Saturday, October 10, 2015

roof rack

bought some iron, for fabbing a roof rack, seat support etc.

 decided to build a roof rack, 165 cm by 120cm, height 9cm.

replaced triangular shaped rail with old style flat one and rack bolted to rectangular nut inside rail.

Monday, October 5, 2015

Seat from Subaru STI

fitted a reclining seat from Subaru STi

They are wider and sit a bit higher than stock seat. Shaved all mounting holes and made a support from angle iron, inner front end touches on transmission tunnel

Saturday, September 12, 2015

with a friend

with a friend, 2001 XJ RHD, 4.0, Auto, imported from Japan. ~4" lift

Monday, August 24, 2015

Monday, August 17, 2015

Interior working

Decided to check floor for rust and replace headliner with some insulation add-on

starting disassembly

passenger side floor has a little rust and small hole, overally not so bad

painted rusted area and put a silicone on the hole

glued a rubber sheet on the floor,

removed old headliner fabric, cleaning 

glued new fabric

and installed everything back.

Sunday, July 26, 2015

fuel pump

A new Bosch fuel pump and Airtex fuel strainer arrived

All assembled and ready to mount

Mounted and tested. It is relatively quiet and hope performance is good.

Saturday, July 25, 2015

WJ brake booster and Master cylinder upgrade

Long ago ordered and received WJ brake booster with master cylinder. Today decided to upgrade my brake.

everything is ready, brake booster & master cylinder, brake tube, flaring tool, brake fluid, tools etc.

stock brake booster

My brake pedal connection to booster rod is different than one I read from write-up.

It has just a clip, instead of bolt.

Old brake fluid is out

see then stock, old and leaky one

XJ single and WJ dual diaphragm boosters met once

rod length - XJ

rod length - WJ

a bit of dust mud etc

cleaned well, where I can reach to, there were clean

Rod has 6mm (1/4") length difference, need an spacer. Instead of spacer, I use a little bigger nut on thread and used a foam as a gap filler

seam above booster is massaged up and test fit

fit and tight, brake switch working

making tube template

tube ends flared, master cylinder end  - bubble & proportioning valve end - double flare

flared and bent, ready made tube


both tubes made and tightened at master cylinder, instead of bench bleeding of master cylinder,
- 2 clear hoses connected to the ends of tubes and
- other ends of clear hoses were in brake fluid in coke bottle
- added brake fluid in reservoir

then bleed master cylinder till no air bubbles in coke bottle

bottom ends tightened

seam massaged back, there is little cap ~ 5-6mm

Rear brake hose replaced with longer one.