Reaver's 03 XE Build thread!

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
206k
oil gets changed when it doesn't mean a shortage of busch lite, using only supertech 20w50
I change mine every 3k or 6 months. I've put maybe 500 miles on the X since the last change, and that was back in November, I think. I'd have to look at the sticker.
 

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
So, with the plan being to do the Idaho BDR next year, there's going to need to be some prep work done before we tackle it.

We will be taking the trailer, and towing it with the X. Knowing that mpgs are already pretty terrible, I'll need to carry more fuel. I will also need to get the tow hitch on (already have it, just need to install it), run a 3 way Anderson for the DC charger in the trailer, install either an add-a-leaf or new springs to accommodate the extra weight on the rear end, do the timing belt, and swap the radiator for a 1.25 in thick SC radiator. I also need to change the brake fluids, diff oil, transmission fluid, and transfer case fluid.

I should probably go ahead and make sure the brakes are in top notch shape while I'm at it. They work great, but I don't know when they were last done prior to purchase.

There might be other things that get done or purchased, but these are the MUST do items prior to the trip.

Lots to do in the next year!
 

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
I've been dealing with some pretty severe pain the last few days, but managed to get my plano boxes mounted to the crossbars of my rack.

IMG-20220828-135806.jpg

IMG-20220828-135754.jpg


They're mounted using 4 12mm bolts for each box. There's a piece of 1/2in plywood in the bottom as well. Bolt goes through the plywood, through the box, and into a spring channel nut in the superstrut crossbar.
 

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
I've begun ordering parts for the next stage of upgrades, in preparation for doing a 10 day trip on the Idaho bdr next year.

Sometime in late October, we'll be doing the following:

1. Installing a brand new supercharged radiator installed 10.21.22
2. Installing a secondary trans cooler
installed 10.21.22
3. Installing oem tow hitch
installed 9.19.22
4. Installing flush mount backup lights in the bumper caps installed 9.19.22
5. Running new power/ground wires for bumper light bar isn't - Installed 9.23.20

6. Installing 4x4 Parts 3 leaf add-a-leafs packs (Decided to try adjusting my shackles first and see how that works, as 4x4 Parts wants $160 to ship the AAL)
7. Cut and install a new superstrut cross bar, and mount my aluminum toolbox to the two front bars.
8. Build and install a 3-pin anderson harness to charge the battery in the trailer installed 9.19.22


Parts needed:

3 pin anderson plug
Anderson terminals for 8 GA wire
30A inline breaker
8 GA welding wire
Supercharged 2 Core radiator
Transmission Cooler kit

One piece of superstrut
U-bolts
OEM hitch installation bolts
3 leaf add-a-leaf packs
Nilight Flush Mount LED Lights
12/2 power wire
 
Last edited:

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
I forgot to mention.... My stereo doesn't want to turn on at all. Checked fuses, and can't seem to find any blown. Maybe it just died.

I've wanted to upgrade to a Bluetooth capable radio for a while. I'm debating on going with a cheaper Bluetooth stereo, or spending a little bit on an android auto head unit...
 

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
I forgot to mention.... My stereo doesn't want to turn on at all. Checked fuses, and can't seem to find any blown. Maybe it just died.

I've wanted to upgrade to a Bluetooth capable radio for a while. I'm debating on going with a cheaper Bluetooth stereo, or spending a little bit on an android auto head unit...
I replaced my stereo with a boss audio 508uab. It's a basic single din unit with aux input and Bluetooth. So now I have tunes again!

I've got 25 feet of 8awg welding wire in red and black coming today. As well as my 30a breaker, and 8awg anderson contacts.

Sunday, my buddy and I will build the harness for the the DC-DC charger in the trailer, mount my auxiliary backup lights, and install the tow hitch.

If we have time, we might even run new wires for my bumper light bar, as the way it's setup now, it gets power from the auxiliary relay box, but grounds at the starter battery.

This works when I'm not running the dual battery setup in the X, but it doesn't work once I've plugged in the second battery.
 

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
Made some progress today!

Step one was to install the tow hitch.
IMG-20220918-194133.jpg


Didn't have bolts, so off to the hardware store we went to get m12 grade 10.9 bolts. $52 worth of bolts, washers and nuts later the hitch was on.

Next up was to install the new auxiliary backup lights in the plastic caps. We used an oscillating cutter and a template, and managed to do it without even having to take them off.
IMG-20220918-194128.jpg


The last step was to build the 3-pin anderson harness to run the DC-DC charger in the trailer when I'm towing it.

Moved all the auxiliary wiring to the extra studs on the battery.
IMG-20220918-194222.jpg


Ran it to a 30A breaker right behind the 100A breaker for my aux system:
IMG-20220918-194231.jpg


Ran the harness along the frame rails:
IMG-20220918-194247.jpg


And mounted the plug to the safety chains mounts in the steel bumper:
IMG-20220918-194144.jpg


Got a few more things to try and knock out this week after work. I need to run the power for the backup lights through the passenger tail light grommet, and run new power and ground for the bumper light.
 

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
Ran new wires for the bumper light bar last night. It's now grounded to the same place it gets power, so it should work regardless of which battery it's pulling from.

Also work on figuring out where all my screens for monitoring cameras are going to go.....

shiat got real busy!
IMG-20220921-214128.jpg


But, everything is out of my sight line, and it doesn't impede my vision in any way. We're gonna give this a shot.

I suspect I'm going to have to order a better ram mount for the dji controller. It moves around a bit due to the weight.

These screens allow me to view and control all my cameras. I have 3 action cameras, the drone, an osmo pocket.

The screen next to the tablet is my android auto unit that has navigation and music control.
 

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
Dude. That's possibly too many screens.
Yeah, there's a whole lot going on there. We'll see how it works out. I've done the phone + Android auto thing before, and that works well. We'll see how adding in the drone screen works.

In the meantime, I've been working on doing a clean redesign of my electrical system.

Going to be making everything modular using DT, DTP and Anderson SBS connectors.

This will be a winter project, and I'll bring the drawer system down into the basement and work on wiring everything up in the evenings.

Xterra-Electrical-Diagram-Update.png
 

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
OK, much work this weekend, though most of it on the trailer, and the frontier.

I added some organization bags to the kitchen box. We'll see how they work this weekend, but I think once labeled and attached to the wall with velcro, it'll work quite well.

media-1664076096587-Sep-24-2022-5-31-PM.jpg


I also had to replace one of the plugs for the trailer camp lights.

I also tightened all the bolts that hold the box to the frame. The nuts had started to work themselves a bit loose. I had also drilled two additional holes per side when we built the box, but never added the bolts. So instead of 1 large bolt in each corner holding the box on, there are now 4 bolts per side holding it on.

I also noticed that the bolts that held the tounge box on had lost their nuts. Replaced all those nuts with larger ones, and added lock as hers to both sides. I'll keep an eye on it this weekend, and possibly replace with nylock nuts.

Then I put everything back in, and moved onto installing my auxbeam switch box in the Frontier:

First step was getting the switch cable through the grommet:

IMG-20220925-165215.jpg


Then I made a bracket so that I can mount it on top of the OEM fuse box, at least for now:
IMG-20220925-165159.jpg


Zip tied the wires to the OEM harness along the firewall:
IMG-20220925-165208.jpg


Last step was to get the switch panel mounted on the dash:
IMG-20220925-165148.jpg


I guess I need to get some lights now....oh darn.
 

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
Ordering my supercharged radiator in the morning. Between that, and the auxiliary trans cooler, I shouldn't have to worry about this thing getting hot.

We'll see about the AAL after this weekend. I suspect I'm still going to want them to help handle the weight.

The last thing is my aux lights. For the front, I'm going to switch to a pair of 90W spots. I was going to do a set of high powered auxbeam spots, but then stumbled across these:

7 inch 90W LED Driving Light Compatible with Jeep Wrangler Off Road Vehicle ATV UTV Golf cart Lighting Trucks Pickup Ford f150 Work Light, Pack of 1 https://a.co/d/4L3eHYK

I dig the combo. True spot, a bit of flood, side shooters, and DRL. I figure that, plus a single row 32in bar up to for more flood should give me everything I need for night driving. Plus, I plan on adding some small cubes on the rack for helping to setup camp, since I have one more switch in the X.
 

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
Supercharged radiator inbound.

I'll decide on what to do for the rear of the X after this weekend, but I have 3 options for the rear.

1. Adjust the shackles to get a little more height, but doesn't address additional weight

2. 4x4 parts 3 leaf AAL pack.

3. Custom rear springs from a local spring shop.

I also ordered a SetPower AJ30 fridge to keep in the X. I wasn't planning on picking it up this early, but it was on sale, so I went ahead and ordered it.

Screw you bank account.
 

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
Installed the Koyo Supercharged radiator yesterday, as well as my auxiliary transmission cooler. Process was pretty easy, and we had it back up and running in a couple hours.

Bonus - There's no leaks, and nothing exploded! Ended up having to add about half a Quart of trans fluid to account for the transmission cooler.

I also built myself a tilting fridge slide for the new 30L fridge. Seems to be working well, but I've not had it on a trip yet.

IMG-20221009-164313.jpg
 

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
Waiting on a new light bar for the roof to show up. I ordered a 33 inch Auxbeam 5D pro light bar. Apparently, it's a very effective spot light, with some flood as well. It's taking its sweet time getting here.

Also, not so much an upgrade, as it's a necessary device... Bought myself a zoleo satellite communications device. I'm going to start heading out solo, and I promised my wife I'd get one before doing a solo trip.
 

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
I've not updated my thread in a while.

I've been making progress on my prep work for the bdr trip this year.

However, not everything has been flawless.

After installing the auxiliary transmission cooler, I went to go on a trip with a friend of mine. I was towing the trailer, and when I hit the gas on the highway. The transmission cooler started spewing from around the hoses on the radiator. Turns out the hose clamps failed. I didn't have any spare hose clamps, so we towed the X to my buddies.

Spent the next day underneath cleaning everything off, and replacing the hose clamps, and double clamping it.

We still saw some dripping, so I limped it to my mechanic for them to check out.

Turns out the dripping we were seeing was residual, so it was good to go.

Then, I found a crack in the hard shell on my rooftop tent. Filed a warranty claim with Ironman 4x4, and they ended up sending me a whole new tent! So I patched up the original with marine-Tex epoxy.

IMG-20221117-082739.jpg


I put the new tent on top of the Xterra!

IMG-20230121-162809.jpg

IMG-20230121-162743.jpg


I had my shovel mounted to the rack, but with the tent up there, that obviously wouldn't work.

My solution:

Use some small diameter tube mount on the Jerry cans, and put quick fist
clamps on them.

IMG-20221229-145511.jpg

IMG-20221229-145516.jpg


I also added a wrap around tire mount from rock slide engineering, and mounted a 5lb propane tank mount from bns overland here in Idaho on it. I'm still trying to decide what to put on the other side.

IMG-20230107-145133.jpg


The most recent project was cleaning up the wiring in the back. I replaced my old relay box with a new one. This time I used proper 12ga marine wire, and terminated the outputs of the relay box with anderson powerpole connectors. I had two unused slots in the original, so I moved two of the extra Relays into the box.

IMG-20230203-100757.jpg

IMG-20230205-165408.jpg

IMG-20230205-165349.jpg


I also swapped one of the 12v cigarette sockets for a dual 30A powerpole socket. And I have a 25' 10ga powerpole extension cable that I can use to power my diesel heater.

I also mounted a 25A solar charge controller next to my inverter, since I plan on adding a permanent 100Ah lifepo4 battery to the X.

IMG-20230205-165355.jpg


And I added a dtp pigtail so that I can plug in power for my rooftop tent to run the light, and power our cpaps.
IMG-20221228-121455.jpg

IMG-20221228-115630.jpg


I also got a new hatchet for Xmas, so I mounted that to the inside of the hatch.

IMG-20221228-123505.jpg


And finally, I replaced the roof light bar with an auxbeam 5D spot/flood combo bar.

I was going to replace the 20in bar in front with two 7in spots, but with the roofbar having the bight spot light, I don't think I need to.

IMG-20221106-162542.jpg


That covers what I've gotten accomplished up till now.

All these modifications have exposed some flaws though.

The leaf springs.

The back end of Gamora is really sagging, and that needs to be addressed. Initially, I was thinking I would just adjust my shackles, but the more I thought about that, the more I realized that's not the proper solution. I was going to initially go with the 4x4Parts 3 leaf AAL. Then their shipping calculator quoted me 160 bucks for shipping.....

At that point, I thought it would make more sense to have custom springs made and installed locally.

Then I decided to call 4x4Parts to get an accurate quote on shipping...

$50.

Thats way more reasonable.

So those will be ordered before the end of February.

Then I need to get around to finally installing the HD tie rod adjusters. So I'll order new tie rod ends (suggestions on brand?), and keep the old ones as spares for the bdr.

Then it's belts, fluids, spak plugs, wires, and other various maintenance items, and lots of trips to shakedown the build.

I may or may not need to upgrade shocks along the way.

That's all for now.
 

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
Well, I've not got around to ordering the AAL yet. Instead, since it didn't cost any money, I decided to max out my shackles and see where it got me.

Before (pay attention to the space in the rear wheel well):

IMG-20230121-162809.jpg


After:
IMG_20230319_102553.jpg


It's not perfect, but better than it was. I still plan on ordering the AAL pack, but this will hopefully buy me a bit of time.
 

Fromfrontier2Xterra

I bought a Taco
Super Moderator
Supporting Member
Location
All over PA
Well, I've not got around to ordering the AAL yet. Instead, since it didn't cost any money, I decided to max out my shackles and see where it got me.

Before (pay attention to the space in the rear wheel well):

IMG-20230121-162809.jpg


After:
IMG_20230319_102553.jpg


It's not perfect, but better than it was. I still plan on ordering the AAL pack, but this will hopefully buy me a bit of time.
Love it.
 

TerryD

Total Tease
Supporting Member
Location
Covington, Va
Well, I've not got around to ordering the AAL yet. Instead, since it didn't cost any money, I decided to max out my shackles and see where it got me.

Before (pay attention to the space in the rear wheel well):

IMG-20230121-162809.jpg


After:
IMG_20230319_102553.jpg


It's not perfect, but better than it was. I still plan on ordering the AAL pack, but this will hopefully buy me a bit of time.
You might need to extend your bump stops with the shackles maxed out. You can get in a situation where you are over flexing the leafs and they will break down faster.
 

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
You might need to extend your bump stops with the shackles maxed out. You can get in a situation where you are over flexing the leafs and they will break down faster.
It's still weighed down and below stock height in the back. I doubt it will be much of an issue, but if you can point me to a solution, I'll probably order it, since I'm still going to be doing the AAL in the future.
 

TerryD

Total Tease
Supporting Member
Location
Covington, Va
It's definitely an issue. If it's still too low, you are putting more stress on the leafs and running the risk of over flexing them when you compress them.

You should look at getting an AAL or new springs pretty soon. Your stock springs are most likely going to continue to drop.
 

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
It's definitely an issue. If it's still too low, you are putting more stress on the leafs and running the risk of over flexing them when you compress them.

You should look at getting an AAL or new springs pretty soon. Your stock springs are most likely going to continue to drop.
I was tired when I responded originally, but realize what you meant by over flexing now. It's definitely my next purchase. Adjusting the shackles was merely meant to be a bandaid.
 

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
I realize that I've not updated this thread in a while.

I've been busting butt trying to get the X and the trailer prepped for the BDR. It's been ALOT of work (and more money than I'd care to admit).

I went ahead and ordered, then installed the 4x4 Parts 3 Leaf packs. What a PITA, but what a difference it made, both in ride quality, and height!

Before:

IMG-20230319-102553.jpg


After:

IMG-20230521-131942.jpg


I also built some additional drawers in the back that are modular, and bolt down into the original platform, and is held in place via those biting t-nuts

IMG_20230618_081938.jpg


I redid the headliner as well.

I went from this:
IMG_20230618_133417.jpg


To this:
IMG_20230618_165801.jpg


I also decided to install a 100Ah battery into the back, as my battery packs won't run the fridge for more than 12 hours anymore.

DC-DC and solar installed:
IMG_20230708_171356.jpg


Mounted the screens to a temporary faceplate I made:
IMG_20230709_214537.jpg


And installed the battery between the fridge box, and the rear driver's side panel. I had JUST enough room!
IMG_20230710_202957.jpg


There's also been a bunch of maintenance done, including diffs, transmission, transfer case, etc. Full inspection to check belts, steering, suspension, and everything else. I've been very busy the last few weeks, but now it's just a matter of making sure everything's loaded, and ready to go!
 

Prime

Shut up Baby, I know it!
Admin
Location
Denver Adjacent
I realize that I've not updated this thread in a while.

I've been busting butt trying to get the X and the trailer prepped for the BDR. It's been ALOT of work (and more money than I'd care to admit).

I went ahead and ordered, then installed the 4x4 Parts 3 Leaf packs. What a PITA, but what a difference it made, both in ride quality, and height!

Before:

IMG-20230319-102553.jpg


After:

IMG-20230521-131942.jpg


I also built some additional drawers in the back that are modular, and bolt down into the original platform, and is held in place via those biting t-nuts

IMG_20230618_081938.jpg


I redid the headliner as well.

I went from this:
IMG_20230618_133417.jpg


To this:
IMG_20230618_165801.jpg


I also decided to install a 100Ah battery into the back, as my battery packs won't run the fridge for more than 12 hours anymore.

DC-DC and solar installed:
IMG_20230708_171356.jpg


Mounted the screens to a temporary faceplate I made:
IMG_20230709_214537.jpg


And installed the battery between the fridge box, and the rear driver's side panel. I had JUST enough room!
IMG_20230710_202957.jpg


There's also been a bunch of maintenance done, including diffs, transmission, transfer case, etc. Full inspection to check belts, steering, suspension, and everything else. I've been very busy the last few weeks, but now it's just a matter of making sure everything's loaded, and ready to go!
Holy shiat man, been busy!

Hopefully that's a solid state battery you've got up on a 90° tilt.
 

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
Got back from the BDR. The X did fantastic, but man, does it struggle pulling the trailer up hills on the highway.

The only issue the X gave me was the knock sensor set off the SES light on day 2. Scanned it using torque.

Drove the rest of the trip with it on, but no adverse effects.

Now, time for some pictures!

First days camp:
IMG-20230728-180917-Liana.jpg

IMG-8170-Greg.jpg

IMG-8171-Greg.jpg


We found a nice forest service campground right on the middle fork of the Boise river.

The next camp site was at deadwood reservoir:
IMG-8185-Greg.jpg

IMG-8188-Greg.jpg

IMG-8189-Greg.jpg


The next day, we drove up through Yellow Pine, and over the summit of Elk Mountain:

On the way up, we could see smoke from a young forest fire. Thankfully, it was the opposite direction from where we were heading.

IMG-8197-Greg.jpg


IMG-20230730-164938-Liana.jpg

IMG-20230730-164925-Liana.jpg


On the way down, we stumbled across an old bus.

IMG-20230731-113636-Liana.jpg

IMG-8211-Greg.jpg

Somebody had drawn some adorable kitty cats in the bus! Thankfully, the girls are young enough to not know any better. My daughter kept talking about the kitties, and I swear I almost peed myself laughing...

IMG-8217-Greg.jpg


We continued up into the mountains, finding camp just off the road, in a small clearing. There was JUST enough room for all the vehicles.

IMG-8226-Greg.jpg

IMG-8228-Greg.jpg


The next day, we dropped out of the mountains to resupply. My buddy wasn't feeling good, so he decided it was best to head home from here. We were down to four rigs.

After refilling water, gas, and the fridge, we headed towards elk city, finding camp about 5 or 6 miles outside of town.

We camped next to a creek, giving everyone the opportunity to get clean, and gave my wife the opportunity to do some laundry.

IMG-8233-Greg.jpg

IMG-8234-Greg.jpg

IMG-8238-Greg.jpg


We set up the projector, and put on some bluey for my daughter.
IMG-20230801-202521-Liana.jpg


The next day, we took our time rolling out. One of the guys decided to stay and work on some issues on his rig. He said he'd meet us in Lolo...

We headed for elk city, to refuel, and the headed toward the Magruder corridor. We went a bit off route to find camp, and headed up to the Green Mountain Fire Lookout.... We were not disappointed.

IMG-20230802-182830.jpg

IMG-20230802-160633-Liana.jpg

dji-fly-20230802-202244-18-1691032971596-photo.jpg

IMG-20230802-201433.jpg

IMG-20230802-204728.jpg


The next day, we drove the Magruder Corridor.


When we hit Montana, we drove about 20 miles south of Darby, and camped next to a nice little creek.
IMG-20230803-204735-Liana.jpg


I'll be adding more pictures later!
 

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
The wife and I want to do the run again, but just the two of us.

But, if you get the opportunity to come up and do it, let me know. I'll tag along for a few days with ya!

Our milage goal was 100mi / day. Doing that, you can complete the trip in 12 days.
 

ThatGuy

Need Bigger Tires
Supporting Member
Location
Big Island
Haha. As a wise woman once told me.... shiat or get off the pot.

She followed her own advice, and picked up an 02 after the trip.
Awesome photos and trip!! I really miss road-trips Hard to do on an island. So very cool And I love my 02! Hope your wife loves hers.
 

reaver

Lockers Installed
Supporting Member
Location
Caldwell, ID
Awesome photos and trip!! I really miss road-trips Hard to do on an island. So very cool And I love my 02! Hope your wife loves hers.
She says she drives great. And front what I saw on Saturday, is every bit as good at this stuff as mine is.

I just need to figure out where in going to put some extra gas for a a trip in a month. Im thinking two 2.5 gallon tanks in the basket about the front doors.
 
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