Making Room for 40's! Rear Quarter Panel Rebuild Cherokee XJ One Ton Swap

Rebuilding the rear quarter panels and making new wheel wells on my 99 Jeep Cherokee XJ the "TrailPlug". Lots of sheet metal and body work with a few tips and trick along the way.
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[@MrJka1920]

For gaps with thin sheets instead of using a mess of wire, I scrape a 6013 welding rod clean and just lay it on/in the gap. I’m a fan of the “whatever works” method. Looks good from my house sir

[@MuddyBeards4X4]

Sounds like a good idea

[@CPPDIYJEEPXJ]

I am so excited you’re continuing this build!!! Great job. Your Jeep is going to wheel so well. And have bulletproof axles! Thank you for the great content.

[@MuddyBeards4X4]

I'm excited too

[@jpwhre]

Rock krawler 8" LA coil over conversion (they don't do xj anymore) This is a good build for gas shock conversion. (Air Shock) if you do front to match. Full traction made the only skid plate to fit kit.

[@moejr14]

How wide is that thing? I’m looking to do one ton swap on MJ. Wanna keep an eye out for a trailer wide enough to haul it!

[@ryanbrown33]

Tig rod can work pretty well for filling in gaps like that. Pretty much the same idea. Nice work !

[@XJrick303]

Is this thing completed, haven’t seen any updates?

[@northernmichiganoverland]

Nice to see some more work on the XJ!

[@MuddyBeards4X4]

More to come

[@ghettoluxurycustoms2848]

Seam sealer is your friend after doing a job like this.

[@DrHavok1]

looks good i am glad you are getting rid of the garbage leafs

[@jeepindave5464]

Whos this guy? 😉

[@MuddyBeards4X4]

Some guy that occasionally works on jeeps

[@slowfox89]

It's on occasion cause jeep = just empty every pocket. I've owned an xj for 2 weeks and have spent almost as much on upgrades as I gave for it. Hahaha $$ can't take it with ya in the end

[@jpwhre]

Interested in what you do with front.

[@paularbon5810]

Good to see you getting back at it.

[@MacsSpecialitiesMotorsports]

Glad to see the TrailPlug hasnt been forgotten on #muddybeard4x4 Well done sir!!

[@emtjc8465]

looking good! keep up the good work. very interested to see the "finished" product. we all know these things are never finished.

[@williamfrye9441]

Happy to see you back on XJ giving me inspiration to go weld and wrench on my ZJs

[@littlebro9051]

The mask didn't have any filters on it?! Could see the check valves

[@MuddyBeards4X4]

Haha you caught me. My dog got to the filters. I put in these little foam inserts. Felt like it was better then nothing. I have to get better about ppe

[@rickmarquart3277]

Looks great, Robbie! Can’t wait to see flogging on it. 👍🏼

[@charlesboetel1324]

It is still a unit body, weld plates to the tube and bolt or spot weld them to the tubs, seam seal and done.

[@millwright15]

Man, you’re making me want another XJ!

[@MuddyBeards4X4]

Do it!. They are not cheap anymore though

[@millwright15]

@@MuddyBeards4X4 ain’t the the truth! But, ain’t nothin cheap anymore!!!!

[@firstwordcar]

Looks great, inspiring me to think more outside the box for my future ZJ plans. Any reason you didn't weld the wheel well to the crossover tube? Or at least put a rubber edge seal around it to try and keep more dirt/water out? It being a unibody I feel like you don't have to worry about the wheel well moving away from the frame mounted coilover hoop like a body on frame application so welding them together wouldn't be an issue?

[@MuddyBeards4X4]

I'm going to seal up the hole somehow. Prob use some rubber or foam

[@PNW_Rodeo]

Seam sealer should fill that gap nicely.

[@erscustoms911]

Turned out great man more like this please !!! 😎

[@pierre-simonlaplace9496]

amazing work, and nice welds! looks badass

[@richcoons9048]

good job

[@CopeManMTNDEW]

That turned out great. Knowing what I know now. I would have done mine differently. You adding tube/fenders to the comp cut? I did with mine. It's awesome at protecting the body

[@MuddyBeards4X4]

I am not sure yet maybe just a towl rack or something

[@moejr14]

What gauge is the xj sheet metal?

[@MuddyBeards4X4]

I am actually not sure. It is thinner then the 20 gauge for sure

[@forreststrong797]

Did you make sure your hatch shuts and clears the fender wells at the bottom corners? I'm used to the older style hatch and that hatch recesses into the body past the seal a good bit. I think this turned out good I like that your towers are sealed to the outside I don't like when people leave holes open in the back. I really like the little wheel well arch you left.

[@MuddyBeards4X4]

You had me thinking. Had to go check. It does shut but barely

[@old_con]

Wow ! This turned out so good ! The tips you give whilst welding is great for us newbie’s. We need the axle’s now !👍🏽

[@MuddyBeards4X4]

Working on it. More coming soon

[@jtcustoms1182]

Glad to see this again. For welding the gaps I put a copper block on the opposite side and just build it out.

[@MuddyBeards4X4]

I have seen those copper welding spoons. I always wanted to try them out

[@FlawedOffroad]

Nice work dude

[@MuddyBeards4X4]

Thanks

[@Kyle-ev4fk]

Nice work, glad to see this project moving forward.

[@MuddyBeards4X4]

Me too

[@scottadvevture2022]

nice clean look and still have room on the inside thank you for sharing your time and build

[@MuddyBeards4X4]

Thanks 👍

[@raystevens687]

Nice job thanks

[@MuddyBeards4X4]

👍

[@tedz74]

I applaud your attention to detail with the Bondo on the seams. As an alternative, I found polyurethane-based construction adhesive to work great on welded seams. It fills pin holes and makes the welds look cleaner. You can sand it once fully cured and can paint too. Home Depot sells Loctite PL premium.

[@MuddyBeards4X4]

Sounds like something I need to try

[@slowfox89]

I'm interested in giving this a try

[@brianmorrow9815]

Nice job I like it.

[@MuddyBeards4X4]

Appreciate it