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Old 07-22-2013, 06:05 PM   #1
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Poor Boy Racing: Everyman Challenge XJ Build

Hey everyone,

I would like to invite you all to watch as my team and I build a 1987 Cherokee to race in the Everyman Challenge in February 2014. Here we will talk about what we are doing, what we will be doing, and what we have done. If you have any input about our rig, do not hesitate to post your comments or suggestions. This isn't just a build thread...but also a learning thread. We are trying to make it a point that you do not need the biggest bank account and most friends to participate in this race. Enjoy!

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Old 07-22-2013, 06:05 PM   #2
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Here is what we are starting with. This jeep was originally owned by one of the current team members. He then sold it to his roommate who later moved to Idaho. He was having some issues with it...and that is when we decided to pursue the Everyman Challenge and bought the Cherokee back.

Here is the jeep loaded up for the long tow back from Idaho:





Here we are back in California, ready to work:


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Old 07-22-2013, 06:05 PM   #3
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Time to gut it...nothing but the essentials:







No longer sitting on it's own:


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Old 07-22-2013, 06:06 PM   #4
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The first parts arrived! XJ Chassis Channel Reinforcement from RuffStuff. This should help strengthen that unibody. Chassis Reinforcement



Cleaning out the engine compartment:





Not much left for wires inside:
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Old 07-22-2013, 06:06 PM   #5
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Break Time!

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Old 07-22-2013, 06:06 PM   #6
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Here is the donor truck that we got our axles from. Unfortunately...it turned into only one usable axle. Apparently a 1978 F-150 has a HP44, however, the radius arm wedges are actually cast into the housing. If you are looking for a worthy HP44 axle to swap in...get it out of something Pre-77. The wedges on the pre-77 are welded on the tubes...so removal is easy (possible). The rear 9" is just fine though...31 spline big bearing.




After a trip to the junkyard though, we managed to get a "good" HP44:
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Old 07-22-2013, 06:07 PM   #7
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During this whole ordeal we got the base of our suspension in the mail from Rough Country. We went with the 6.5" Long arm kit (no pics yet). While this kit may be ok for your weekend warrior, there will obviously need to be some changes made for this kit to work to it's full potential. 6.5" Long Arm Lift Kit
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Old 07-22-2013, 06:07 PM   #8
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T-Shirts are in...you know you want one

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Old 07-22-2013, 06:08 PM   #9
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Here is part of the team wheeling their personal rigs on what will be one of our "test" courses for the EMC build!

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Old 07-22-2013, 06:14 PM   #10
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This weekend was one of Wranglerforum Socal's big semi-annual meet and greets. A couple of members that attended generously donated this piece. It is a little old, but we think we can make it work. We now will have eyes on the trail!



Not only did we get a lowrance gps, but we also hosted a 50/50 raffle. In this raffle we gave away a shirt, as well as raffled off half of our earnings over the weekend. We earned a total of $320 from all of the wranglerforum participants!! This means $160 was going to the winner! When the winning number was called, the winner kindly donated all of his $160 winnings right back to the team!! The Wranglerforum group never fails to impress! THANK YOU!
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Old 07-22-2013, 06:42 PM   #11
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Looks like a fun project. I want to come by for break time.
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Old 07-22-2013, 06:44 PM   #12
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Looks like a fun project. I want to come by for break time.
You are more than welcome to! Come on by next time you are up this way!
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Old 07-22-2013, 09:53 PM   #13
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Old 07-22-2013, 11:19 PM   #14
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BOOM. in.
Welcome

You are also welcome to join in on break time.
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Old 07-24-2013, 12:48 AM   #15
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This evening we tore apart all of our axles. One of our D44s is out of a 1978 F150. Unfortunately when we bought this we did not know that the radius arms fit on a CAST wedge. The cast wedge pretty much makes it 'impossible' to rebuild with new brackets. To solve the problem we went to the junkyard and picked up a new front D44 out of a 1978 or 1979 F250 with leaf springs. Since we are trying to stick with a 15" wheel setup we would not be able to use the brakes that are on the F250 axle. Therefore we need to swap all of the outer 5 lug stuff off of the F150 axle onto the current 8 lug F250 axle. We also pulled apart the 9" to find out some measurements since we are putting in an order for gears and master install kits soon. Here are pics of the axles torn down, the size difference between rotors, and a few of our spare axle shafts. We should also be putting an order in for new chromo shafts soon too!



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Old 07-24-2013, 10:32 AM   #16
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Did the 87 XJ come with a HP D30? Do you know if that housing will bolt into a TJ? Do you still have it? :-)
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Old 07-24-2013, 03:03 PM   #17
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Looks ambitious :-)

I remember this like it was yesterday. I too started with a XJ and built for 2012 KOH What fun and long days, nights, and weekends...

Great platform to start with. There are better of course, but not for the $ and easy of build of a XJ.

Any questions or if you want to look over or check out a Ultra4 Stock Class XJ, I am only down in Yorba Linda. Its full race though, but somethings might still apply.

Things like fuel system, cage integration, etc might be nice to see what another XJ has done.

I will say, reinforcement is KEY! Shock valving is Key. And fun comes later lol...

I have a crap load of pictures also, if you want anything particular.

Good luck and get er done...

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Old 07-24-2013, 04:20 PM   #18
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Your shop looks like my garage two weeks ago
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Old 07-24-2013, 04:24 PM   #19
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Did the 87 XJ come with a HP D30? Do you know if that housing will bolt into a TJ? Do you still have it? :-)
It did...but we sold both axles off in the beginning to get some cash flow. The new axles under Jeff (turdhurdler)'s rig are our old axles

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Looks ambitious :-)

I remember this like it was yesterday. I too started with a XJ and built for 2012 KOH What fun and long days, nights, and weekends...

Great platform to start with. There are better of course, but not for the $ and easy of build of a XJ.

Any questions or if you want to look over or check out a Ultra4 Stock Class XJ, I am only down in Yorba Linda. Its full race though, but somethings might still apply.

Things like fuel system, cage integration, etc might be nice to see what another XJ has done.

I will say, reinforcement is KEY! Shock valving is Key. And fun comes later lol...

I have a crap load of pictures also, if you want anything particular.

Good luck and get er done...

Great to hear, I will keep that in mind! You wouldnt happen to have a build thread floating around would you?

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Your shop looks like my garage two weeks ago
Shop? This is a garage build too those axles are torn apart in my buddy's side yard
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Old 07-24-2013, 04:42 PM   #20
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Shop/garage = same thing

I had enough room in mine to store the parts, but that's about it... Time to build a front now though I'd be d60 hunting now if it weren't for PA laws.

I can't wait to see this thing come together, I love XJ builds. I have a buddy who wheels with us and he will bring a basically stock XJ that he just buys for cheap, he beats it til it dies then parts it out and buys a new one. He bought one last thursday for 1K just to come wheel with us and he dented half that rig. They are very capable and so much cheaper than a wrangler I can see why you'd use one for your platform.
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Old 07-24-2013, 04:51 PM   #21
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Shop/garage = same thing

I had enough room in mine to store the parts, but that's about it... Time to build a front now though I'd be d60 hunting now if it weren't for PA laws.

I can't wait to see this thing come together, I love XJ builds. I have a buddy who wheels with us and he will bring a basically stock XJ that he just buys for cheap, he beats it til it dies then parts it out and buys a new one. He bought one last thursday for 1K just to come wheel with us and he dented half that rig. They are very capable and so much cheaper than a wrangler I can see why you'd use one for your platform.
It worked out very well for us. Two of the guys on my team are brothers. They owned this cherokee. After a while they sold it to their roomate for 4K. A few months later, he decided to move to Idaho. On the drive up to Idaho, I guess it was shaking so bad that he could barely drive into town. He took it to a shop and they said the rear end is trashed and will need completely rebuilt. He decided it wasnt worth his time or money. That is when the brothers sparked the idea to buy it back and build it into a race rig. They figured "we will swap out the axles anyways, so that wont be an issue for us." He sold it back to them for 2K. So in the end they came out on top. Turns out, once they got it hauled back down here to CA...my buddy crawled under it and noticed that the U-joints in the rear driveshaft were SHOT. This explains the horrible vibes their roommate was dealing with. With this, we came out on top again, since we were able to sell off the set of axles to another member here on the forum. It is also safe to say our friend, that is now up in Idaho, WONT be going back to that shop
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Old 07-24-2013, 04:59 PM   #22
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Good luck with the build Geoff (and team).

Someday when I get to somewhat of a stopping point on my JK (never?) I'd like to build a CJ and/or a TJ.
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Old 07-24-2013, 05:09 PM   #23
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Good luck with the build Geoff (and team).

Someday when I get to somewhat of a stopping point on my JK (never?) I'd like to build a CJ and/or a TJ.
Thanks Rick!

And what do you mean "stopping point?" Is there ever such a point ?
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Old 07-24-2013, 05:20 PM   #24
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It worked out very well for us. Two of the guys on my team are brothers. They owned this cherokee. After a while they sold it to their roomate for 4K. A few months later, he decided to move to Idaho. On the drive up to Idaho, I guess it was shaking so bad that he could barely drive into town. He took it to a shop and they said the rear end is trashed and will need completely rebuilt. He decided it wasnt worth his time or money. That is when the brothers sparked the idea to buy it back and build it into a race rig. They figured "we will swap out the axles anyways, so that wont be an issue for us." He sold it back to them for 2K. So in the end they came out on top. Turns out, once they got it hauled back down here to CA...my buddy crawled under it and noticed that the U-joints in the rear driveshaft were SHOT. This explains the horrible vibes their roommate was dealing with. With this, we came out on top again, since we were able to sell off the set of axles to another member here on the forum. It is also safe to say our friend, that is now up in Idaho, WONT be going back to that shop

Sounds like a nightmare at that shop for the roommate, but good for you guys
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Old 07-24-2013, 05:37 PM   #25
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Sounds like a nightmare at that shop for the roommate, but good for you guys
Definitely
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Old 07-24-2013, 05:42 PM   #26
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Great to hear, I will keep that in mind! You wouldnt happen to have a build thread floating around would you?
Sorry I do not. When we started it was the first year of EMC, and we didnt want to "give" away any idea's. Being the first year and a whole new class, we had some things going that I didnt see or know of anyone else doing. So we didnt really do a build thread. We did have some threads here and there about it though.

Heres one - RWK Stock Class KOH EMC 4692 - NAXJA Forums -::- North American XJ Association My site is having issues so might take a few hours till the pictures show back up.

Few things that I can think of off hand, that might help you.
Plate the rear rails also. Especially where the bumps are, no matter what kind of bumps you use.

Daystar stinger bumps are likely the best suspension mod you can do other then perfectly valved shocks.

Reinforce everything twice Now, so you dont have to go back after it tears off or rips off. Double gusset everything. If you see something and think, aww yeah 1/4" thick will be good for that. The step up to 5/16" thick.

Push every rule! And dont forget that you will fall under the new rules for cage sizing! Tie in Everything (Everything) to the cage. Especially the shocks and control arm mounts. You cant go thru the body with those items but you Can sandwich plate on both sides with 1/2" gr8 hardware and tie in to the cage that way!

I know you mentioned JV was your back yard, it is alot of ours. And alot have found that ever with over kill its not enough when you push past limits for hours....

We started with complete strip and build from ground up. And still found items that we could have built more into to keep it from failing.
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Old 07-24-2013, 05:58 PM   #27
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Sorry I do not. When we started it was the first year of EMC, and we didnt want to "give" away any idea's. Being the first year and a whole new class, we had some things going that I didnt see or know of anyone else doing. So we didnt really do a build thread. We did have some threads here and there about it though.

Heres one - RWK Stock Class KOH EMC 4692 - NAXJA Forums -::- North American XJ Association My site is having issues so might take a few hours till the pictures show back up.

Few things that I can think of off hand, that might help you.
Plate the rear rails also. Especially where the bumps are, no matter what kind of bumps you use.

Daystar stinger bumps are likely the best suspension mod you can do other then perfectly valved shocks.

Reinforce everything twice Now, so you dont have to go back after it tears off or rips off. Double gusset everything. If you see something and think, aww yeah 1/4" thick will be good for that. The step up to 5/16" thick.

Push every rule! And dont forget that you will fall under the new rules for cage sizing! Tie in Everything (Everything) to the cage. Especially the shocks and control arm mounts. You cant go thru the body with those items but you Can sandwich plate on both sides with 1/2" gr8 hardware and tie in to the cage that way!

I know you mentioned JV was your back yard, it is alot of ours. And alot have found that ever with over kill its not enough when you push past limits for hours....

We started with complete strip and build from ground up. And still found items that we could have built more into to keep it from failing.
Good info! Under these circumstances, I dont think there is such a thing as "overbuilt" My only question is on the bumpstops...I thought I recall the use of air bumps not legal in the stock class. Time to refer back to the rules!
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Old 07-24-2013, 06:04 PM   #28
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Good info! Under these circumstances, I dont think there is such a thing as "overbuilt" My only question is on the bumpstops...I thought I recall the use of air bumps not legal in the stock class. Time to refer back to the rules!
Stingers are not a pressurized bump stop. They use poly foam EVS inserts in a piston style can.
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Old 07-24-2013, 06:10 PM   #29
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Stingers are not a pressurized bump stop. They use poly foam EVS inserts in a piston style can.
Interesting...I will look more into these then!
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Old 07-24-2013, 08:34 PM   #30
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Thanks Rick!

And what do you mean "stopping point?" Is there ever such a point ?
Yeah, seriously!

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