Here is the latest project that's been occupying my time.  Last fall, I picked up this unloved 1995 Jeep Cherokee SE 2wd for $500.  I bought it for parts, but decided to turn it into a project since it ran alright and was drivable.  Unfortunately, among it's problems was a failing head gasket and cooling system leaks galore.  It had a major meltdown one day that finished off the head gasket.  Attached are photos after I've removed the head.

Still hard to beat the good ole inline 6 engines.

It is.  Project has been on hold.  Other priorities.  The car needed a new timing belt and the other jeep needed new tires.  Also repairing my old 4-wheeler.  Hopefully I can get it back together and running later this summer.

I see there quite severe corrosion damage (probably from the neglected leaking and consequent overheat), I'm afraid it would be beyond repair (unless you will use other head and maybe block in better shape)... The head could be probably machined,but that will eat up almost 2mm of material, quite a lot...

I had a machinist clean it up and check it out.  It cleaned up quite nicely.  It is warped out of spec and needs to be machined though.

What model/brand is your ATV?

It's a 1992 Suzuki Quadrunner LT-4WD 250cc.  It's kinda old and has a lot of problems.  I just got done pulling the fenders off and the carb out.  The "choke" cable had seized and snapped.  Turns out the cab has some issues of it's own.  The rocker cover has a bad oil leak that I'm going to fix, and I just discovered a rear inboard driveshaft u-joint had blown to bits.  It also needs a break job and a little cosmetic work.  My goal was to get it up and riding by the first of June, but that isn't going to happen.

I have an Arctic Cat TRV diesel. It is a BEAST and quite a workhorse!  I did a little "fuel enhancement" trick to it too! 

I haven't had the chance to see the Arctic Cat diesels in action.  I know the 500 gas certainly gets the job done   

As far as the Suzuki goes, I took the front drums off and found the shoes were fine, but the wheel cylinders were seized up.  I don't know how much new ones from the dealer would run, but I did discover that I could go to the auto parts place and get cylinders for a 1992 Suzuki Swift hatchback and they are an exact fit.  Don't have it fully bled yet, but the front brakes work now.  I have to return my float parts I ordered for the carb, because they don't fit the one I have.  I did find the needle was set too high, and might not have been put together right, so I lowered it, put the carb back on and it started nicely, idled nicely, and didn't blow clouds of black smoke when revved.  Cleaned the choke plunger port, new plunger and cable.  Added a power outlet and was able to put the front fenders back together.  Next phase of the project is the rocker cover oil leak.

Turns out both rear drive shafts have blown inboard U-joints.  According to the book and dealer, the joints aren't serviceable, and the whole shaft needs to be replaced.  I'm going to pull them out and see how much that holds true, or if a replacement from eBay will work.  Also have to see what's going on inside the rear brake drum.  When engaged, the best it does is drag, and it won't release without a pry bar against the lever arm.

Slightly off-topic, but I never would have guessed a Geo Metro part would fit a four-wheeler! Dad had two of them for a few years, Chevrolet Sprints to be exact.

Yeah it was a handy thing to find out!

4-wheeler isn't done yet, but I did slap the fenders back on and take it for a ride at the end of June.  Ran great, but I almost sank it in an overflow.

Back on the topic of the Heep, I just picked the head back up from the machine shop.  Got the crack fixed, valve seats ground, gasket surface machined, and a fresh coat of AMC blue paint.  I had also cleaned up the valve cover and intake manifold, and replaced the CCV elbows.  If the rain lets up tomorrow, I'd like to get the head back on, pushrods/rockers back in place, and valve cover back on.  Won't be ready to go yet though.  Still needs a radiator and exhaust manifold.

Well, I got the head back on the day after I picked it up, than had to leave town for a month.  When I got back, I had some time off, and in a rush of progress, got the engine mostly put back together.  Than gone for another week, than got final things buttoned up.  New radiator and all new coolant hoses, and had my nephew weld up the crack in the exhaust manifold and give the throttle body a good cleaning.  Screwed up putting the thermostat housing back together, so it leaked, and I had to redo it (twice).  Also ended up with fuel leaks when I tried to pressurize the fuel system, and had to get new O-rings for the fuel rail fittings.  Fired it up and it ran, but only on 5 cylinders.  Compression test came out acceptable for a 200,000+ mile engine, and the ignition system was new, so I checked fuel.  The injector for #6 was totally plugged up, so in went a new fuel filter and a new injector.  After everything was buttoned up, it runs great now.  Had some other issues to take care of.  New lift gate struts so I didn't have to prop the rear gate up with a stick anymore.  Also, some bad things happened to the interior.  The previous owner had spilled diesel all over the back, one window wasn't all the way up, and while I was out of town, rain got inside, than molded up.  Finally, a mouse had gotten inside, messed on the rear carpet than died inside while I was gone.  Took it in for a detail and thorough interior shampooing.  Below are some final pictures.  It stared out as a collection of spare parts destined for the junk yard, but has been turned into a road worthy vehicle again.

I had an 89 Cherokee Sport (2-door) with the 4.0.  Best 4X4 I ever owned.  Never once left me stranded and it got me thru several feet of snow that disabled some of my neighbors Land Cruisers, Land Rovers, and other expensive 4x4s.  I was grinning ear to ear that day we had that 2-3 feet of snow and I was able to make it up the street and around the stuck 4X4s as they looked on in disbelief.  The engine ran great and the 5-Speed didn't give me too many issues, but the seats, dash, trim, and what not was falling apart on it, as was typical of Chrysler products of that era (and still so in many cases to this day)  Yes it was an AMC designed vehicle, but bah humbug on all the little crap falling apart.  Sold it at 140,000 miles for $3000 which wasn't a bad price for it at the time.  I also owned an 89 Wrangler with the 4.2L I-6 (carburated version of the 4.0 more or less)and it too was a thrill to drive.  Had 180,000 miles on it when I got it. (fully stock) Only issues I had with it were oil leaks everywhere, and an alternator issue which was finally resolved when I gave in and took it to a repair facility that had a top notch Jeep mechanic. Only kept it for about 6 months then grew bored with it and sold it for more than I paid for it, so not too bad of a deal either.  Then I got into trucks.  I also had an 94 Grand Cherokee with the 5.2L V-8 that I got from my brother with 130,000 miles on it.  Was a great vehicle, but like everything chrysler, everything fell apart on it minus the engine (and transmission) It leaked oil, transmission fluid, and power steering fluid and even after spending almost $1000 on having all those seals and gaskets replaced, it still leaked.  Got tired of that and sold it for a decent amount of $$$. 

My first Jeep is my 1999 Cherokee Sport.  I've had it for over 13 years.  It's been a great vehicle, and the fit and finish is a huge improvement over the one pictured above.  It's also lead a better life.  There was a time that some of its aging and abuse issues were starting to catch up with it, and I was starting to feel down about it and pondered selling it, but I decided to start fixing the issues, and it's the best it's ever been.  The rear leaf springs had sagged to the point where they were inverted, so it got new springs and a 1" simple lift.  There is a better 1.5" lift I wish I had been able to use at the time, and if I get the chance, may get and put on.  Also had fuel pump issues, which turned out to be a plugged up fuel strainer.  As great of a 4x4 as it was, it was hobbled by it's open differentials, and the rear axle bearings were starting to get loose, so I had the rear end rebuilt with a TrueTrac diff and all new bearings, seals and brakes.  All in all, it's done everything I've ever wanted to do with it, and never left me stranded.  Well, except for a few times I didn't pay close enough attention to the fuel gauge 

Wow, we're all so well-rounded! I'm mechanically ignorant, I must admit.  I can pull the dipstick and check oil, check radiator fluid, and probably even change oil in something like one of those 2000w Honda generators, but that's it LOL.
DieselNut, what do you do with your ATV? Offroad? Work?
I'd like to get an ATV myself someday...