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  #73  
Old 31-05-2016
alexbrown64  alexbrown64 is online now
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Project came out quite tidy. Must of taken the bar on and off about a hundred times so that i could set the winch plate orientation. I ended up extending the hawse part of the plate forward about 40mm so that it would abut the bullbar.
I still have some wiring to do as i want to add an isolator. Also, while i had the bar off, i drilled some 40mm holes in the bullbar and plate behind it to ventilate the Derale tranny cooler.
The next step is to power it up, pull the rope in and attach the hook to a shackle.
I have also ordered some 38mm bullbar clamps to refit the light bar.

As far as VSB 14 and NCOP 11 projects go, i have completed all the work, so at some stage in the next few months i will need and engineer out to check over everything.

However, for roadworthy inspection, i am still installing the new extractors and new engine mounts, and then for cooling purposes, i will be installing the new high flow pump, tsat, radiator, tranny cooler and hoses etc..
Whew..



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Last edited by alexbrown64; 22-03-2018 at 07:54 PM.
  #74  
Old 06-06-2016
alexbrown64  alexbrown64 is online now
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I knew this next project was going to be tough but christ.. what was Jeep thinking. It is going to take a few weeks to re-grow the skin on my hands and forearms.
I started off pulling the cooling system off, then the intake manifold and exhaust, followed by the left hand engine mount. That was a days work and left me bruised and battered.
I found a lot of problems, but they are all mostly problems that all XJ's get at some stage so i was prepared.
The water pump bearing was lumpy and hard to turn.. time to replace with the FlowKooler. The thermostat came apart in my hands and was knackered. One of the pulleys had a bad bearing which i have heard while the car has been running. A surprise was the radiator which was weeping on both sides. Not sure what brand it was as its not printed on it and i got it on Ebay years ago. The headers had a 50mm crack which i could see and hear. My Wildcat headers are at CIC getting ceramic coated and will be ready in a week.
I couldn't believe the state of the left engine mount. Completely shot. I have the new Brown Dog heavy duty rubber engine mounts to go in.
I have not inspected the welch plugs yet, but i have a new brass set to go in.
So, during the week i will start replacing the entire cooling system, headers, engine mounts, welch plugs, bearings, hoses and anything else i can find.

Cheers,
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Last edited by alexbrown64; 22-03-2018 at 07:55 PM.
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  #75  
Old 10-06-2016
alexbrown64  alexbrown64 is online now
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Been a testing week on the Jeep. Nothing wanted to come out/off without giving me a tough time. Car is on gas so crimped fittings on inlet manifold are driving me crazy as i cant get the manifold out of the way. I took the head off, gave it a clean up and replaced the rear welch plug. Used permaflex #3 aviation liquid gasket as per Go Jeep.
Attacked the 5 plugs on the left side of the block and used the same technique to replace them all with brass 2" ones. I got 6 out of 7, as i am not going to tackle the one behind the bell housing... just too much work.
Next was the Brown Dog engine mounts. Very tight fit, almost an interference fit. I checked the tranny mount which was OK, as i had to slot it slightly to bring everything forward 10mm. Not sure what was going on there, but it worked and now engine/mounts etc..all sit nicely.
My light bar brackets arrived, so i mounted the bar and plugged it all in.
Also, the idler pulley bearing arrived ($5 delivered) so i will fit that soon.
Now waiting on new Felpro head and rocker gaskets and cylinder stud kit and also the headers to come back from CIC.



Cheers,
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Last edited by alexbrown64; 22-03-2018 at 07:57 PM.
  #76  
Old 12-06-2016
alexbrown64  alexbrown64 is online now
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Found a bit of time to fit the Derale transmission cooler. Got the idea from Go Jeep and also some of the cooling threads on AJOR. It fits under the radiator on the left side. Pic below of the new cooler v the OEM cooler. The Derale comes with a puller fan and in the pic is also the custom frame i made for it so it bolts straight in underneath. With this setup i bypass the radiator and old cooler.

There was a fair amount of grinding, drilling and cursing to get it to sit in nicely. Once i got it all bolted in, i used two 3/8 barbs, 6 new hose clamps and 500mm of new 3/8 transmission hose to plumb it all up. The hot fluid runs into the bottom of the Derale and the return comes out the top. Fan is wired so that it comes on when the first of my triple electric radiator fans comes on.





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Last edited by alexbrown64; 22-03-2018 at 07:59 PM. Reason: correct a mistake
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  #77  
Old 12-06-2016
werd  werd is offline
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So the oil cooler is getting its cool air through the aircon and the radiator?
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  #78  
Old 13-06-2016
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As per "Go Jeep" it sits under the radiator.
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  #79  
Old 13-06-2016
alexbrown64  alexbrown64 is online now
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Quote:
Originally Posted by werd View Post
So the oil cooler is getting its cool air through the aircon and the radiator?
Its a bit hard to see the exact location in my pics as i have the bullbar on, but i have borrowed this pic from Marcus's site http://www.go.jeep-xj.info/HowtoAutoCooler.htm to show exactly how he did it, and what i also did, based on his idea. Pic below is of holes in bull bar. Derale sits just behind those...



Thats why i have drilled a bunch of 40mm holes in my bullbar and the plate behind it to get more airflow.

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Last edited by alexbrown64; 22-03-2018 at 08:02 PM.
  #80  
Old 13-06-2016
alexbrown64  alexbrown64 is online now
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My factory headers were cracked and would not pass an inspection. In preparation for the new headers, i removed the factory down pipe. The factory down pipe has a restrictive dent in it that many think has happened while off roading. In fact, it was put there by the factory to help clear the front drive shaft. Its a terrible design that restricts a narrow pipe even further. My wildcat headers come with a dual down pipe that has no restrictions and less bends. While the headers are getting ceramic coated, i painted the down pipes with 1000C ceramic high temp paint inside and out. If you cure it correctly, it should last.



Cheers,
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Last edited by alexbrown64; 22-03-2018 at 08:03 PM.
  #81  
Old 15-06-2016
alexbrown64  alexbrown64 is online now
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At one stage my brakes were hopeless and i was not going to go ahead with this project until i sorted them. I ordered the EBC Yellow Stuff pads, front caliper rebuild kits and rear cylinders all at the same time. I put the pads on and the difference was a miracle, so i never bothered with all the other stuff. That was up until today. I got down and dirty and covered in brake fluid. Tackled the rear cylinders first. They were pretty old and i could of swore i saw one weeping a while back. These were quite easy, but i had preplanned by getting a handy 3/8 flare nut spanner which really helped.



The fronts took a bit longer as the pods in the calipers were a stuck in. Everything was really dirty and worn. Cleaned everything up, got the pods out and replaced them together with all new seals. My old dust seals were missing, so hopefully this setup will give all the brakes a new lease of life... I used about a liter of brake fluid bleeding everything through. Pedal feels good but i may give them another go after a few drives.


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Last edited by alexbrown64; 22-03-2018 at 08:05 PM.
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