Project Eileen

[The_XJ_Eileen]

This week I focused hard on getting the front end put back together. I needed something I could take some pictures of and feel a sense of accomplishment. So I got the new KC fog lights installed and wired up and finished the fenders. I clearanced them a few weeks ago and had to replace the driver side as it has been badly damaged since I got the Jeep.
I will post pictures of the switch panel I got for this Jeep next time as I'm still getting it fully installed. I am very excited about this part of the project and very happy with how it's coming together. So much to do still but this week I'm finish welding the rear axle again since I did it incorrectly and I will be buttoning up the odds and ends from the front end part of the project. Next weekend will have all my attention on the interior to wrap up the floor pans and hopefully get started on the bed liner on the rear hatch area. This is all taking so much longer then I'd like but I'm trying my best not to rush the jobs so I am happy with the product once it's on the road. Lots to learn and lots to do!!

[The_XJ_Eileen]

Spent this weekend getting new battery terminals installed with a the new battery tray. This battery tray is from a local company called mountain vista fabrication.
Got all new ends on the wires to make it all look neat as I could.
Cleaned up some rust and sprayed it with a self etching primer. I'll go through with the POR-15 another time to kill off the rust but that'll do for now.

Also pulled apart the rear axle again to reweld the axle perches. They're much more secure now and I'm not worried at all about them holding up to abuse and time. Of course I need to re assemble the axle and tie up some loose ends but this part is nearly complete.

Also installed the new switch panel. This was super exciting to me finding something that uses a stock location makes a very clean look.

Next week it's full steam ahead on the interior.

[a1gemmel]

Nice work! Project jobs aren't always glamorous but you'll never regret the time you spending painting and rust-proofing. Welds on the perches look great.

[The_XJ_Eileen]

This weekend I was able to get 2 of the 3 floor pans welded in place. They are about 90% done I need to grind down the welds so they are more smooth and apply steel reinforced bodo on some of the rusty spots that can't be welded too and I don't have the skill set to fabricate lots of little patches. Of course I'll be doing POR-15 on all the rust I can find before I do the bondo extreme.
Then I'll do seam sealer on all the new seams top and bottom before I finally throw down some fresh primer and a quick coat of paint then I'm doing sound deadener on the floor then lastly I'll install the new carpet. At some point in here probably after I lay down paint on the passenger area.
I'm doing raptor liner in the rear hatch area lol this is all taking so long but I know I'll be so happy to have done this all the way I wanted the first time.
This is about 1,000 tack welds and only a few fine beads where I was able to make it work.
Also smoked my transmission wiring harness while welding but I think it's only for the reverse lights which never worked.
Oh and I got a new tool box that I am very proud of. My tools were all stolen about 5 years ago by my childhood best friend. About $12,000 in snap on and matco tools were all lost.
I've finally built up a new tool box and although the tools aren't snap on I am still extremely proud of myself for getting this box together again!

[Jim]

Good work - nice to see it coming along.

[The_XJ_Eileen]

This will be a bigger update since I haven't done one in some time.
Since my last post I've finished welding in the new floors and patching rusty places with fresh steel.
I also got the rear brake lines built and installed.
Currently I'm working in the engine bay installing a new intake and exhaust manifold gasket with new bolts and repairing a broken stud.
At the same time I am installing the new "Dave's custom designs" brake booster, master cylinder, and manual adjusting proportioning valve.
This marks a huge upgrade in braking power for me which was the original issue I set out to fix!
That issue lead me to everything in this thread. 😅

[The_XJ_Eileen]

I also re-did my oil pan gasket and gave it a fresh paint job. I did this and the rear main seal a year ago and haven't driven the Jeep since but in the few times I ran it it was leaking.
So I'm hoping I fixed that.
The oil pan skid plate is from Barnes 4WD.
Next I'll be finishing the intake and exhaust/brake job and then I'll be building the new exhaust.

[The_XJ_Eileen]

Finally got to build my exhaust over this long weekend.
This is a cat back exhaust and only me second one every. I'm pretty proud of this and it sounds fantastic!
I still need to install another hanger for the rear section and clean up some of the weld spatter.
Also need to mount the exhaust tip.
Jeep runs great but I found a vacuum leak at the injectors. O-rings are shot.

[TjMike]

That exhaust looks great! Looks like you're getting close.

[Jim]

Nice to see the progress!