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Project MULE - Expedition build on a 1991 1500 4x4 Suburban

While you have the springs off.................. whats the inside measurement (width) of the front spring pockets?

I've been told it should be 3.5 but I keep hearing that the 88 and up are different.

I actually measure 3.5"+ but I would call it 3.5" If you want exact it was like 3-5/8" on the inside.
 
Removed the steering shaft this afternoon. Looks like the XJ shaft I have might be for the 97+ XJs I am stopping by my friends XJ shop tomorrow anyways so I will see if I can verify which is which.

steering-001.jpg


steering-002.jpg



Gear box is out. I hope to starter cleaning the frame up for the weld in kit tomorrow.

steering-003.jpg
 
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Making progress man, awesome. I grabbed two different XJ shafts from the junk yard when I got mine to make sure I had the right one. What did you paint your grille/bezels with? What kinda prep work did it need to paint over the chrome? It looks really good.
 
I just scuffed up the chrome with some 180 grit and painted with rustoleum epoxy appliance paint gloss black. You can find it at HD. No primer needed. Just make sure surface is clean and paint in the open. This paint grabs on to everything and is a pita to remove. When I painted the roof rack the entire shop and everything in it got a slight dusting on it. And it's not like other paints that dust if this stuff sticks
 
Ok... You need a index for this build thread. You've done so many cool things I want look at again for ideas and we are up to 81 pages lol! =)
 
I just scuffed up the chrome with some 180 grit and painted with rustoleum epoxy appliance paint gloss black. You can find it at HD. No primer needed. Just make sure surface is clean and paint in the open. This paint grabs on to everything and is a pita to remove. When I painted the roof rack the entire shop and everything in it got a slight dusting on it. And it's not like other paints that dust if this stuff sticks



Cool, thanks.

Ok... You need a index for this build thread. You've done so many cool things I want look at again for ideas and we are up to 81 pages lol! =)


Only 17pages for me.
 
Not a bad idea but then I have to go thru all 81 pages and index those post links. :D

Maybe I will see if i can get to that this weekend.
 
I was just trying to hunt down the pics of your roofrack fab and how you made the mounts inside and out. And not to mention a bunch of other mods with great pics youve done
 
To the manufactures of this weld in plate. Would it kill you to take 30 seconds to deburr the edges left over from the stamping process? I think I lost about a pint of blood from a fountain gash.:whistle:

Plate kit can be found here

steering-005.jpg


First step in beating it into submission

steering-006.jpg


I am pretty sure others have done it but I used 4 bolts to pull the plate down while heating it up. plus I also knew the holes would still line up.

steering-007.jpg


Side Plate welded in

steering-008.jpg


Wife likes to catch in the process.

steering-009.jpg


Bottom plate all welded up. This part of the project is done.

steering-010.jpg
 
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mine was a little rough around the edges, sorry to hear you cut ourself. looks like you got it burned in pretty well.
 
Some updates

Plan "B" for mounting sliders directly to the frame. Just had these made up and finally had a reason to use my bender!

sliders-031.jpg


Nice coating of epoxy paint on the frame

steering-011.jpg


ORD order came in

steering-012.jpg


suspension-017.jpg


suspension-018.jpg
 
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With those front springs out, it sure would be a good time to install a new cross member. Especially since you need to drill the frame bottom.
 
ORD engine cross member, you know you want one.
 

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