Building Homer (2005 TJ Build Thread)

[FarFire70]

Installed Big 3.

I don't love how the + cables are run and how the fuse is mounted. I'll likely put loom on the + near anything they may bring on (if still close after another adjustment).

Fuse: I may weld in a permanent mount once the second PDC goes in because the fuse has more play than I like but will likely move with the addition on another PDC. I can't get zip ties tight enough for my liking.

 

[FarFire70]

Realized the alternator cable was turned at the fuse so fixed that. It's better.

Still want to do another visual before feeling comfortable.

 

[FarFire70]

Land out the spare cable that is labeled 'battery' and 'fender'.

It's so long that I figure it was meant to go to the driver side. But I can't see where it would go...

All the electronics work that are mounted to the Genright fender.

Maybe I'll use this cable as a strong ground when I mount the ARB Compressors in the stock lockers pump tray...

 

[FarFire70]

I'm tired of looking at all my aluminum (Genright fender - front and inner + rears) that look like shit.

I left lots of sweat and loctite sitting on them during the install (contaminates sat for years...). Haven't had success with my approaches (dish soap, 97% isopropyl alcohol, aluminum cleaner).
So reached out on the forum.

Test tonight:

Pet forum, tried 99% isopropyl on paper towel & Quick Detailer on a microfiber cloth.

No change.

Saw the idea of WD40 with Scotch Brite on a post for @Fluxor's bumper that someone did to great effect.

As a test, I just grabbed the green Scotch Brite from into my kitchen sink and used WD40 as lube....

This is the result after about 5 (low pressure) wipes...

Still more to go but trading complete, I have a path forward hopefully that the staining isn't beyond the top layer...

I'm beyond ecstatic that I may be able to fix $1k+ worth of parts that I worried I ruined...

 

[FarFire70]

There's hope!

About 7-10 swipes of the pad with WD40.

The grit is all wrong (too aggressive) but I have a path forward with a more appropriate Scotch Brite pad!

I can't express how happy I am to see a path ahead for the aluminum!!

 

[FarFire70]

Intake had a lot of issues. Hitting the hood is biggest issue. Getting out off sitting on all the cables is next. Crappy connection of the breathe hose.

Hood issue needs to be tracked first.

Here's where I drilled the firewall.

Clears the grounding nut and the spot welds.

Loosened all the clamps and ran a tape test.

You can see where the hood rests on the filter box.

I need to lift the rear of the filter box to clear the cables by at least a bit. But that causes the filter box to go even higher at the firewall making the problem worse.

I'm struggling to think I have a better solution than cutting into the filter box and adding a flat panel... I placed my hole in the firewall just like others I'd seen use this so I'm struggling. Surprised that they didn't deal with this issue of Hood impact..

This is using the Windstar filter box that so many others have used and I'm struggling that I'm having a problem here that I didn't see others having...

 

[FarFire70]

Pick this up a while back so this is what I'm going to go with to wax the Jeep.

Hoping to have some time this weekend to finish polishing and apply the wax.

Need the paint protected while it sits in the garage. I'll sand through the wax to do the touch-ups of the paint.

After the paint is polished and waxed, I'll work on the aluminum more likely before I get to the paint touch-ups.

 

[FarFire70]

This connection is also proven to be a failure point.

I need to be able to remove the intake and a clean the throttle body and I don't think getting this hose off the breather will be any easier when I want to clean the throttle body.

So I'm thinking maybe some sort of quick disconnect might be needed here too...

This Windstar air intake is presenting itself as less a solution and more of a problem...

 

[Wildman]

Can you get a short flex hose similar to what I'm using on mine? And add the piece on the firewall like mine & Jeff's are setup? Might give you a little more flexibility?

 

[FarFire70]

Can you get a short flex hose similar to what I'm using on mine? And add the piece on the firewall like mine & Jeff's are setup? Might give you a little more flexibility?

Got a link? Wasn't tracking your air filter box wasn't directly attached to to the firewall.

Was going to do a bit of digging in your thread but, since you reached out, who makes your air box because your build came to mind immediately if I replace this one?

 

[Wildman]

Got a link? Wasn't tracking your air filter box wasn't directly attached to to the firewall.

Was going to do a bit of digging in your thread but, since you reached out, who makes your air box because your build came to mind immediately if I replace this one?

What is the size of the hole you have in the firewall?

The parts I used are all made by Spectre Performance

 

[Wildman]

This is what I have on my firewall. The one issue I see is they only offer it in a 4" diameter but you can get reducers.

https://www.spectreperformance.com/91489-intake-tube-duct-mounting-plate

 

[Wildman]

Then I have this connecting the duct mounting plate to my air cleaner

https://www.spectreperformance.com/accessories/9775-flex-coupler

 

[FarFire70]

What is the size of the hole you have in the firewall?

The parts I used are all made by Spectre Performance

3 1/8" hole

 

[Wildman]

3 1/8" hole

So putting that 4" duct mounting plate should work. The hard part will be to do the reducer.

 

[FarFire70]

The parts I used are all made by Spectre Performance

Thanks!

Got some thinking to do for sure. I like this current air filter 'idea' but these issues are well... Issues

I'll take a look around at what Spectre offers to add to my options.

 

[Wildman]

Thanks!

Got some thinking to do for sure. I like this current air filter 'idea' but these issues are well... Issues

I'll take a look around at what Spectre offers to add to my options.

I was thinking more of using something to connect to the firewall and then a flex hose to the Windstar air filter housing. That would allow you to move it around a little more.

 

[FarFire70]

I was thinking more of using something to connect to the firewall and then a flex hose to the Windstar air filter housing. That would allow you to move it around a little more.

Open to ideas!

It's way more a project than I anticipate it when I started....

 

[Wildman]

Open to ideas!

It's way more a project than I anticipate it when I started....

Is the Windstar 3 1/8" tubing? If so then we'd need to reduce from 4" to that? They make some reducers to 3.5" so then a short piece of hose that went from 3.5" to 3.125"

 

[Wildman]

They make this support bracket which is what I'm using.

https://www.spectreperformance.com/9710-t-bolt-clamp-bracket

They also make this one but don't say what diameter the tube is.

https://www.spectreperformance.com/9702-air-intake-support-bracket