Minimum size MJ

[omega_rugal]

What would be the minimum metal you need to rebuild an MJ using XJ parts? my plan is to strip the MJ to its bare minimum, leave only the MJ specific parts, excluding the obvios bed and tailgate, from the doors forward the cab + the X frame are unique right? doors, fenders, hood exchange with the XJ

[omega_rugal]

empty

[ghetdjc320]

Not sure what specifically your asking form but even the control arm brackets are different on an MJ. The “bolt on” parts are the hood, fenders, doors etc. A lot of interior pieces are different. Kick panels, center console insert, floor bracing, interior trim etc. Lots of differences but practically anything can be fabbed and modified to fit

[omega_rugal]

I'm going to remove all the interior, swap a 97+ dash, bucket seats...

 

the idea is to strip the truck entirely, i assume i will end up with a doorless cab attached to a X frame. this way it will uncover any rust or hidden damage, and give clear access, right now on the list is to fix or replace the passenger side rail, it was damaged in an accident and not fully fixed by the PO, also there is rust  on the floors that needs patching, the driver side hinge is loose

 

all this while i take the engine apart for rebuild, it s been running weird lately and i suspect a broken spring

[Sir Sam]

Find a 97+ donor vehicle to do this. 
 

I basically did the same on mine, check my build thread in epic builds. 
 

ya you wind up with the body stripped down, takes longer to put together than take apart. 

[Dzimm]

As stated, full strip of the front half of the truck.  Plenty of build threads on 97+ swaps that's how the process.  There is a little fab work here and there but overall it's mostly bolt in.

[omega_rugal]

right fender and grill are out, whoever ' fixed' the truck deserves to eat $#!&, they didnt even bothered to straighten it, just pull the thing toghter and weld

[omega_rugal]

found the problem, those spot welds really make it difficult

[omega_rugal]

Sheet metal is harder than i thought, even with a hammer it won't budge, does heating it make sheet metal softer?

[omega_rugal]

question

 

i don't have a good MJ/XJ to check

 

- is that bolt supposed to rest flat on the rail?

 

- is that normal or is the steering box pushing against the rail?

 

[derf]

There should be a spacer between the gear box and the frame rail.  Maybe 3/4" thick or so.

 

The stock spacer is weak.  Aftermarket upgrade spacers are inexpensive and easy to get.

[omega_rugal]

13 minutes ago, derf said:

There should be a spacer between the gear box and the frame rail.  Maybe 3/4" thick or so.

 

no, nothing between the steering box and the fram rail, how is supposed to look like?

[derf]

7 minutes ago, omega_rugal said:

 

no, nothing between the steering box and the fram rail, how is supposed to look like?

You can google "XJ Steering Box Spacer" and see a bunch of different options along with pictures of stock spacers.

 

I'm running this one on my XJ and will put one in my project MJ when it's time:  https://www.jcroffroad.com/product/XJSTSPC.html

[omega_rugal]

oh that spacer is there, the round part of the steering box what touches the frame rail...

[derf]

It could be a Durango box.  That box is a little bigger and they suggest adding a couple of washers to each bolt to space it away from the frame.

[omega_rugal]

maybe, the box sits perfectly except for the round part... i´ll take a pic from above to confirm if i already have the upgraded box