End-to-end overland XJ build: ~3" lift, 31-33" AT, dual battery, drawer system, roof rack, recovery kit.
A canonical overland XJ build aimed at multi-day backcountry travel with sleeping/cooking capability, not hard-core wheeling. The core spec:
**Suspension & tires**: 3" lift (Old Man Emu or RockKrawler short arm), 31x10.50 or 32x11.50 BFG KO2 or Toyo AT3, 15x8 wheels 3.75" backspacing.
**Gearing**: regear to 4.10 (31s) or 4.56 (33s) — non-negotiable with AW4 and bigger tires.
**Protection**: front winch bumper, rear bumper with swing-out + tire carrier, sliders, gas tank skid, transmission/transfer case skid.
**Recovery**: WARN VR EVO 10-S, kinetic rope, soft shackles, MaxTrax, ARB Twin compressor, fire extinguisher.
**Electrical**: Big-3 wiring, 160A alternator, dual battery via Blue Sea ACR, Switch-Pros SP-9100, aux fuse block, LED ditch lights, LED reverse.
**Cargo & sleeping**: Goose Gear or DIY plywood drawer system, sleeping platform, fridge slide (ARB or Dometic), water can mount.
**Roof**: lightweight roof rack (Hutchinson Hardware, Smittybilt Defender), awning (ARB or Smittybilt), Note the ~75 lb dynamic load limit on the XJ roof — RTT is borderline; many overland XJ owners ground-tent and use the roof for storage.
Total investment: $8,000-$12,000 in parts (DIY labor), $14,000-$20,000+ shop-built.
Written and maintained by an AZ wheeler and driveway wrencher. Always cross-reference your factory service manual — modifications affect vehicle safety and warranty. Work at your own risk.