ORF Bumper Install

I purchased a ORF front non winch bumper last year.  This install was a bit of a pain and actually put the jeep out of commission for about a week while I waited for a new heavy duty steering box bracket to show up.  I began the install by removing the the old bumper and mounting brackets along with the three bolts for the steering box.  While removing these three bolts I broke the small stock steering box spacer.  This was a good opportunity to install a heavier duty spacer that spreads the surface area of the force from the steering box and will be strong enough to turn any size tires with out cracking the unibody.  I also went on to trim the plastic wheel well liners so the Jeep would have a cleaner appearance.

new heavy duty steering box braket 

Steering box not bolted in yet

 I then went on to mount the center section and the two side sections of the bumper, bolting  it through the unibody.  I also remounting the steering box with the new bracket sandwiching it all between the bumper and the steering box. Once this was completed i mounted a set of square fog lights, Hella 500ff driving lamps, a set of D-rings from Quadratec and also my homemade license plate mounting bracket.

I recently have also constructed a grill guard that bolts directly on top of the bumper.  It is made out of 1 3/4 inch metal tubing and 1/4 inch thick flat stock steel.  I have also welded up a license plate protector.  This is made out of an old snowmobile sway bar which is 1/2 inch thick solid steel.

Intake system upgrade

I installed a Airaid throttle body spacer as well as a Rusty's Offroad intake and exhaust package awhile back.  The Airaid spacer was very easy to install.  All I had to do was remove the 4 bolts on the Throttle body as well as the two bolts on the cable support.  I then slide in the new spacer, gasket, and cable support spacer in place and then tightened everything back down with the new hardware.  The new space gained me noticeable horsepower and about 2 mpg.

Same as the throttle body spacer, the new intake was also very easy to install.  I removed the stock air box with 4 bolts then installed the Rusty's Offroad airtube, securing it with the one bolt needed, connected the vacuum hose and then simply slide on the new 6x9 K&N filter and tightened down the clamp.

I then decided to build a debris shield out of some aluminum to try and keep the filter a bit cleaner.  I cut out of a sheet of aluminum, got it fit properly and then secured it with zip ties.  I then took some roofing tar and sealed the bottom joint and filled some holes underneath the filter.

Herculiner Application

I have applied Herculiner to the exterior of my Jeep Cherokee along with a Toyota Pick up truck bed and also Jeep Cherokee floor boards as you saw in a earlier post.  Applying Herculiner which is a truck bed coating may sound intimidating but it is actually a rather simple process.  You begin with prepping the surface which means removing any unwanted objects such as the fender flares and then clean up any rust and bondo if needed.

Edges are taped off and first coat
has been applied

With fender flares and rust removed.
Ready for sanding,

Edges are taped off and plastic
is protecting the cab.  Applying
the second coat here.

Once you have cleaned everything up you can then tape off all the edges as you can see above.  Once this is complete, all the painted surfaces have to be sanded so there can be a good base for the Herculiner to adhere to.  Once sanded the surface has to be cleaned with a solvent, I use acetone.  After that it is as simple as rolling on a thiner primer coat of the hurculiner with the textured roller provided. Then once tacky or dry to the touch apply a second coat as thick as desired.  Once that is complete the tape can be removed and the Herculiner can cure completely.

Herculined fender flare

Aftermarket parts and information

Some good places to purchase aftermarket parts for Jeeps:

Essentials-Quadratec
http://www.quadratec.com/default_cherokee.php

Rusty's Offroad Products
http://rustysoffroad.com/

4Wheel Drive Hardware
http://www.4wd.com/

JcWhitney
http://www.jcwhitney.com/

Some fourms I have read:

NAXJA- North American XJ (cherokee)  Association
http://www.naxja.org/

Cherokee Forum
http://www.cherokeeforum.com/

While some good off-road magazines are:

FOUR WHEELER
http://www.fourwheeler.com/index.html

Petersons 4Wheel and off-road
http://www.4wheeloffroad.com/index.html

What I own, Jeep Cherokee's

I figured i'd share what I own and products that I've installed and am using.


My daily driver is a '99 Jeep Cherokee Sport which includes:

picture not up to date
Millage: 159,500

- 4.0 Inline 6 engine
- Dana 30 and Chrysler 8.25 axels
-3 inch heavy rate Rusty's Offroad suspension lift w/ new spring packs and trac-bar
- Rusty's Offroad transfercase drop kit
- 31 x 10.50 Goodyear workhorse tires on American Racing Wheels
- ORF non winch front bumper with custom build grill guard
- Reinforced steering box spacer
- Custom build roof rack with custom build bike rack
- K&N Rusty's intake package
- Airaid Throttle body spacer
- Flowmaster 40 series muffler and tailpipe
- Custom build tool box
- Hella 500FF driving lights
- Herculiner truck bedcoating (applied up to second crease in the body work on sides of Jeep)
- Pioneer Head unit with JVC and Sony 2 and 4-way speakers


New Project/ Future winter driver is a '99 Jeep Cherokee Classic:

Millage: 182,000

- 4.0 Inline 6 engine

- Dana 30 and Chrysler 8.25 axels

Have installed:

- Hood pin set 

-Key part floor boards

Future Plans for the new Jeep?

Floor board install on 99' Cherokee Classic

I have recently purchased a 99' Cherokee Classic that was in pretty rough shape for 400 hundred dollars.  I have been working on getting it back to good operating order and a big project I undertook was replacing the rotten floor boards and striping the disgusting interior out.  The previous owners were heavy smokes while they also were dog owners which left the uncleaned interior in very rough shape.  After the seats where removed and the carpet was striped and thrown away I discovered that the driver and passenger floor boards where pretty rotted as displayed below.

At this point I decided to order some custom molded floor boards from Keyparts Inc. Once the old sheet metal is removed the new floor pans are molded to fit right in and be installed.  To install the new parts I began by cutting out as much of the rot as possible, and then grinding and wire brushing any small amounts that was left. Once this was complete I fitted the new floor pans into place, trimming the edges if needed.  Once this was completed I then spot welded the floor pan into place.  Since the drivers side was so rotten I also and to install a new cross member to mount the seat on, which is the green section in the pictures below.  Once I installed both floor pans and had them securely welded in place I purchased Fiberglass resin and mesh cloth and then fiber-glassed over all the edges.  I choose to do so for added strength and to also fill any small holes left behind.

With joints fiber-glassed

After I completed the fiberglass and that was completely cured I came in with Herculiner (Truck bed coating) and applied two coats to seal everything up.  Once this was completed I also sealed and the joints from the other side with a tube of silicone.  I also cleaned the frame rails from surface rust and then sprayed a rubberized coating over the back side of the floor pans and the frame rails.

After first coat of Herculiner was installed

With the rust removed, new metal installed and rust preventative coatings sealing everything up this should be a strong long lasting set of new floor boards.