able to run a ½ inch impact off this in short bursts.
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I have some other mods that I did not post earlier.
The 4wd shifter was in the way when engaged and I could not get my leg in a comfortable position on the trail, so I cut it handle off and put a small one on.
(http://i306.photobucket.com/albums/nn279/waytec/insideJeepandNewCorolla003.jpg)
I added a thumb throttle. Really nice when I am have to stop on a hill and then start agene one foot on brake one foot on clutch one hand on wheel and one hand on throttle. Also nice when running the OBA that works at engine speed. It is now my curse control as well.
(http://i306.photobucket.com/albums/nn279/waytec/insideJeepandNewCorolla002.jpg)
Added some safety equipment.
A real fire extinguisher mounted up out of the way and easy to get at.
(http://i306.photobucket.com/albums/nn279/waytec/insideJeepandNewCorolla005.jpg)
For light that is easy to grab.
(http://i306.photobucket.com/albums/nn279/waytec/insideJeepandNewCorolla006.jpg)
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It has been some time since I have updated my build.
I finished the bracket that holds the oilier of the OBA. After trying different clamps I found the best way to hold it on was Zip Ties.
(http://i306.photobucket.com/albums/nn279/waytec/swingtankskid006.jpg)
I picked up a damaged Garvin Industries swing out.
(http://i306.photobucket.com/albums/nn279/waytec/Swingbefor.jpg)
After some help from a friend and $30 of end cut material you have to look hard to find the new metal. I did not like the way it mounted only using four bolts per side to the sheet metal. I modified the mounting system so a piece of 1 1/5 inch plat goes back into the sub-frame and bolts to it, the same way a trailer hitch dose. Now I can pull on it as much as I want and it will not move.
(http://i306.photobucket.com/albums/nn279/waytec/swingtankskid015-1.jpg)
Due to the accident that damaged the bumper the bolt and handle that held the swing out closed was broken off and not usable. We used some artistic flare and what we could find around the shop to make a new handle.
(http://i306.photobucket.com/albums/nn279/waytec/swingtankskid018.jpg)
The tire blocked the stock plat location so I mounted on the handle that secures the tier.
After being informed by the RCMP one night on the way home from work that a plat light is required I mounted a LightPlate LED light.
(http://i306.photobucket.com/albums/nn279/waytec/swingtankskid016.jpg)
I tend to drag my diff in the mud and scag and I am surprised that I have not found a rock yet. So being proactive a Rock Crusher diff cove in sported up front now. Over winter I will be building a new rear axel and it will get armored out as well.
(http://i306.photobucket.com/albums/nn279/waytec/swingtankskid002.jpg)
Last fall a stone was thrown from a trucks rear tire completely smashing my head light. The rock was still in the bezel when I stopped. So I picked up a set of YJ light covers and modified the mounting to work for me. I kind of has the Defender look to it now.
(http://i306.photobucket.com/albums/nn279/waytec/swingtankskid004.jpg)
And finally a fuel tank skid to protect agents trail rash. TOMKEN it one of the only companies that is still making parts for the XJs that I can easily get shipped to Canada.
This skid has now been well field tested by me.
(http://i306.photobucket.com/albums/nn279/waytec/swingtankskid020.jpg)
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I have planning the next step of the build for some time now. I did lots of research because not to many XJs have flares made to take a hit. Most people use plastic and the first tree you come to rips them off. So I decided to make mine tree and rock proof. In the end you cannot really call them flares but more lower armour.
Front Before
(http://i306.photobucket.com/albums/nn279/waytec/Mods/PB130003.jpg)
Front After
(http://i306.photobucket.com/albums/nn279/waytec/Mods/Dec012009082.jpg)
Rear Before
(http://i306.photobucket.com/albums/nn279/waytec/Mods/PB130001.jpg)
Rear After
(http://i306.photobucket.com/albums/nn279/waytec/Mods/Dec012009081.jpg)
Because the XJs are long. I tend to hit the rear quarter panel when departing rock ledges. So I cut the panel and folded it up to increase the departure angel a little. I tied the fender and rear bumper together for added strength and if I am going drop down onto something slider will take the brunt of the hit and not the sheet metal.
(http://i306.photobucket.com/albums/nn279/waytec/Mods/Dec012009086.jpg)
The up grad completely changed the look of the rig. I will be able to run 33's with no issues at all, 35s with no up travel.
(http://i306.photobucket.com/albums/nn279/waytec/Mods/PB230001.jpg)
(http://i306.photobucket.com/albums/nn279/waytec/Mods/Dec012009090.jpg)
33's on a XJ with a RE3.5" lift. I don't think you will find that one on a chart anywhere. ;)
During the summer I dent a few of my steering links. After having to bend them back to get off the trail and swapping used set I had on I decided to upgrade to a set that I wouldn't bend to easily.
Currie Heavy Duty Tie Rod
(http://i306.photobucket.com/albums/nn279/waytec/Mods/Dec012009091.jpg)
I also put on a drop pitman arm that I have had for some time but never put on.
(http://i306.photobucket.com/albums/nn279/waytec/Mods/Dec012009094.jpg)
Next is gears, locker, and bigger rubber.
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Here we go agene.
As you can see and for most of this build I have been reactive. I brake something, so I change and up grade. This time I wanted to protect my grill before I broke it. I had a couple close calls, so I called up my buddy Brink. "Brink I need a hoop to protect my grill." "dude I have something on the go come by on Sunday and I can bend it up" "I am going out Saturday" "you have not had issues before"
Look at had happens on Saturday.
(http://i306.photobucket.com/albums/nn279/waytec/006.jpg)
So Sunday after one hell of a guilt trip I have a hoop, to protect the outer edges and a small one for help the winch out.
(http://i306.photobucket.com/albums/nn279/waytec/002.jpg)
(http://i306.photobucket.com/albums/nn279/waytec/003.jpg)
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I won the lights last year at the CJA show and shin, thank you Modern Motors for donating them.
To control the lights I needed a switch. I did not like the IPF one. So I went to Bear and we found something that I liked. Instead of ordering 1 I got 12. Switches for all the lights and ones that are to come, the winch, compressor, and lockers and some extras.
I was able to get the compressor switch in, but I needed to make mounting plats for the rest. I did get some material and Trevor started to build them but we ran out of time and making the square holes is a pain in the arse. So a talked to friends and am now going to have them laser cut.
(http://i306.photobucket.com/albums/nn279/waytec/007.jpg)
I got all the holes cut into the dash and consol panels and most of the wiring pulled but now I have to wait for the panels and I am back in business.
the location for the lockers
(http://i306.photobucket.com/albums/nn279/waytec/010.jpg)
location of all the light switches
(http://i306.photobucket.com/albums/nn279/waytec/009.jpg)
location of the winch controls
(http://i306.photobucket.com/albums/nn279/waytec/008.jpg)
I still need to figure out the winch cab controls. I found some diagrams on the net but when we pined them out the winch did nothing. I has to be something simple that we are missing because it is only to weirs that control the winch. The Warn controller has 5 wirers and the switch I have has 3 power in and two power outs.
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Great mods! I really like the onboard air setup!
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Thanks Slappyman
I picked up my 33s yesterday in Calgary and today went out and put them on Grumpy.
(http://i306.photobucket.com/albums/nn279/waytec/Mods/013.jpg)
Also see what showed up for me.
(http://i306.photobucket.com/albums/nn279/waytec/Mods/014.jpg)
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33's and lockers? WHO ARE YOU! You can't be Waytec... ;D
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you need 35s
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you need 35s
Ditto. ;D
He's going to be real scary now with 33's and lockers. :D
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Yup just watch how far I am going to get stuck in the hole now.
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might even make it 6ft into 2" of mud instead of 4ft....
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I got the laser cut switch panels this week, mounted the switches and pre wired as much as possible.
Now I am hoping for good weather this weekend so I can get them mounted.
(http://i306.photobucket.com/albums/nn279/waytec/Mods/DSCF1003.jpg)
(http://i306.photobucket.com/albums/nn279/waytec/Mods/DSCF1001.jpg)
(http://i306.photobucket.com/albums/nn279/waytec/Mods/DSCF1006.jpg)
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Where did you get the switches from?
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Finally page 2.
I got mine though Bear at Bear Trax Outfitters 780.651.1621
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So after all day Saturday and most of Sunday the switches are in and all working. This was a project that started then snow balled into fixing other issues at the same time with 4 trips to CT.
(http://i306.photobucket.com/albums/nn279/waytec/Mods/012.jpg)
(http://i306.photobucket.com/albums/nn279/waytec/Mods/013-1.jpg)
(http://i306.photobucket.com/albums/nn279/waytec/Mods/014-1.jpg)
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Looks sweet dude. I took your engine for a ride out to Rocky today...I think it enjoyed getting out again for a bit.
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Thanks it need to get once and a while.
once this one is done that s next on the projects list.
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No worries.....
(looks over his shoulder)
.....there's still room in the living room here. ;D
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Lookin Good
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Thanks Ron
I had no idea that getting verything set up and mounted was going to be so much work. but it is worth it.
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Its looking really good Aaron. Now it just needs some swampers ;D
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It's going to be alot more "Lookin Good" after this weedend. ;D ;D
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Ya the easy buttons will not be for show anymore.
To clarify for everyone I am not getting a front locker right now. I was not going to take the dash apart agen for the front locker next winter so I ran everything now.
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Thanks Ron
I had no idea that getting verything set up and mounted was going to be so much work. but it is worth it.
if its hard work then the otucome will be better. if its too easy then you're not doing it right ;D
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It is all worth it in the end.
I got it back looks the same but does not work the same. 4.56 gears and a ARB in the rear. I had to call Trevor and ask what the all the way to the right and up gear was. I had forgot. :D
Air system is all hooked up and no more air leaks. :)
I missed the shake down run because my front drive shaft CV gave up on the way back from Calgary. :( Robin happens to have one so today was down to Airdrie and back.
I cleaned up the back, got rid of a bunch of stuff I have been carrying for 2 years and have never needed.
shake down run this weekend with the RDJ guys. ;D
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the saga continues
from October
I have started the 2010/11 modifications ,not by chose but buy Camshaft coming out through the block circumstances.
I have been a long time starting this from when the incident happened. I moved into a rented house with a garage (or at least half a garage). The guy in the basement gets the other half. So I have been setting that up.
Jeep in the door
(http://i306.photobucket.com/albums/nn279/waytec/Mods/Oct082010044.jpg)
Started the tear down. Hood off
(http://i306.photobucket.com/albums/nn279/waytec/Mods/Oct082010042.jpg)
Winch, lights and bumper off. Needed to cut where the fenders where welded to the bumper.
(http://i306.photobucket.com/albums/nn279/waytec/Mods/Oct082010049.jpg)
Front clip off, I cut the condenser off as well. A/C never worked and I converted the compressor over to OBA a long time ago.
(http://i306.photobucket.com/albums/nn279/waytec/Mods/Oct082010054.jpg)
Found one of the resins for the overheating issue.
(http://i306.photobucket.com/albums/nn279/waytec/Mods/Oct082010052.jpg)
I found a other failure analyses clue.
(http://i306.photobucket.com/albums/nn279/waytec/Mods/Oct082010061.jpg)
What I am thinking right now is - when I sucked the little water into the engine I stretched/strained the timing chain. It broke piled up stopping and braking the Camshaft that then exited stage left.
I will get some pics of the side of the bock folded out. right from the chain cover past the mounts.
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So I got snowed out working in a non heated garage. Today I moved the rig to a buddies place that is heated should have the engine out shortly and lots of other things planed mostly reworking old projects, and adding one of the most newbie things but they are actually practical for where I spend a lot of time wheeling.
Pulse a somewhat snorkel
http://www.spectreperformance.com/#CATALOG.9945
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That thing looks like it belongs under a kitchen sink :o
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That thing looks like it belongs under a kitchen sink :o
?
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That spectre intake does look shiny, (and a little bit like a sink trap :P ). That cone filter seems a bit small, I'd want to see some surface area or flow numbers and compare to the stock filter. Also, the pragmatist in me wonders how easily one could find a replacement filter. Still, I like the idea of drawing air from under the cowl.
Great build by the way, I love how clean looking the switches turned out! 8)
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I going with the spectre performance for two resins one because with the flat fenders I have a aftermarket snorkels wont fit, an air flow might but not 100%, the other risen is I saw 2 snorkels get ripped off last year. So this way it is inside and can modify it if needed down the road to be a snorkel.
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Today's progress
(http://i306.photobucket.com/albums/nn279/waytec/Mods/Feb052011009.jpg)
good shot of the damage
(http://i306.photobucket.com/albums/nn279/waytec/Mods/Feb052011008.jpg)
(http://i306.photobucket.com/albums/nn279/waytec/Mods/Feb052011007.jpg)
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So I got snowed out working in a non heated garage. Today I moved the rig to a buddies place that is heated should have the engine out shortly and lots of other things planed mostly reworking old projects, and adding one of the most newbie things but they are actually practical for where I spend a lot of time wheeling.
Pulse a somewhat snorkel
http://www.spectreperformance.com/#CATALOG.9945
(morerpmfred)
u should take a look under Andy's hood he built something like that I beleive he used a bigger filter.
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I,m thinking on going to Aaron,s set up as it is cleaner under the hood and not ghetto like , like mine ;D Was not available when i built mine.
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this is something new for these guys. is company is more known for their street rod stuff. look around the site very bling bling stuff.
The other set up I was looking at was http://www.dpgoff-road.com/site/airflow_xj_snorkels.htm but I like the idea of not having anything on the outside to get ripped off. and if I have water high enough to such it in thru the cowl I am in bigger trouble then that.
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I like the idea of not having anything on the outside to get ripped off. and if I have water high enough to such it in thru the cowl I am in bigger trouble then that.
Id have to agree with that... The likelyhood of getting it ripped off the outside in Alberta seems high, with the scratches and scrapes and new pinstripes we all seem to get on the trails here it almost seems inevitable... And yeah. When your junk gets wet, you know your in deep water then for more reasons than just that ;)
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So over the last couple weeks I have been busy.
engine is in all hooked up and running.
(http://i306.photobucket.com/albums/nn279/waytec/Mods/March06036.jpg)
(http://i306.photobucket.com/albums/nn279/waytec/Mods/March06038.jpg)
I modified the compressor to being grease-able, no more oiler. I have 2 o I converted the other one as well as a spare.
(http://i306.photobucket.com/albums/nn279/waytec/Mods/March06050.jpg)
(http://i306.photobucket.com/albums/nn279/waytec/Mods/March06046.jpg)
Front end all back together
(http://i306.photobucket.com/albums/nn279/waytec/Mods/March06053.jpg)
I have been doing / will be doing lots of other little things as well, like new ends soldered onto the battery connections, adjusting the t-case shift linkage, cutting a foot of my Brink shovel .
I took the rad to the car wash and removed about 4 pounds of mud.
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today's update.
Front drive shaft new u-joint and in.
Adjusted t-case linkage so shifts correctly
T-case skid on
chased down the dim right light and no high beam. cause - corrosion in the connections. I have no idea where the dust, dirt and water keeps coming from. lots of electrical grease to try to keep the water out from now on.
Stock air box in
Changed out driver's seat to another stock one. We are not going to talk about my fat arse and the old seat.
Finally the to do list is shorter than the done list.
To Do
Cut, and drill bumper bringing it closer to the truck. and mount
Free spool is gone, need to take winch apart and clean and regrease
Change out 5 pin on solenoid box. mount and relocate box.
check fluids, Grease unit, Recheck fluids
Test drive
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So I have not updated in a several weeks.
so all the small tedious jobs are now done. took it for a test drive and found the axel seals leaking. not something easy to do.
her it is at my buddies fathers farm up the road from the shop. before the fenders where welded down and the hoop put back on.
(http://i306.photobucket.com/albums/nn279/waytec/Mods/March272011020.jpg)
no as many pics because I don't think you just are interested in looking at wiring and zip ties before and after.
I cut about 4 inches out of the front bumper and remounted the winch, a little closer to the grill. No more Brink shovel for me. Trev I am thinking you are the last.
(http://i306.photobucket.com/albums/nn279/waytec/March272011025.jpg)
(http://i306.photobucket.com/albums/nn279/waytec/Mods/March272011026.jpg)
Now I am waiting for the new intake to come in and then I can relocate the control box to where the air box is right now. and put the wire rope back on the winch.
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Holly crap I am done and everything is back together, other than the fairlead supports that have to be welded on.
lots have happens over the last couple months and I did not take any pictures.
Everything in and drove it around for a couple weeks. all working good.
Took it down to Langdon for new lower control arm brackets (thanks Raf), I folded the old ones over.
On this trip I found a really bad leak. did some looking around and found that the valve cover had a hole in it from the lifting brackets. brought it back and changed out the valve cover for one I had kicking around.
I ordered a new air filter system relocation the intake to the fire wall. that took some time to come in and thin it took me some time to go to Edmonton to get it.
All installed today, and noticed a difference right away. This should keep the water out of the engine. and if I am in water deep enough to get water in the intake I have digger worries then that at that moment.
(http://i306.photobucket.com/albums/nn279/waytec/Mods/June52011005.jpg)
(http://i306.photobucket.com/albums/nn279/waytec/Mods/June52011004.jpg)
I also relocated the winch solenoid box to the where the air box once was.
(http://i306.photobucket.com/albums/nn279/waytec/Mods/June52011007.jpg)
about half way through last summer i lost free spool on the winch. I took it all apart this winter and found the grease had hardened up and the caller could not move. After cleaning everything and repacking the crap out of it with grease, back together it went and back on the rig in its new place as close to the rad as possible.
Now drive it around this week and off to the trails this weekend.
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Aaron - you have digger worries than most...
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Right on ... I like that cowl air intake set up and cheaper than a Safari 8)
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Wow, this rig makes me really want to focus on doing more to my XJ. Nice job!
I love that air intake.......
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You make my XJ seem severely lacking in switches. I like that intake... but I have some noob questions:
Are the vents really water tight? (Heavy rain / car washes)
Any worry about the vents getting clogged with mud / ice?
Is it loud in the cabin?
Thanks!
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There are drains in the bottom of the vents and the only time you get water in the filter is when you hood is under two feet of water. Ask me how I know 8)
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There is drainages for water. If I am in a water hole that deep my computers are under water as well so sucking water is not a concern at that point. In the notes the kit said to clear snow from the vents before starting.
It is not any louder in the cab than normal. under heavy acceleration. I get a whistling nose coming from the glove box area but I am not concerned about it enough to pull it all apart to seal it.
The kit was real easy to put in the only thing is it did not give any direction on what to do with the vapour/bather tube from the fuel tank filter canister, if that all makes sense (I don't know what the thing is called) I cut it off and tied it down and the rocker cover vent line was to long so I shortened it.
All the switches have a purpose and I have found they are in a very logical layout. the only ones not being used right now are the, Front locker - I don't have one yet , Wind shield lights will come with exo cage, and one rock light will come with exo as well.
The best switches I have ever done and will recommend to anyone is hard wire your winch into the rig. where mine is they are very easy to use. I set it up that the "winch" switch powers the "in and out" switch so I cannot accidently bump the winch when driving. this set up gives very accurate control and no delay unlike the remote control that warn has.
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Sweet build thread. I especially liked the switches. I've seen so many poorly mounted.
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Lookin pretty good Aaron.
What kind of air system have you got? That looks like something I could use. "home fab" or did you buy it?
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http://www.spectreperformance.com/#CATALOG.9945
Here is the web address for the site. I got mine through Bear so I did not have to pay the brokerage.
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The last time I was out(up that was a long time ago, I skidded along a rock face and turned my non folding mirrors into folding.
I looked around for a cheap option and found aftermarket Yamaha R6 mirrors.
So some fab work was needed and they are on. I am hoping they rub off on the XJ a little and give her more speed on the hyw.
the old stock mirror off.
(http://i306.photobucket.com/albums/nn279/waytec/Mods/IponeJanuary14072.jpg)
new bracket I made
(http://i306.photobucket.com/albums/nn279/waytec/Mods/IponeJanuary14073.jpg)
(http://i306.photobucket.com/albums/nn279/waytec/Mods/IponeJanuary14074.jpg)
mounted and silicone
(http://i306.photobucket.com/albums/nn279/waytec/Mods/IponeJanuary14076.jpg)
Done
(http://i306.photobucket.com/albums/nn279/waytec/Mods/IponeJanuary14077.jpg)
(http://i306.photobucket.com/albums/nn279/waytec/Mods/IponeJanuary14080.jpg)