DIY Fabrication: Pop-Top Camper Build – 2000 Jeep Cherokee
How do you change the cabin air filter on a Jeep Cherokee XJ? You don’t. Being that in all years of production the XJ never came equipped with a factory cabin air filter. No big whoop for a dusty rock crawler, but a sealed in Cherokee camper build could use a little added luxury: DIY time.
The XJ Cherokee HVAC system (Heater & A/C) pulls fresh air from the windshield cowl (where a cold air intake can be routed as well – another DIY hack). On a street only vehicle this air may be isolated enough – but rip through the desert and that Cowl is jammed full of dust and dirt.
Side Story: One particular weekend rip out in Ocotillo Wells, the Jeep plowed through a swarm of flying desert larvae. Whatever these shrimp-looking buggers were, a freak proportion dropped dead inside the cowl and the following week the A/C reeked like a rotten shrimp salad. Low and behold, went in to shop vac the cowl and where’s the cabin filter? The Cherokee never came with one. No big deal. But that got the gears turning.
While doing a complete teardown on the Jeep XJ HVAC system (between insulating the Cherokee camper interior & firewall) a #DIWHYNOT moment struck. Let’s stick a quick cabin filter in this ol’ Jeep.
The DIY XJ Cabin Air Filter was brought to life not just to filter dust and dirt, but was sealed in with a raised profile to fix the leaking XJ Cherokee’s cowl. This grew problematic especially after installing the XJ’s Cold Air Cowl Intake. Anytime it would rain and the jeep was parked on an incline, water would leak through the HVAC box and puddle on the floor.
A common rainwater leak with older Jeep Cherokees.
The Build: A generic cabin filter was sourced and installed into a custom aluminum welded mounting plate. This DIY cabin filter block raised 3/4″ above the cowl profile where water likes to pool.
A secondary filter material is fastened on the air intake port to be easily replaceable. This cabin air filter intake pulls air in from the side and has a slanted top to further redirect rainwater. A few little details that brought a quick sketch to life.
The cabin filter assembly is sealed in place with a urethane flashing caulk. PLS-30 by Loctite – a sealant used for many odds and ends on the DIY camper build. The mounting plate was also secured with flashing tape.
The final product is a cabin air filter that sits between the cowl intake and HVAC box opening. The build continued with a full interior sealing and sound-deadening/insulation. Fresh air for a freshened Jeep.
Done & Done.
Related Content:
DIY Pop-Top – Finished Redesign (Fiberglass Mold & Production)
