Anti-Rice

Anti-Rice: The Cereal => Membermobiles => Topic started by: 87Warrior on August 01, 2010, 01:24:03 AM

Title: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on August 01, 2010, 01:24:03 AM
January 31, 2009
I picked up a 1992 Comanche. It has the 4.0 HO, AW4, NP231, Dana 30/35, AC, PB, PS, and even a CD player. As far as I could tell, the truck was generally untouched, just driven 185K miles.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P2010007.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P2010006.jpg)

This truck suffers from some major body rot around the rear flares, cab corners, rockers, floor pans, and doors. Initially I had planned on doing some small repairs to the truck and driving it.  However, now my plan for this truck is to build it as a stock 1999 MJ (if Chrysler ever built one) with some tasteful modifications and drive it for another 185,000 miles!!!!

I spent a little time getting a loose rendering done of what my ultimate goal for the MJ is.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/Cartoonnew.png)

- 4.0/AW4/242 (2-AWD-4H-4L)
- Dana 30/44 axles with 3.55 gear ratio
- Rebuilt stock suspension with V8 ZJ front coils to level it out and JKS swaybar disconnects
- Rubicon Moab wheels with an aggressive 30" tire
- Black flares
- Full on 97+ conversion (harness, drive train, interior, doors)
- Jeepsticker's "Comanche" door sticker
- SkinnyPedal's IPF/HID headlight conversion
- Tinted side and back windows
- K-State tag up front to support my alma mater

The only thing that my be different would be a tougher front bumper and tow hooks.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on August 01, 2010, 01:32:47 AM
The Donor
After months of searching, getting close then coming up with nothing, I picked this beautiful donor up from a little town near Columbia, MO.

1999 Jeep Cherokee
- 4.0
- AW4
- NP231
- 8.25
- Cruise
- 155,100 miles
- New 235/75r156 tires
- New AC system
- Rolled on its side into a ditch
- Exhaust cut right after Catalytic Converter
- Shot front axle outter shaft u-joint

(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00087.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00089.jpg)

I worked with the donor, thinning down the wiring harness for the MJ to make sure everything works 100% before I take it all apart to shove in the truck.

(http://img.photobucket.com/albums/v233/87Warrior/MJ/DSC_0186.jpg)

Image of the vitals:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00097.jpg)

I was able to get my grubby hands on an XJ Infinity stereo system for the Jeep. Comes with the factory CD player, amp, harness, and speakers. I have always liked factory Jeep radios, and their sound, over the misfit aftermarket options. I will have to get creative to get all of it shoved in the MJ.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on August 01, 2010, 01:42:58 AM
The Bed
I picked up a new RUST FREE bed/tailgate and cab corners from a comancheclub member. This is the bed I got:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/Picture003.jpg)

The inside of the bed was not painted, just had the factory paint pulled off. I am going to use the UPol-Raptor spray in bed liner for this. The UV protection is primarily why I am going with it.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P6170100.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P6170105.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P6170101.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P6170104.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P6170103.jpg)

I decided to prep and spray that shiny red bed with bed liner. I used the U-Pol Raptor liner kit. It comes with 4 quarts of liner, hardener, an air gun to apply it, and it it UV stable... all for about $130.

I worked on prepping the surface. Generally all you would need to do is scuff, clean, and spray. This bed has several to the metal scratches and scrapes, so I sanded them down smooth, masked the bed and sprayed the areas with self-etching primer as suggested by the U-Pol instructions.

(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00051.jpg)

Then I started with the bed liner. I was very nervous about doing this since I have never used an air gun to apply any sort of paint. Luckily it was a piece of cake. Dump 250ml of hardener into a quart of liner, shake, screw it to the gun and apply between 40-70psi of pressure. The more pressure, the finer the texture. Set the regulator to 70psi and went to town. Be sure to wear some sort of mask, the fumes are insane. I applied two cost of this stuff, and still have a 1 quart bottle left for touch ups later on down the road.

After the first coat:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00049.jpg)

The texture is very nice. I ran the gun at 70psi wide open and got a nicely textured, hard as a rock finish. It is just a touch more textured than plastic drop in liners.

(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00050.jpg)

Once it was well set up, not tacky to the touch, I removed the masking to see how well I did at taping. Not half bad. Also took the opportunity to hang the tailgate and set the unit in the garage just in case it tried to rain. 

(http://img.photobucket.com/albums/v233/87Warrior/MJ/PB080033.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/PB080028.jpg)

I replaced the chrome/black 4.0 badge with a vinyl cut out for a smoother look and added a 'retro' style 4wd in the same.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00052.jpg)
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on August 01, 2010, 01:47:18 AM
The Truck
It was time to pull the drivetrain out. Decided to take out the 4.0/AW4/231 as one piece. Used our John Deere 4210 loader to pull it out, worked great!
(http://img.photobucket.com/albums/v233/87Warrior/MJ/DSC_00552.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/DSC_0056.jpg)

Some MJ nudes:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/DSC_0057.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/DSC_0058.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/DSC_0059.jpg)

Then I gutted the interior:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00267.jpg)

My next step was getting the XJ dash fitted. First I used a spot weld driller to remove the 3 brackets from the firewall. Then I started testing out how the XJ dash will fit. Need to get the top of it mounted securely. I was surprised how little effort this took. Just needed a couple new holes drilled and she was up and in place.

(http://img.photobucket.com/albums/v233/87Warrior/MJ/P7030252.jpg)

Dash to windsheild clearance.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P7030255.jpg)

I removed the MJs doors. Lets just say, 200K miles of rust made this a chore. I wound up cutting off 6 of the bolt heads due to their rusted nature.

I got the doors hung and continued to test fit more of the dash pieces
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00308.jpg)

Loose striker pin attachment. At this point they keep the doors shut as I do not want to finalize their location before I get the hinges repaired.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/th_IMG00309.jpg) (http://smg.photobucket.com/albums/v233/87Warrior/MJ/?action=view&current=IMG00309.jpg)

Door stop bracket was busted, so I replaced it:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/th_IMG00300.jpg) (http://smg.photobucket.com/albums/v233/87Warrior/MJ/?action=view&current=IMG00300.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/th_IMG00299.jpg) (http://smg.photobucket.com/albums/v233/87Warrior/MJ/?action=view&current=IMG00299.jpg)

Rough dash mounting:
Still needs finalized and cleaned up -
(http://img.photobucket.com/albums/v233/87Warrior/MJ/th_IMG00307.jpg) (http://smg.photobucket.com/albums/v233/87Warrior/MJ/?action=view&current=IMG00307.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/th_IMG00305.jpg) (http://smg.photobucket.com/albums/v233/87Warrior/MJ/?action=view&current=IMG00305.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/th_IMG00303.jpg) (http://smg.photobucket.com/albums/v233/87Warrior/MJ/?action=view&current=IMG00303.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/th_IMG00302.jpg) (http://smg.photobucket.com/albums/v233/87Warrior/MJ/?action=view&current=IMG00302.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/th_IMG00301.jpg) (http://smg.photobucket.com/albums/v233/87Warrior/MJ/?action=view&current=IMG00301.jpg)
I still have one dash tab to be retrofitted, but need to get an extra tab welded to the body.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: jeepinator on August 01, 2010, 02:59:52 AM
Dude, still so sick and an awesome idea to make a new version mj.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: Nava on August 01, 2010, 04:52:55 AM
I love this thread for two reasons:

1.  I love Comanches.
2.  I love that you're modding it with a purpose.  Its not just "to be a sweet crawler, bro."  That your basically making a factory Jeep that doesn't exist makes it cool.  It may not turn any heads or destroy all trails, but its still cool as hell.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: logikfive on August 01, 2010, 04:46:47 PM
I love the interior upgrade!

One thing I would HAVE to do if I picked up an earlier Cherokee or Commanche. I think I would have probably gone with all graphite instead of the two-tone, but hey it's still a very big improvement!

Only thing I notice, is you've got a 4-door window switch in the drivers door. Can you put a 2-door switch in that place or do you have to deal with 4 switches?
Title: Re: 1992/1999 Jeep Comanche Project
Post by: LiverOfSteeL on August 01, 2010, 10:34:19 PM
Very nice!  I really like how you're paying attention to all the little details.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on August 02, 2010, 12:56:41 AM
Thanks for all of the comments. Makes it a whole lot easier to fight the heat and wasp to do some work on it. All I got done this weekend was removing, and preserving, the brake/fuel lines.

I love red Jeeps with gray interior.  In addition the the dash and doors, the headliner, seat, and trim pieces will be gray. Since Chrysler changed their gray tint from 92 to 99, I will be painting all of the gray interior pieces with some of that Mopar interior trim paint to get it all uniform. I have some spare dash pieces that I may experiment with. That is still a long way down the road, heck I need to find a gray Dakota bench seat first.

I know this truck will not be a head turner for ordinary people. That is fine in my books. Anybody that knows Jeep history at all or has a sharp eye, will probably crank their heads, just as I do on a regular basis with rusted out MJs. My anal side has really kicked in so I have been recreating the under hood emissions tag and door sticker in illustrator, combining the 92 and 99 diagrams into one accurate representation of what is really there.

I have been kicking around the idea of installing rear disk brakes on the MJ D44. Not so much for the "hey, I added disks" mentality, but for parts availability. The MJ drums are the rare 11" version which I can not locate the shoes or parking brake cables for. By going with disk brakes I would simply use the TJ Rubicon backing plates and off the shelf parts.

Thanks for reading :)
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on November 14, 2010, 11:53:28 PM
November Update
- I have removed the passenger side upper 'frame' rail and floor board. Next up is the driver side. There are still a few hidden spot welds from keeping it from coming off. Once those are free and clear, the truck will go to get soda blasted followed by a chassis coat of POR15.

AND... temptation bit me in the butt. I picked up this D44 front axle out of a 2005 Rubicon with 17K miles today. It has the 15" Vanco Big Brake kit (EBC Green Pads), ORO U-Turn steering with 7075 Aluminum Tie Rod (new TRE's), RE Track Bar, RockCrusher Diff Cover, 4:10 Gears, Alloy USA Axle shafts and Alloy USA axle seals. Has a busted front locker (typical for the rub lockers when loaded up). Figure $2500 in after market parts  :eek:

(http://img.photobucket.com/albums/v233/87Warrior/MJ/sale-064.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/sale-066.jpg)

My plan is to take the ORO Steering, trackbar end, shafts and seals out of this axle and install them in my Rubi. All of the stock stuff I take out of my axle will go into this housing for the Comanche, resulting in a stout axle for my project truck...

Rubi D44 going into the MJ will contain:
- 4.10s
- Rockcrusher Diff cover
- Vanco Brakes
- Replacement locker

I will need to get the rear MJ D44 overhauled and geared to 4.10, locker included and Rubi disk brakes installed.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on December 13, 2010, 12:21:20 AM
December 12 Update:
Progress has been slow and cold weather has set in. However, I managed to make some forward progress on the truck.

The floors had me slowed down. They need replaced and I did not want to do a patch job around the frame rail, so I spent a fair amount of time locating, drilling, and popping the spot welds along the upper frame support. This was done in preparation for the sand blaster as well, so the inside frame rails can be treated with POR15. It took a long time, but they came off straight with minimal deformation:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00406.jpg)

To my surprise, the inner frame is very solid with only minimal surface rust along the passenger side:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00404.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00405.jpg)

I also removed the sheet metal, doors, and dash from the MJ (again). After spending a few hours with the XJs steering column sub frame, I think I have come up with a solution to use the factory MJ parking brake pedal assembly with relocated release. I will be using a bench seat so the typical XJ parking brake handle wont work for my application. I will also be using the XJ steering column brace that is spot welded to the cowl, for proper fit and structure.

Here you can see the TCU (trans control unit) bracket and markings on the firewall where it will need to be mounted:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00409.jpg)

After a lot of careful measuring and comparing, it seem the HO firewall needs fewer modifications to it than the Renix era firewalls need when doing this swap. Two holes need welded shut, two need modified (steering shaft/engine harness grommet), and one needs added (above the blower motor).

Also got the AC/Heater box pulled from the XJ along with the engine harness and other under hood components.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00413.jpg)

Hopefully I can get the final fitment of the dash done in a few weeks so I wont have to drill any more holes in the firewall after the body shop gets it.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: logikfive on December 16, 2010, 05:24:30 PM
Love it man!

God I want a Cherokee or Comanche. Too bad they are all rotten and beat down around here.  :(
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on December 16, 2010, 06:17:39 PM
Love it man!

God I want a Cherokee or Comanche. Too bad they are all rotten and beat down around here.  :(
Rotten is the name of the MJ/XJ game :lol: Anywhere you look, besides the deep south, they will be rotted out. Both of these rigs (Donor XJ and my MJ) are/were in real rough shape. Even the 99 XJ donor has holes rusted through the floor on the passenger side.

Thanks for the compliment. It is hard to get out there and bust knuckles when it is 0.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on December 31, 2010, 05:14:53 PM
Last update of 2010 I suppose. I do apologize for the terrible cell phone pictures.

Today I pulled the heater box from the XJ and got it mounted in the MJ. This required drilling one hole to the right side of the blower motor. I also noticed the firewall is different between the XJ and MJ where the heater core and AC lines go through. Looks like another patch that will need to be cut and welded.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00430.jpg)

I also removed the steering column brace from the XJ firewall. I temporarily mounted it and the TCU bracket using a few sheet metal screws while I get everything fitted.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00431.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00433.jpg)

I also modified the aluminum steering column/brake support bracket so it would fit around the MJ parking brake studs. The parking brake pedal assembly should bolt up with minimal modifications. Then I will need to figure out the release, without cutting the XJ dash.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00432.jpg)
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on January 02, 2011, 12:59:27 PM
January 1, 2011
After a bit more measuring and compounding ideas, I will be following the masses and leaving the square'ish' heater/AC box opening alone. To fill the gap at the bottom edge I will use an over sized single piece of super dense foam (material to be determined later) around the heater core and AC lines backed with some sort of barrier.

I did some more test fitting and metal work today.

99 XJ brake booster and pedal assembly bolted in place:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00434.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00436.jpg)
(booster clears the lip in front of the cowl but needs clearance cut like the XJ)

MJ parking brake pedal assembly in place with 99 XJ sub-frame:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00435.jpg)

Now that all components affected by the sub-frame have found their spots it is time to drill/mount the left hand side of the sub-frame mount. I held off on doing this simply because I wanted wiggle room. Truth-be-told, the sub-frame moved less than 1/8" since I first held it in place.

Cut the driver side firewall out of the XJ. I decided to take it out as one piece so the steering shaft hole is in exactly the right spot as well as the engine harness grommet hole. How these get attached will be up to the body shop guy since he will be welding them in after I mark their locations.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00437.jpg)
(saved the inner fender well because it is good and straight, good for somebody that is fixing a wiped out XJ)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00439.jpg)
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on January 10, 2011, 09:11:14 PM
January 10
Minor interior update

I finally got the Steering Column/Brake pedal brace finally bolted through the A pillar cab side, less the upper right bolt. The back side of the mounting hole is in an open space between panels on the back side. Will get a stud welded in place for the missing mount. In addition the MJ parking brake mechanism is mounted and moved freely in conjunction with the aluminum brace:

(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00441.jpg)

Here is a reference picture for anybody pondering this swap:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00444-ADIAG.jpg)
The green locations are the mounting holes for the '97+ steering column/brake pedal brace.
I gained access to the lower right hole via the hole were the door wires go through, utilizing a wire to hold the bolt and prevent it from falling. This bolt will be welded on the inside to prevent it from turning and falling between the cab body panels. The upper left is the mount I have not yet finished. The cowl seam comes down and prevents access as it sits. Hopefully a stud and be welded on the inside of the cab to support.

The yellow locations are the factory MJ parking brake mounts
The two mounts on the right are still being used while the third on the left has been relocated. I used a button head bolt through the relocated parking brake bracket to clear the locking mechanism, secured with a nut against the bracket, then through the lower left (green) XJ aluminum bracket and hole. You can see the 2nd nut on the button head bolt shared with the aluminum brace to hold the unit in place.

Another reference shot from the inside firewall. You can cearly see the factory MJ dash with a paper template of the XJ dash indicating how different the steering shaft holes are.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00445.jpg)

Fusebox is also mounted on the passenger a pillar/kick panel.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on January 23, 2011, 01:07:12 AM
The truck saw the light of day for the first time in over a year today. It was quite exciting to just move it around, after filling a flattened tire.

(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00454.jpg)
BTW- I really like how it sits with no weight. From my calculations, this would be a 2-3" lift.

Started to blast with my new Harbor Freight 20lb blaster and Black Diamond media from Tractor Supply. This is how it started:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00456.jpg)

It took awhile to get the blaster setup and working correctly. Used up the two bags of media and almost got the rear frame rails cleaned up. The undercoating was tough/slow going, but the Black Diamond media cut through it with two passes. I need to get more of the media and finish up the rear frame rails, under the cab and engine bay.

The finish:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00461.jpg)

This was my first pass, with the smallest nozzle so it is a little splotchy:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00463.jpg)

The finish should react well with the POR15 3-step paint process. It is a very lightly etched surface that is smooth to the touch.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: Johnny Butt on January 23, 2011, 03:46:25 PM
This is shaping up to be the best build AR has seen since that orange 2ndgen Camaro (silverC10? I don't remember the username.)

I'm insanely jealous, not only that you have the time and space to actually restore something, but also at the fact that when you're done you're going to be the owner of one of the cleanest examples of one of my favourite trucks of all time.

Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on January 23, 2011, 09:26:19 PM
This is shaping up to be the best build AR has seen since that orange 2ndgen Camaro (silverC10? I don't remember the username.)

I'm insanely jealous, not only that you have the time and space to actually restore something, but also at the fact that when you're done you're going to be the owner of one of the cleanest examples of one of my favourite trucks of all time.
Thank you! The Comanche has been a long time favorite of mine, but I never expected to go this far with it when I bought it. I would have never imagined this truck would be on par with that orange 2nd gen (I remember reading that build too!).

I sure have a lot of space at my disposal, albeit not primo and 2.5hr from my apartment. Most guys would never consider even working in an old drafty dirt floor barn, let alone attempting a total rebuild. I will be hauling the truck to my folks garage to do any of the small scale painting... No dirt speckles for me!

It may seem like I do a lot of boring, unimpressive, updates... I am just trying to be thorough.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: Johnny Butt on January 24, 2011, 12:02:52 AM
Updates are updates, otherwise the thread fizzles out!

Again, great work so far.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: ling427ttvette on January 24, 2011, 12:12:10 AM
I wouldn't really call these updates boring, sure they might not be the impressive updates with sweet custom built go fast goodies, but it shows the true work that goes into something like this, which I love. All the little details like this make it a much more interesting read. That, and anyone else looking to do the same thing has a reference point to go off of.

Doing great work so far, can't wait to see more.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on January 24, 2011, 11:48:33 PM
Thanks guys  ;D

I will be buying 4 more bags of Black Diamond this week along with a screen so I can actually recycle some of the media. Might get two uses out of it. Hopefully I can get the frame fully blasted within the next couple of weeks (sucks only having the weekend to work on it). Then I will POR the frame rails and drop it off at the body shop...
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on February 08, 2011, 11:03:50 PM
Made some more progress on the frame.

This was in the way, so I removed it:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010178.jpg)

Some of the post-blasting-pre-update pics:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010248.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010249.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010250.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010251.jpg)

This is the worst of it. Located above the rear bumpstop location.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010260.jpg)

After some blasting, the under carriage:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010172.jpg)
(I need to degrease the rest of it. I burned through A LOT of media trying to blast the 1/4" layer of grease over the under coating)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010171.jpg)

Just how good is that cab corner... blasted until the sheet metal quit disappearing.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010173.jpg)

Cleaned up spring hanger:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010256.jpg)

Progress was quickly halted when a rain shower dampened the used media while I was in town at lunch. Just turned the media to mud. I was able to reuse some of the media I previously collected and bagged. A simple 6" strainer from the Walmart kitchen section was used to filter the used media. Worked perfect!

Since I have been getting to know every square millimeter of this truck, I have been noticing some rather bizarre things.... primarily the front suspension:

Passenger coil spring is busted... No wonder this truck never had the typical MJ driver side lean:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010179.jpg)
Bowed out to the Knuckle:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010180.jpg)

Driver Bumpstop is tweaked... almost rubbing the coil:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010181.jpg)

These issues, along with the upper control arm that is smashed on the TOP, lead me to believe this truck has been air born at some point in its life.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: MiniVanMan on February 09, 2011, 11:26:23 AM
Any thoughts about using that bed liner stuff for the frame/underbody?
Title: Re: 1992/1999 Jeep Comanche Project
Post by: Mick on February 09, 2011, 12:09:01 PM
Any thoughts about using that bed liner stuff for the frame/underbody?

Quote
I will be buying 4 more bags of Black Diamond this week along with a screen so I can actually recycle some of the media. Might get two uses out of it. Hopefully I can get the frame fully blasted within the next couple of weeks (sucks only having the weekend to work on it). Then I will POR the frame rails and drop it off at the body shop...
[/quoite]
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on February 09, 2011, 03:04:37 PM
Bed liner is generally rock hard, therefore it would not absorb s rock hit or sound like an under coating. It is also more likely to chip with a continuous showering of sand and gravel. Once I get done blasting I will clean and treat the metal with Marine Clean and Metal Ready. Then I will brush on POR15. My body shop guy says spraying it is a PITA and actually does not adhere as well as brushing.

Once everything is PORed, including the replacement floor pans, it will be coated with the POR Primer and sprayed with a few layers of rubberized undercoating. I want this truck to be quiet when on the road. I plan on spraying everything from the inner fender wells, to the firewall, floor pans and inner door with the under coating. I will use a product similar to Dynamat on the roof,
A/B pillars and back of the cab. Any where water may leak in or sit will be PORed (rust prevention) and under coated (sound deadening). Not to mention it will be getting new, thicker carpeting for climate control.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: Sharp on February 09, 2011, 04:21:08 PM
Sounds like a well thought out build! You're turning a rickety old truck into something that sounds like it'll have the interior qualities of a luxury sedan. :lol:
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on February 09, 2011, 11:21:55 PM
Sounds like a well thought out build! You're turning a rickety old truck into something that sounds like it'll have the interior qualities of a luxury sedan. :lol:
That is my general plan. If I am going to sit behind the wheel for another 200K miles, it might as well be comfortable :yup: I have watched so many builds fall just short of 'going all the way', so I want to avoid it. Plus, after reading through a few of the 97+XJ conversions on the MJ I have an idea of where some of the flops and fails may occur. Some of the nay-sayers of AR might say 'rice', I say 'thorough'.   
Title: Re: 1992/1999 Jeep Comanche Project
Post by: Sharp on February 09, 2011, 11:48:36 PM
I say smart... Why not make the truck practical AND comfortable?
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on February 22, 2011, 11:01:42 PM
Finished blasting the frame/chassis today. Took much longer than I anticipated, but the HF blaster held through it all and is ready for more  :wrench:

Overall Shots:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010011.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010010.jpg)

Engine Bay:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010001.jpg)

Passenger Inner Fender:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010002.jpg)

Driver Inner Fender:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010003.jpg)

Under Carriage:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010004.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010007.jpg)

A few spots need cleaned up, but I will use a flapper wheel on an angle grinder. Now I need to blow out the frame and brush on POR15.

I decided to drag the truck to a garage with CONCRETE FLOORS  :thumbsup: Here she is getting ready to go into the "POR15 Booth"
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010015.jpg)

Here is an image of some stamping I found on the MJ frame (passenger inner fender well and inner frame and driver inner fender well and inner frame)
The deeper number changes from location to location (26155, 12134, 13571 and *unknown*)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010023.jpg)

9-13-91 build? Not sure about that, maybe when the frame was built. The build sheet indicates a 9-26-91 build date with an In Service date of 10-26-91.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: LiverOfSteeL on February 23, 2011, 12:52:33 AM
The level of detail in this build is really impressive.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on February 23, 2011, 11:52:00 PM
The level of detail in this build is really impressive.
Thank you  ;D I hope to end up with something that could resemble a step-by-step manual for somebody else doing the swap. Not to mention I have the ability to go back and see exactly what I did, hopefully with an explanation of 'why'.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: Johnny Butt on February 24, 2011, 12:30:32 PM
I'm still blown away by how much you are putting into this man!

I wish I were close enough to see it when it comes to fruition.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on February 24, 2011, 12:48:01 PM
Yeah I maybe crazy for doing it, but this truck will be the perfect truck per my taste. Where about are you located? I may be visiting a town near you once it is done. I plan on driving it A LOT... With some mild wheeling.

Now that the body/chassis will be going to the shop, I am planning my next steps:
- Rebuild Rubi front axle with new locker - Rebuild and gear rear 44 to 4.10 and install disk brakes
- Obtain 22gal OBDi Dakota tank, or pan less 20gal MJ tank to fit the XJ fuel pump and sender
- Pull motor from XJ...

Still undecided what I want to do with the motor. At 150K miles I certainly want to put gaskets and seals in it. But if I am that far I should rebuild it. Then I question stroking it since I am there. Do I really want to run premium fuel in a Jeep? Oh only time will tell.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: Johnny Butt on February 24, 2011, 01:12:10 PM
I'm about 45 mins outside Toronto.

I'd rebuild it to stock.. a nice, reliable 4.0 is nothing to be ashamed of.. especially if you're driving it a lot.  The stroker would be a neat addition, but for what the truck is going to be used for I'd say it's overkill.

Also
Then I question stroking it since I am there.

:mrgreen:
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on February 24, 2011, 01:28:10 PM
You know if you were there, you'd stroke...

Alaska is one of my desired destinations. So its not out of the question.

I am leaning towards a simple rebuild. Maybe a mild cam. (need to research 4.0 cams) I also agree that the truck won't NEED a stroker, but its just one of those things I ponder.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: Scotty on February 25, 2011, 08:20:21 PM
You gonna do the old 258 Rods in a 4.0 trick?
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on February 27, 2011, 04:42:10 PM
You gonna do the old 258 Rods in a 4.0 trick?
Doubtful, but that was my option #1. Having done a lot of reading at Jeep Strokers I have decided to maintain the 4.0, just moded some. I will assemble an engine build sheet soon.

This weekend I made the first permanent forward steps on the truck. I coated the media blasted frame, floor that wont be replaced, and inner fender wells with POR15.

Rear frame rail:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010025.jpg)

Cross member:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010003-1.jpg)

Floors and under the cab:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010011-1.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010013.jpg)

Inner fender well:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010018.jpg)

Front end:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010021.jpg)

I used less than a quart of POR15 and brushed it on with some of those cheap foam brushes. Seemed to work very well. Once new floors are installed they will be PORed. Then I will apply their Tie-Coat primer followed by undercoating.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: Scotty on February 27, 2011, 05:20:27 PM
What made you change your mind from stroker to modded 4.0?
Title: Re: 1992/1999 Jeep Comanche Project
Post by: Meatywand on February 27, 2011, 06:53:22 PM
Holy shit I'm so jelly my name should be Smuckers...
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on February 27, 2011, 10:27:07 PM
What made you change your mind from stroker to modded 4.0?
Premium fuel, primarily. According to the experts at Jeep Stroker any stroker, especially a well built one, will require at least 91 octane if built on the OBD I or II system (99 XJ is OBDII) due to the lack of a knock sensor. It is just a Jeep that will be driven every day, a vehicle which I don't want to dump premium in to. Plus with 4.10 gears and 30/31" tires, it will be rev'ing pretty well on the highway, where the stroker wouldn't provide much benefit. Obviously additional power anywhere in the power band would be a plus, but I am confident I can get excellent drive-ability and additional power out of the 4.0 with a few internal mods plus balancing and a header.

Holy shit I'm so jelly my name should be Smuckers...
I love me some Smuckers strawberry preserves  :yup: Thanks man.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on March 07, 2011, 09:51:28 AM
Not much exciting has happened to the truck this week. Got all of the busted bolts out of the frame and cleaned up the threads with a tap. Finished applying POR15 to all of the spring mounts and control arm mounts. Also coated the inside frame rail with the POR15. In studying the construction of these trucks, it is easy to understand why the frames like to rot away. Next step will be blasting the front frame rails and rear frame rails with hot high pressure soap/water, soaking with Marine Clean, treating with Metal Ready then using a 3M Rust Fighter-I Application Wand (http://www.amazon.com/3M-08998-Rust-Fighter-I-Application/dp/B0038D7GB2) to shoot POR15 in the inaccessible frame.

Visited with the body shop guy who strongly suggested I NOT use undercoating on the outside of the truck. He says with the POR15, Tie-Coat primer, and Chassis coat there will be absolutely no chance of chipping the paint. I asked about sound deadening and he said it would be OK to spray it over the inside sheet metal after it was treated with POR. Upon his direction I also placed an order for new outer rocks and floor pans for the truck.
He wants the truck in his shop at the first of April to start body work.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on March 22, 2011, 11:13:50 PM
No real exiting updates lately . For the last couple of weeks I have been preparing the inner frame for POR15, cutting out the floors and sanding the POR on the frame for Tie-Coat and Top-Coat.

Ordered the outer rockers and floor pans from Classic to Current:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00469.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00470.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00471.jpg)

Cut out the floors:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00476.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00477.jpg)

I used the spray gun that came with the U-Pol raptor liner kit and attached the3M Rust Fighter-I Application Wand (http://www.amazon.com/3M-08998-Rust-Fighter-I-Application/dp/B0038D7GB2),a flexible wand for the 3M Rust kit, to spray the POR. *note: the wand does not thread securely to the U-Pol gun, so I wrapped the threads several times with Teflon tape* It came out very fine and sparse, so it took awhile to coat the inside of the frame rails but had nearly no waste. Also figured out that plain turpentine does a great job cleaning up POR15.

Getting close!!!
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00474.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00475.jpg)

Whenever the paint shop gets a space opened up, it will be on its way. He will weld in the floors and paint the truck and I will start the engine work. Also got some 3" lift coils on the way. I will couple those with some longer shackles (2" lift) to have it sit level and ride like a caddy.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on April 21, 2011, 11:51:48 PM
Removed some of the seam sealer around the inner firewall of the truck. I found RUST forming at the TOP of the firewall/cowl/a-pillar seam. I almost left this area alone since it appeared rust free. If you blame the clutch master for allowing water in, you should remove the seam sealer in that corner as well.

Inside the rear frame rail:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P4170532.jpg)

Inner the frame rail, floor pan will cover this: (yeah, I know its dusty)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P4170530.jpg)

Coated the back 1/2 of the frame with POR's Tie-Coat primer. This stuff surprised me. First off, IT IS BLUE! Secondly, it has the consistency of house latex paint:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010026.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010027.jpg)
It requires a minimum of 24 hours to cure, above 65 degrees.

Then a lot of sanding and two coats of Chassis Black:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P4170536.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P4170531.jpg)

Went back to the donor to pull some more panels, this time for rust free steel for the body shop to use.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010028.jpg)

If you ever wanted to know what gives the A pillar its strength in an XJ/MJ:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010029.jpg)

Removed the stock door striker backing plate assembly. I quickly gave up on using the Dremel and just drilled the spot welds:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P4170535.jpg)

Also picked up a 22 gallon Dakota OBDI fuel tank, should be almost bolt in with the 99 XJ pump and sender:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P4170533.jpg)

Once the body shop gets a freaking horse carriage out of shop the truck will go in for rust removal and floors, followed by paint  :yup:
Title: Re: 1992/1999 Jeep Comanche Project
Post by: Flea on April 22, 2011, 07:18:17 AM
Looking awesome!  I love it.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on May 09, 2011, 12:01:03 AM
I dropped the truck off at the body shop a few weeks ago. He has begun replacing the floor pans and removing rust. Since he is really slow, I don't expect the truck back before summers end.

But the truck being gone is not slowing me down. Look what I opened up today:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00497.jpg)
Warn VR8000. Warn's first entry level winch...meaning reasonably priced, but backed by the Warn warranty. I will start fitting the Hidden Winch design on my donor XJ before pulling the motor. Have to verify clearances.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: Snakestress on May 19, 2011, 02:36:09 PM
Looking good.  I actually do not know why but I love the Comanche.  There is one in town that is parked in someone's front yard.  Looks to be good shape other than the dirt and leaves on it.  Was tempted to see if he would sell it for the right price.  What is the market price on one of these in running condition right now? Non rusted I would assume.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on May 19, 2011, 04:29:11 PM
Thanks!

The going rate for these trucks is funny. I have seen solid running trucks from $300 to $9000. (yes, 300) Assuming no rust but certainly not cherry, the 87-90s average $1500 while the 91-92s average $2500. The 86 requires a special person to buy due to funky engine options and unibody differences. The value of these trucks keep going up as more and more are crushed, good thing the non-Jeep enthusiasts havent got the memo.

I don't really know what it is about the Comanche that makes it cherished by so many. Probably its uniqueness and the fact you never see them on the road anymore. You certainly don't find people who like the S10 or Ranger as much as the Comanche.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: MiniVanMan on May 19, 2011, 10:45:03 PM
There's a really tired looking Comanche for sale near where I work. Body looks terrible.. didn't get a close look so not sure if it's bad rust or just terrible paint, but it doesn't look like it was taken care of, that much is certain.

Are there any similarities between these and the Dodge Dakota?
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on May 20, 2011, 12:27:10 AM
Are there any similarities between these and the Dodge Dakota?
Little to none. The tail lights look similar but mounts completely different. The Dakota fuel tank will fit but requires a modified filler neck and top mounted pump/sender, the MJ pump/sender mounts in the side of the tank.

I will be using a 22gal Dakota fuel tank with the 99 XJ pump and sender mounted.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on June 15, 2011, 08:57:44 PM
June update.

As you know, the truck has been at the body shop slowly being worked on. The body shop guy said he expects the truck to be out of his hands this fall, which is good because I have a lot of to do before I am ready for it. Here are some picture of the truck at the shop:

Driver side floor pan is 99% done
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00040-20110610-1504.jpg)

Don't forget the seat belt hole!
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00044-20110610-1508.jpg)

Passenger side cleaned up awaiting the floor pans
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00042-20110610-1507.jpg)

I have finally made a few decisions on the suspension. The build will include:
Rear:
- Hell Creek 3" lift packs
- JKS Shackles

Front:
- 3" Skyjacker coils purchased
- ACOS Pro (spacer for winch weight/leveling and bumpstop repair) purchased
- JKS control arms
- JKS Trackbar
- JKS discos purchased

If you think it seems like I am a fan of JKS, you would be correct. Of all the products I have run on my TJ, the JKS have required the least amount of maintenance and have had the longest service life. 

Some eye candy arrived today:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P6100032.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P6100034.jpg)

I pulled the XJ's motor/tranny/t-case last weekend and gave it a pressure wash. Hopefully I can have it at the machine shop around the first of July.  :yup:
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on July 11, 2011, 11:50:53 PM
I pulled the donor 4.0L a few weeks ago and have been doing a lot of research getting a build sheet assembled for my 4.0L. Starting discussions with the machine shop.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00520.jpg)

Objective: This motor will be based upon a 99 XJ block and will be going into my Comanche, which will be a daily driver turning 4.10's and a 30/31" tire.

Goal:I want to pull more power out of the motor yet maintain fantastic drive-ability and reliability without the need for premium fuel.

The motor will be getting a thorough going through and rebuilt. I am thinking work along the lines of bearings and seals/gaskets, cam, pistons, porting, etc. I will build a higher power 4.0 and drive it for another 200K miles. The 4.0L I rebuilt in '03 (stock, 0.030 over) is nearing the 100K mile mark in my Rubi.

This is my current plan:
- Stock 4.0L Crank and Rods
- Comp Cam 68-321-4 Camshaft
- Sealed Power Pistons 0.030" over
- Block decked 0.00"
- 0.051" Compressed Head Gasket

(http://img.photobucket.com/albums/v233/87Warrior/MJ/EnginePlan.jpg)

Compression Ratio: 8.95:1
Dynamic Compression Ratio: 7.77:1
Quench: 0.051"

Head
Head Gasket: Fel-Pro 0.051"
Camshaft: COMP Cam 68-231-4
Lifters: 822-12
Valve Springs: Mopar High Performance P5249464
- Retainers: Mopar High Performance P4452032
- Locks: Mopar High Performance P4529218

Ford 19lb or SRT4 Injectors
Banks Header
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on August 30, 2011, 09:34:02 AM
Having not done much to the truck lately I decided to start working on a project I have been putting off, mostly due to the fact I didn't know what to do. A few year ago I picked up a set of 5 TJ Rubi Moab wheels, for CHEAP. These things were trashed. They looked like the previous owner sprayed acid on them and let it sit for 3 weeks. My intention was to sand them down and paint with silver wheel paint, but I decided to try and see if I could save one of the wheels.

Sandblasted with used 40/60 Black Diamond
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00567.jpg)

Even after blasting the wheel, the finish was very irregular
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00570.jpg)

I attacked the wheel with sand paper. 80, 120, 180, 400, 1500 then 2000 wet sanding. Quick polish with harbor freight white and red bars followed by some Mothers Mag polish
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG00572-1.jpg)

It has taken me about 2 hours per per flat spoke. My plan is to polish the flat face of the spokes and bead then use a finer blasting media to texture the inner edges and lips. Clean it up real good then shoot with clear.

Comanche is going to get some *bling*
Title: Re: 1992/1999 Jeep Comanche Project
Post by: PileDriver on September 18, 2011, 05:11:45 PM
Aw man, I can't believe I just noticed this. I really dig it. Comanche's are the best.  :yup:
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on September 19, 2011, 12:05:48 PM
Comanches are the best! And, they are even better when not in the body shop. I think I will give the body shop a call. I need to get this truck on the road!
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on September 22, 2011, 06:12:23 PM
I have been sanding and polishing for what seems like ever. Still have 3 wheels to go  :o

In the meantime I have been gathering more parts for my disc brake swap.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010006-1.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/P1010004-1.jpg)

- Longer OEM wheel studs
- OEM disc brake retainer plates
- OEM rear axle brake lines (for a TJ and will need some tweaking around the MJ spring plates)

I should now have everything needed to complete the ZJ rear disc swap on a MJ D44.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: MiniVanMan on January 26, 2012, 05:50:55 PM
Man... looking back over this thread, and this build is right up my alley. It's extremely meticulous which is pretty much exactly how I usually do things - every detail has to be taken into account.

I wish I had the time, money, tool and facility to do a project like this.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on January 26, 2012, 11:12:20 PM
Never fear, this build is not dead!  :slap2: Truck is still at the body shop. Floors have been replaced and the firewall modifications are done. He was just getting ready to start on the rockers and cab corners.

I did order two more pieces for the front suspension yesterday; JKS Lower Control arms (6100).

Nick, truth be-told, I have not used many tools to do this build. Example:
80% of the truck was disassembled using this Husky 60 piece tool kit from Home Depot... The BEST discount tools I have ever used:
(http://www.homedepot.com/catalog/productImages/400/10/102250c7-3656-424f-85fa-f11b37c4d7d4_400.jpg)

Another 10% of the truck needed 1/2" motivation:
(http://imagethumbnails.milo.com/000/945/143/trimmed/945054_15676143_trimmed.jpg)

And the remaining 10% of the truck was pulled apart using air tools, angle grinders, drills, sawzall and a blow-torch.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: MiniVanMan on February 08, 2012, 11:28:47 AM
You should post this here:

http://www.cherokeeforum.com/f46/

Those guys would drool over this build.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on February 09, 2012, 07:51:17 AM
Thanks Nick, but I don't think I am going to post this truck on any more forums. My free Photobucket account would run out of bandwidth.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: The Beef on February 10, 2012, 09:05:53 PM
Make an Imgur account man
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on October 17, 2013, 12:47:58 PM
April 2011 to October 2013.....  IT IS BACK!!!

It has been a long time coming, but the results make it oh-so worth it. Yesterday I picked the truck up from the paint shop, drove to the hanger and attached the bed, then drug it across the county to my garage.

(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG0048.jpg)

(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG0049.jpg)

(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG0050-1.jpg)
Title: Re: 1992/1999 Jeep Comanche Project
Post by: MiniVanMan on October 17, 2013, 10:18:25 PM
Can't wait to see it assembled!!!
Title: Re: 1992/1999 Jeep Comanche Project
Post by: jeepidude on October 17, 2013, 10:50:55 PM
That is gonna look amazing  :yup:
Title: Re: 1992/1999 Jeep Comanche Project
Post by: GTR on October 18, 2013, 01:15:31 AM
Sweet truck and trailer! and jeep! great looking build can't wait to see the finished product.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on October 18, 2013, 07:31:57 AM
I am looking forward to putting it all back together. It will be a new experience for me since it is rust free and clean!

Truck and trailer are owned by a good friend.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: AirForceOne on October 19, 2013, 07:16:40 AM
That truck will be epic once you get it all buttoned up! 
Title: Re: 1992/1999 Jeep Comanche Project
Post by: Meatywand on October 21, 2013, 03:31:48 PM
ZOMG....mad, mad jelly over here dude.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on November 10, 2013, 11:10:35 AM
I would say it was time for this poor 150K mile 4.0 to get a rebuild.... Rod bearings were well worn:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG0092-1.jpg)

Then parts started to show up. Mopar Performance Cam, lifters, timing gear set, pin/spring....
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG95201311079518003495785-1-1.jpg)

I picked up the block and head from the machine shop last night. Ended up going 0.020" over and decking the head, not block (for simplicity). 3 intake valves were replaced as well. She is also balanced and polished. Now to start putting it all together.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG0086-1.jpg)

(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG0090-1.jpg)

(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG0089-1.jpg)
Title: Re: 1992/1999 Jeep Comanche Project
Post by: FrameScrapeee on November 11, 2013, 09:28:56 PM
I can't wait to see the final product... this build is amazing.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: Meatywand on November 13, 2013, 12:24:45 PM
All of MUH BONERS....
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on November 17, 2013, 09:56:31 PM
I decided to clean up the dash from the donor XJ. The Jeep was a smokers rig and reeked of smoke. Plus everything was coated in cigarette tar. Bleck. I fully disassembled the dash and cleaned each piece in soap and water. I also did away with the cigar lighter.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG0115-1-1-1.jpg)

Started to reassemble the motor. Cam, lifters, and head installed:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG0121-1.jpg)

Timing gear and chain, push rods, and rockers installed:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG0123.jpg)

Called it a night with the installation of the timing cover, new Mopar harmonic balancer (these things cost too much $), Melling oil pump and Mopar pick up tube, oil pan, and valve cover.

(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG0126.jpg)
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG0125.jpg)
(ignore the wall art )

Followed up by a semi-gloss paint job. Installed the oil filter adapter, dipstick, water pump and thermostat housing.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMG95201311179515055695938-1-1-1.jpg)
Title: Re: 1992/1999 Jeep Comanche Project
Post by: Kalgorn on November 17, 2013, 10:10:23 PM
Looks like you've put a good bit of time in to it. It looks really good. Any reason for not painting the timing cover? Just curious.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on November 17, 2013, 10:28:49 PM
Looks like you've put a good bit of time in to it. It looks really good. Any reason for not painting the timing cover? Just curious.
Ugh, I am putting in a LOT of time in this truck. But, it will be exactly what I want in a Jeep truck.  :yup:

The timing cover is aluminum. That is how it looked after being hot tanked. I decided to forgo painting it for simplicity. Who knows, I may shoot it with some black paint later on.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: revolt015 on November 18, 2013, 12:39:42 AM
How did the TJ wheels come out?
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on November 18, 2013, 07:17:20 AM
How did the TJ wheels come out?
They aren't finished. It's a lot of sanding.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on January 14, 2014, 12:35:09 PM
I am almost done with the dang wiring on this truck.

The XJ body harness went from this..
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG0185-1.jpg)

To this:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG0189.jpg)

Engine bay harness installed:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG0176-1.jpg)

Mounted dash:
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG0184-1.jpg)

Now I am working on applying Fatmat sound insulation to the doors, b pillars, back wall and roof.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: Meatywand on January 14, 2014, 05:03:36 PM
All that wiring made me shudder :lol: Just wiring up my new headlights for my GC was too intimidating so I let my Brother In Law do it :lol:
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on January 15, 2014, 12:33:34 PM
I like wiring. I just hope I did it right!
Title: Re: 1992/1999 Jeep Comanche Project
Post by: MiniVanMan on January 15, 2014, 07:41:02 PM
Wiring honestly isn't too bad, especially when you have the whole vehicle torn apart like you do.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on February 16, 2014, 09:31:31 AM
I built brackets so that I could securely fasten a RB1 radio in this truck
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG9527.jpg)

RB1 installed with Ebay Wire Harness Converter. $10 from ebay vs. $75 from Mopar.... Installing this radio, or one shaped like it, will require some bezel trimming. In order for the navigation to work, I will need to feed it a PCI BUS signal. This can be accomplished by piggy-backing a 02+ TJ/WJ PCM and sending the RB1 a PCI BUS signal. I will place the extra PCM under the dash.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG9530.jpg)

It was time to finish up the drivetrain so I installed Bosch EV6 22b/hr 0280155784 fuel injectors (stock flow rate, but 4 hole), the AW4 with fresh seals and gasket, and the 242 tcase. Since the drivetrain was being built at my folks' place, it was time to bring it home.
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG9568.jpg)

(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG9570.jpg)

(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG9571.jpg)
Title: Re: 1992/1999 Jeep Comanche Project
Post by: MiniVanMan on February 16, 2014, 10:32:14 AM
RB1... that an OEM radio from another model?

I really hate the look of aftermarket head units. I have an Alpine right now and I just don't like the gaudy, shiny body... but hey, it was free so no major complaint I guess.

What I really want is to find a stock, or stock looking head unit that will connect to my iPod or iPhone. I currently have the iPod cable run behind the HVAC unit, through the center console and into the cubby so it's always hidden away.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on February 16, 2014, 11:18:52 AM
I have never seen a good looking aftermarket radio in any 1.5DIN dash. They all look like cheap crap to me.

The RB1 could be found in nearly all Chrysler vehicles from 2002 thru 2006 (?) besides the Wrangler. It is a factory navigation radio that some folks like or hate. I installed on in my TJ back in 2005 along with the Mopar Ipod Integration kit. Now that the RB1 and Mopar Ipod kit are discontinued, they have tripled in price.

I was lucky enough to find the radio for the MJ for the cost of shipping as a fellow Jeeper was upgrading his radio. I plan on using this Ipod integration kit (http://www.crutchfield.com/p_581PA11CHR/USA-Spec-iPod-Interface-for-Chrysler.html). It is designed identically to the Mopar kit I bought for my TJ. I know the Ipod kits work with other radios, not just the RB1.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on February 20, 2014, 07:04:50 PM
I have finished cutting, filling, and texturing the bezel. It hasn't been sprayed with Agate interior paint so it is flat black for now.

Stock bezel compared to the Modified bezel
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG9572.jpg)

Fit in the truck. Yes, I know its not an RB1... The size/shape/mounts/connections are identical. I removed the RB1 so it wasn't damaged during my various test fittings. I also know the steering wheel is filthy and trashed, I have a replacement ready to go....
(http://img.photobucket.com/albums/v233/87Warrior/MJ/IMAG9575-1.jpg)
Title: Re: 1992/1999 Jeep Comanche Project
Post by: AirForceOne on August 16, 2015, 08:13:42 PM
What's the status on this build man?
Title: Re: 1992/1999 Jeep Comanche Project
Post by: 87Warrior on August 17, 2015, 07:30:29 AM
Unfortunately the progress has all but stopped on this truck as I have been working extra long hours in preparation for a 30x40 shop to go up. The crew is set to finish this week. Working on the truck is a challenge in our small garage with all of my extra Jeep parts, my wife's WK parked in there and her woodworking projects.

The last bit of progress I made was getting the Dakota bench to play nice with the MJ seat brackets. Talk about a royal pain! I have it tack welded together and need to finish burning it in.
Title: Re: 1992/1999 Jeep Comanche Project
Post by: revolt015 on August 17, 2015, 11:14:37 AM
My birthday was recently, if you don't need that RB1 anymore...