Make Your Own XJ Rock Rails Neal Hoover designed and built his own rock rails for his 1996 Jeep XJ. He wheels pretty hard and in his own words: "They sure take an honest beating." (Neal, Thanks for letting Mesa 4x4 fearture your work.) Click on image for a larger view. Test Fit I started with 2x6x3/16" box tubing for the rails. I used 2x2x 1/4" tubing for the arms to the frame. And I used 10 gauge sheet metal to wrap the frame where the arms attached.   Click on image for a larger view. Cut to Fit All cuts were done with a sawzall!!!   Click on image for a larger view. Rail Up Tight Against the Pinch Seam I first drilled holes in the pinch seam, then butted the tubing up against the seam and marked through the holes onto the tubing. Then i drilled and tapped holes in the tubing for the pinch seam bolts.   Click on image for a larger view. Tapping Holes for the Pinch Seam Bolts   Click on image for a larger view. 1/4" Grade 8 Bolts for the Pinch Seam   Click on image for a larger view. Cut-Out for the Support Arms Two arms run from the 2x6 tubing back to the frame rail.   Click on image for a larger view. Rear Arm Bracket I used 10-Gauge sheet metal to wrap the frame rail. Then I bolted completely through the frame with 4 bolts per bracket.   Click on image for a larger view. Front Arm Bracket Since the frame couldn't be completely wrapped due to the frame design, I utilized the bolts for the factory crossmember to help support the bracket.   Click on image for a larger view. Bolts for the Rear Bracket   Click on image for a larger view. Rail Bolted Up with Pinch Seam Bolts   Click on image for a larger view. End Caps Again, 10-Gauge sheet metal cut, welded, and ground down for the end caps.   Click on image for a larger view. Front Arm and Bracket Welded On   Click on image for a larger view. Rear Arm and Bracket Welded On   Click on image for a larger view. Garage Art!! ;-) Ready to Prime & Paint.   Click on image for a larger view. Primed & Taped Off for Rhino Lining   Click on image for a larger view. Rhino Lining Done I only did the portion of the rail that sticks out for stepping security. If I did the whole rail, then the bolt holes in the pinch seam would NOT line up due to the thickness of the Rhino Lining.   Click on image for a larger view. Painted and Ready to Bolt On!!!! By design, these rails are truely bolt-on.   Click on image for a larger view. Sliding Them In to Bolt Up   Click on image for a larger view. Finished Pic #1 These were taken after a weekend of wheeling.   Click on image for a larger view. Finished Pic #2 The 2x6 tubing really doesn't stick out very far.   Click on image for a larger view. Finished Pic #3 Notice how the XJ's body is narrower near the front than it is in the rear. (The 2x6 tubing is completely flush against the pinch seam.)