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Looking very good!

I am doing a fairly similar project and need to get a build thread started.

Those axles are going to be pricey!

I had a phone full of pics for updates. Dropped the phone. It shattered. I spent an afternoon replacing the screen, but the board is horked and the screen is still displaying nothing but gibberish... So I give up on the pics.

I got the axles back. They have a nice layer of surface rust on the raw metal parts from sitting, but are otherwise looking nice and ready for metal prep.

The drive-line is roughed in and mounted and accessories are going on the motor. The transfer case sticks out a bit, which I don't like-- but the motor sits low and has good clearance with the hood and the rear firewall (which I do like). It looks like I will have plenty of room for a mechanical fan and shroud. The mechanical on-board air compressor is a bit up in the air. Still looking at the best way to get it, and an ac compressor, mounted up. Edit: In the end, we went with an electric compressor.

Wheels are ordered. 8-lug wheels and rock rings on the way. I hope to get some roller tires mounted asap...

Lost all data on the old phone, so I took some new pictures with the new phone:

Engine roughed in:








Wheels arrived.



Axle internals are done, but I forgot to take pics.

Next steps:

1. Get the turbo, charged air cooler, radiator and ac compressor mounted and clearing all sheet metal (or rework sheet metal to make it clear).

2. Ditch ye old Dana 27/Dana 44 and put the D60 on (SOA ) and the 14-bolt in the rear. Mount up to Chevy 1/2 ton leafs via new leaf mounts on the frame, figure out final selection, location, and installation of power steering box / frame reinforcements / front cross bar modifications.


Lots more to do...

Nice looking wheels!

Front Axle:




Finished installing the ZIP air locker, the 35 splined inner and outer cro-mo's, the ballistic fab shave kit, and the Yukon selectable hub's.

Rear Axle:


Ballistic Fab shave kit installed, gear turned down to fit housing, ARB air locker, 35 splined inner and outer cro-mo's and a flange kit.

First Reassembly



Getting the front end put back on to measure and cut for CAC, radiator, and AC exchanger fitment.

Any updates on this? Loving the build and very hopeful to do something similar to my 88 GW. Thanks for all the info you have provided here!

It is moving along at a snail's pace as I am moving and switching jobs. We are working on fitting a ford one ton steering box and getting it drivable. I am putting the doors back on it and some take off tires so it will drive/move. It might go on hiatus for a bit after that.

You said you were doing a Horton electrically activated magnetic fan clutch, is this something you have purchased? Do you have a link to order or a distributor that sells them?

I got it from my diesel mechanic, who had it laying around. I would think any diesel mechanic can order it for you.

FYI, this build is still progessing... slowly. Steering and suspension are roughed in. No pics yet, as I am seperated from the Jeep at the moment. Hopefully, I will will get to a stopping point on my XJ and can resume messing with the Waggy soon.

Adventure_Wagon88 wrote:You said you were doing a Horton electrically activated magnetic fan clutch, is this something you have purchased? Do you have a link to order or a distributor that sells them?

I am running this unit,but found one for less that half this price.
I am real happy with it i run a 210*/195* switch and it rarely comes on on the highway, and on trails with a 20" fan it will cool down in ~ 1 minuite. I have also noticed that it runs much better/cleaner at low power/boost on the trails with coolant temps around 200*, before i was not comfortable running it that warm but now with the large Dia. engine driven fan I am....$.02
http://www.ebay.com/itm/Cummins-3927735 ... KZ&vxp=mtr

http://www.warnerelectric.com/products/ ... e-clutches

Thanks Eggman! Great to hear you're chipping away at it Pablo do post pics when you have some! Excited to see where it's at

I bought a cheap electric winch for the front last weekend, was the only progress I made this week.

The XJ is sucking up all my time. Now that the weather has thawed I am trying to get that ready for this summer's adventures. I have beat on it all winter and it now needs an increasingly long list of things, as it is a 22 year old vehicle. Found a ChryCo symbol on the muffler and cat this week... Sheesh, probably original.

So this is coming back from the dead. Steering box, steering shaft, spring mounts are done and she now sits on her own axles. A small gas tank and the brake lines are in. Hydroboost is going in. Turbo mount is in.

I will see about migrating the old pics and adding new ones soon.

Update: Old Pics migrated to new hosting site.

Curious if that electrically actuated mechanical fan clutch is not just reinventing the wheel for the sake of it? Why not just run electric fans on temperature switches with manual override to off or on?

Woohoo! Get those updates flowing!

MJMadness wrote:Curious if that electrically actuated mechanical fan clutch is not just reinventing the wheel for the sake of it? Why not just run electric fans on temperature switches with manual override to off or on?

I'm running one like this, which is basically what is a standard A/C electric clutch built into the fan hub. I have a 20" 10 blade fan from a Cummins stationary 5.9 application bolted up to it, it moves an enormous amount of air and draws next zero amps. I use my truck on some tough trails here in AZ.with a small but heavy trailer and my CGVW is normally around 12,000# and this setup keeps things cool even with no vehicle speed to assist air flow.
https://www.ebay.com/itm/Borg-Warner-12 ... OSw7UJa2T1~

MJMadness wrote:Curious if that electrically actuated mechanical fan clutch is not just reinventing the wheel for the sake of it? Why not just run electric fans on temperature switches with manual override to off or on?

For towing, not a "fan" of electric fans here in Arizona. They never move the amount of air advertised-- unless OEM or SPAL. When they do, they require enormous power, beefy power cables, a beefy alternator to support the load, and an expensive and melt prone regulator. All of which can have a habit of going out at the worst possible times.

The clutch needs regular maintenance, but is otherwise good to go. In a pinch, if the electrical nonsense or mechanical clutch mechanism gives up the ghost on the side of the road-- I can put something like a drywall screw through the assembly to lock it up and I still have a fan, so I am moving down the road instead of waiting for a tow.

I am a "fan" of the economy the electrics can provide by not running when not needed. This Horton gets me that by shutting off when not needed, but gives me the beefy power of the mechanical when needed.

I think your build is inspiring me to go the same direction with my build. How much do you think you have into the new drivetrain so far? I’m only asking because I’m 20 and want to set realistic goals for myself haha.


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