This thread will attempt to show/describe each step I took in making the top on my XJ removable. Its already done so this won't be a long thread before getting updates.

This is not another "oh sh*t I rolled it time to cut thread", my intent was to to have a convertible rig with a fully functional hard top that can be run with with full doors, half, or no doors.


First step before cutting anything was to beef up the unibody structure to make it hold together once the top was cut off... decided to build an 8 point cage that ties directly into the sheetmetal of all the main body pillars as well as to the floor with sandwich plates and through multiple points in the floor like seat belt bolts, etc. The whole goal here was to tie into as many points as possible to keep the body rigid.

http://inlinethumb58.webshots.com/633/1160296316032428117S600x600Q85.jpg

http://inlinethumb38.webshots.com/2341/1348122706032428117S600x600Q85.jpg

http://inlinethumb17.webshots.com/144/1147705315032428117S500x500Q85.jpg





Next up was making a solid roof rack/exo cage for the top that could be used as a lifting point as well as keeping it rigid so it would fit back on once it was cut free from the body. It attaches with the factory rack mounting points as well as bolting into a piece of tubing that was welded along the entire length of the rain gutter pinch seam. This tube works well as a slider on trees and rocks too...

http://inlinethumb02.webshots.com/2433/2699094920032428117S600x600Q85.jpg

http://inlinethumb48.webshots.com/175/2333132500032428117S600x600Q85.jpg

After the rack I moved on to the rear hatch which needed to be seperated into two pieces. This part was very time consuming since it was fiberglass and needed all sorts of reinforcement. I used a combination of aluminum, foam, fiberglass mat, and even some wood to get the job done.

http://inlinethumb20.webshots.com/211/2540269710032428117S425x425Q85.jpg

http://inlinethumb08.webshots.com/1991/2090603570032428117S600x600Q85.jpg

http://inlinethumb30.webshots.com/1181/2480467940032428117S500x500Q85.jpg

http://inlinethumb39.webshots.com/1766/2087327260032428117S500x500Q85.jpg

http://inlinethumb09.webshots.com/2376/2117687810032428117S600x600Q85.jpg

I decided to attach the tailgate to the body with a "pin" type of setup... could have done hinges but at the time I decided to go this route and it worked out just fine.

http://inlinethumb57.webshots.com/2424/2269483650032428117S500x500Q85.jpg

These are the female pieces that were sunk into the body and welded in place

http://inlinethumb13.webshots.com/1996/2103787760032428117S425x425Q85.jpg

It can then be placed in the down position by using the same pins that slide into female receivers in the bumper. The brackets on the sides hold the retaining straps to tabs on the cage.

http://inlinethumb18.webshots.com/1361/2055111940032428117S600x600Q85.jpg

http://inlinethumb29.webshots.com/3036/2853740500032428117S500x500Q85.jpg

http://inlinethumb64.webshots.com/1791/2653752860032428117S425x425Q85.jpg

Clamps on the inside pull the tailgate tight against the weather stripping and keep it from rattling

http://inlinethumb44.webshots.com/2091/2902870850032428117S500x500Q85.jpg



The liftgate latch mechanism that locks and ties directly to the cage... it rattles a little must I think I need new weatherstripping to put a little more tension on the latch pins.

http://inlinethumb57.webshots.com/1208/2798767240032428117S600x600Q85.jpg

http://inlinethumb33.webshots.com/1696/2094556050032428117S500x500Q85.jpg

Had to make a spacer that angled the lock mount so that it went in at the right angle.

http://inlinethumb09.webshots.com/3016/2026225200032428117S500x500Q85.jpg

Nice clean work, I really like how you tucked the cage into the A, B, & C pillars.

:smokin:

After the tailgate/liftgate I decided to tackle the doors. Cut the bottoms off of the factory hinges and trimmed the pins so that the doors just pull out.

http://inlinethumb64.webshots.com/2047/2226659460032428117S500x500Q85.jpg

The passenger side hinges have the pins pressed in upside down and they need to be taken out completely and I replaced them with 1/4" Gr 8 bolts

http://inlinethumb57.webshots.com/1336/2155652140032428117S500x500Q85.jpg

Front doors already have wire loom connectors just inside the body but the rears needed to be cut and I just spliced in some cheap trailer hitch connectors.

http://inlinethumb34.webshots.com/2145/2895636320032428117S500x500Q85.jpg



Through this step...

http://inlinethumb53.webshots.com/948/2662888020032428117S600x600Q85.jpg



Enough for today.... I'll post the rest a little later

Damn dude, that is some nice clean fab work. I like what you've done, very innovative.

You do good work paying attention to details....

wow, awsome ideas

Impressive!

Now thats hardcore tech. Dude you got skills!

All that sweet fab work, and you didn't put hinges on the tailgate :flipoff2: :D
When you get tired of those pins...make some sweet hinges or use a commanche tailgate.
I can't wait to see the finished chop.

DAMN!! that's nice work.

Excited to see your top off :D

Nice work on the top rack in the garage, nothing worse than a top always being in the way.

Very nice fab work overall, that'll be a very clean truck.

nice work...very original. i like it

very nice man. i was gona try to do a removable top on my old XJ but i hadnt even thought of braceing the roof like that. i knew i would need to brace the frame though. i was thinkin of usein a simple bolt design like whats used for the top on the old YJ's like on mine. but i sold it before doin to much. Very nice work man i like lol. i also like the finished product looks sharp

That's slick! Nice halfdoors, do you have full doors with roll up windows? Eh...if not small price to pay for a bitchin' hardtop convertible. 'Cage looks good, too.

http://inlinethumb62.webshots.com/637/2095609350032428117S500x500Q85.jpg (http://rides.webshots.com/photo/2095609350032428117QmnwBk)

now you just gotta make the front windshield slide down and forward :p

Thanks for all the comments... well now that the suspense of the finished product is out there, here some more...


Half Doors.... pulled a set from the junkyard for a steal and just had to repair the rust and bang some dents out. Basically I cut everything out above the handle/latch mechanism as well as all the window tracks and hardware. I left the power lock mechanism and welded on a little tab so they can still be locked manually... no real point in being able to lock them becuase you can just reach in and unlock them but figured with possible little ones riding in the future might come in handy.

http://inlinethumb25.webshots.com/2776/2014260030032428117S600x600Q85.jpg

The inner panels are just aluminum sheet with some a quick random pattern with a grinder. Threw a coat of clear on them finished with some rubber trim and attached with stainless screws.

http://inlinethumb33.webshots.com/2656/2637779810032428117S600x600Q85.jpg

Nice cage!

http://inlinethumb58.webshots.com/633/1160296316032428117S600x600Q85.jpg

looks great

The last thing I did before seperating the top from the body was to weld U shaped brackets to the B and C pillars of the body. They wrap around the cage and are drilled for 3/8 bolts to act as guides for not only securing the top once its ready to go back on but also to make sure that it lines back up. Once I started cutting the top free I was surprised how much everything moved, these mounting points definitely came in handy to realign everything.

http://inlinethumb15.webshots.com/1294/2165893960032428117S600x600Q85.jpg


At this point it it was time to get cuttin on the top, nothing fancy about this stage just taped off a line and went to town with a cutoff wheel. Didn't use the sawzall much as it ended up bending the body all to shit and didn't leave the straightest line.

http://inlinethumb29.webshots.com/924/2242811180032428117S600x600Q85.jpg

http://inlinethumb53.webshots.com/2228/2225490370032428117S600x600Q85.jpg

Also got to use my HF hoist setup and garage storage that I spent a bunch of time building mostly for this purpose but turned out to be very useful for storing all kinds of other stuff.

http://inlinethumb22.webshots.com/3093/2544578420032428117S600x600Q85.jpg

Lifted it up and out of the way and didn't touch it for about 3 months while I did the sheetmetal work on the body.

http://inlinethumb01.webshots.com/2560/2713360720032428117S600x600Q85.jpg

I drove it around like this for a couple weeks before getting into the body work... it was awesome, just my old CJ and it was noticeable quicker with all the weight of the top and doors gone.

http://inlinethumb42.webshots.com/1961/2142080600032428117S600x600Q85.jpg

NICE work!!Like you said just like your old CJ.Open air!I also notice my CJ is quicker with the top and doors off.By alot!The straight sixes just don't have the power the V8s do.

Very Cool! I have been toying with that ides on my comanche, and you just inspired me. Now dont you feel better knowing you have changed the build of a fellow PBB'er for the better!

chris

Whats up with your front coils?

gunmetal, afa front coils do you mean the way they tilt twoards the front? Pushed the front axle forward ~4" so they have a wierd shape to 'em.

now that's what I call sacking up and comitting to a course of action, he was so sure he was going to hack apart his Cherokee and make it a convertable that he first hacked apart his HOUSE so he'd have a place to put the top!

Nice work man, can't wait to see what sort of treatment you used for the interface of the pillars and body... lots of squeaking going on?

you REALY wanted that removeable top huh??

nice work hope it was worth it

That looks great. I can'tm wait to see the finished product. I've been toying with the idea but it was going to be, as you put it, wait til I roll it. Which would defeat the purpose of why I did another XJ for the hardtop and heater for my wife and daughter. Props on the great work.

It has definitely been a TON of work but so far its been worth it... I probably end up rolling it and destroying it once its done and just tube the whole thing out.

Having the top for the winter is nice especially up her in Michigan but with a planned move down to Tennessee I don't know how much use the top will get. I need to make a bikini top for it... on the list.

Some more pics of sheetmetal work to close up the body. Don't have any for the work on the top but it was the same deal...

http://inlinethumb61.webshots.com/2492/2403369320032428117S600x600Q85.jpg

http://inlinethumb42.webshots.com/1385/2896593730032428117S600x600Q85.jpg

http://inlinethumb36.webshots.com/995/2973941330032428117S600x600Q85.jpg

Finally... body work finished, sitting in primer, still not sure about the final color.

http://inlinethumb17.webshots.com/1872/2104520460032428117S600x600Q85.jpg

http://inlinethumb20.webshots.com/1875/2579681350032428117S600x600Q85.jpg


With the top on...

http://inlinethumb64.webshots.com/2495/2252010700032428117S600x600Q85.jpg

http://inlinethumb25.webshots.com/664/2246163150032428117S600x600Q85.jpg

http://inlinethumb19.webshots.com/1810/2362636670032428117S600x600Q85.jpg

http://inlinethumb05.webshots.com/900/2950360580032428117S600x600Q85.jpg

very nice!!! :smokin: I wish I had that kind of patience!

I'm impressed, it all looks very clean. Almost makes me want to do the same thing to my DD ZJ...almost. Like Aaron, I wouldn't have to patience to make it look that nice.:laughing:

very clean job !!! Being from NY i can fully understand the desire for a full hard top !!!

Bad Ass!

Does the top seal up good?

That is amazing, great work! You are going to confuse a lot of people, they will think you drive two separate vehicles.

Best exection of the best idea of the best XJ project I've ever seen. This thread is definitely in my top 3 favorites of all time, including Xota's half XJ, half Yota build.

You need to quit your day job and start charging for this fulltime. Give AEV a run for their money.

very nice....super clean....

Unreal, just Unreal... I thought about doing that, dreamed about it for years while I had my XJ. That is excellent. And, the set-up in your garage as well.... WOW!

I live in TN, and still would have loved to have a hardtop. We have some cold, and winter weather. Nothing like Michigan though. I lived in the UP for 3 years, that's winter.

Where in TN are you headed?

Again, Nice Work!!

Arctic, that is one of the best compliments I think I have seen, thanks to all for their encouragement, much appreciated!!

Oh... and for all the haters, did the entire cage with a cheapo HF bender. Its a mixture of tube and pipe... main hoops and all "critical" members are 2" .120 HREW and the rest is a mix of 1.25 & 1.5 sch 40. Not the easiest way to go for doing bending tubing but can be done by modifying the dies, packing tube with sand and taking your time, no kinks what so ever.

If I had to throw a # out there I would say I have less than $1k in almost all the mods to this point minus suspension & bumpers. Doesn't take a huge budget to build what you want but it does take many many hours and a lot of planning.

Waiting for the "pipe is for poop" and "needs triangulation"

Addict, moving to Knoxville in mid March, where are you?

"needs poop" and "pipe is for triangulation"....



:flipoff2:

Addict, moving to Knoxville in mid March, where are you?

When you get here PM me your number and we can go get some food or something like that. There are a good number of us XJ folks down here, It will be nice to see something different.

Not the easiest way to go for doing bending tubing but can be done by modifying the dies, packing tube with sand and taking your time, no kinks what so ever.


How did you modify the dies?

Sweet build. The cage looks awesome! I doubt you'll have the Cherokee lock you inside when you flex the shit out of the suspension with all the internal gussets of the cage.


I hope your full hardtop seals better than some of the other original full top vehicles (Early Broncos, Pre -73 Blazers, Scout 800s & IIs). I never could get my EB hard top to seal right.

Modified the die for the 1.5" pipe (1.9" OD) by grinding away some material to allow the 2" HREW to nest well in the die to keep pressure on the wall uniform during bending. The 1.5" pipe has a nominal wall thickness of .15" compared to the .12" of the 2" HREW so packing the tube tightly with sand helped keep its shape and resist kinking. Just duct taped the ends closed once it was full with sand... no need to weld on caps. In hindsight using water and welding caps on the ends might have been even better.

The key to making a decent bend with the HF bender is to move the outside "rollers" to the outer most notches and gradually move them inward depending on how sharp the bend is. Also put some shims between the tube and rollers to keep from denting the tube (I used sections of 2.5" exhaust tubing as a cushion). Another trick is to place the center of the die in several spots along the bend, don't just put it in the bender and start cranking away in one spot as this will kink it for sure.

Like I said this is definitely not the most efficient way to bend tubing but it CAN work with comprimising the tubing in the process.

The top seals up surprising well along the windshield and quarter panels with no leakage or wind coming through due to the tight gaps. The B pillars have a little larger gap because I butchered them a bit with the cuts and had to take them down a bit more during the sheetmetal cleanup, regardless the foam weatherstripping seal them pretty well. The rear liftgate/tailgate could seal a little better so I'm looking at different type of weatherstripping to help this out.

Overall the cage and the 3 underbody crossmembers stiffened the body up so much that there is minimal movement and therefore few squeeks. The only part that makes noise is the liftgate latch system but I think this could be addressed with new weather stripping to put more preload on the latch pins.

What's up A.O.?!

Again, sweet work. Explain the fender flares you built. I think that is something that even those who don't want to cut the top off could find useful.

You can jump up and down on his fenders and they don't budge!

Mitch

Wow, that is impresive. Awesome execution of an awesome idea. Have you done body work in the past?

Any closer to chosing a color yet?

What's up A.O.?!

Again, sweet work. Explain the fender flares you built. I think that is something that even those who don't want to cut the top off could find useful.

You can jump up and down on his fenders and they don't budge!

Mitch


Yeah, tell us about the fenders. They're :grinpimp:

Wow man thats looks great. All the XJs that I've seen with cut off roofs end up looking like hack jobs. Way to be different being able to put the top back on and should be great for winter wheeling trips. The only problem that may come up is after a flip the top and bottom may not line up right anymore. :smokin:

If I roll it with the top on its going to be pretty ugly and I would most likely have to scrap the top.... with the top off it might hold up ok as long as the body didn't get mashed up too bad. Problem area is always going to be the windshield frame since in every roll its going to hit. I tried to brace it into the cage but you can only do so much.

This shows a 1/2" thick piece of steel that runs from the A pillar cage to the outer sheetmetal of the body. This was an area I would expect to hit first and hopefully it would keep the windshield frame from crushing around the cage.
http://inlinethumb34.webshots.com/2209/1160296285032428117S600x600Q85.jpg

The sheetmetal used to fill all this in is only 16ga and wouldn't hold up to much except making a flop in sand or mud... rocks would bend it up for sure. There is a 1/2" sq tube bent to match the contour running along the face but this was mostly put in as a sealing surface not for support.
http://inlinethumb61.webshots.com/2492/2403369320032428117S600x600Q85.jpg

Sweet build. Have you thought of shaving the handles or installing flush mounts on the half doors?

Steel fender flares in the rear... made these up after cutting and secitoning the wheel tubs to accomodate pushing the rear axle back 3".

http://inlinethumb16.webshots.com/783/2542964380032428117S600x600Q85.jpg

http://inlinethumb37.webshots.com/1124/2074356370032428117S600x600Q85.jpg

http://inlinethumb27.webshots.com/1242/2209397040032428117S600x600Q85.jpg

Started with steel angle 3/4" x 3/4" x 1/8" that was bent into shape to fit the outline of the wheelwell. I just made a bunch of relief cuts to make the bending easier. This step restored much of the rigidity of the sheetmetal and made the overall flare very strong... jump and down on them and they don't budge.

The tube work is just 3/4" sch 40 bent with the HF bender.

http://inlinethumb09.webshots.com/1736/2472875490032428117S600x600Q85.jpg

Then just made a template for a piece to fill the gap, cut from 16ga, crudely bent and welded it in place.

http://inlinethumb35.webshots.com/354/2662202650032428117S600x600Q85.jpg

Grinded/Sanded smooth...

http://inlinethumb51.webshots.com/3122/2639610310032428117S600x600Q85.jpg

http://inlinethumb22.webshots.com/533/2717372120032428117S600x600Q85.jpg

The front was done much the same way as the rears with the exception of some extra bracing to the inner fender.

http://inlinethumb05.webshots.com/2948/2618057840032428117S600x600Q85.jpg

http://inlinethumb01.webshots.com/256/2348144770032428117S600x600Q85.jpg

http://inlinethumb59.webshots.com/1402/2603867440032428117S600x600Q85.jpg

http://inlinethumb33.webshots.com/2336/2931751140032428117S600x600Q85.jpg

http://inlinethumb52.webshots.com/1587/2882723420032428117S600x600Q85.jpg

http://inlinethumb21.webshots.com/3028/2187857770032428117S600x600Q85.jpg

http://inlinethumb56.webshots.com/2103/2972962950032428117S600x600Q85.jpg

Still need to do some work to straighten out the body that got a little wavy from too much heat during welding and then throw on some black paint and call it done.

So black its gonna be, eh? That should hide the convertable top well. It'll be even stealthier. Somebody said earlier that folks will think you're driving two different rigs. Most definitely.

I look forward to reading many more of your threads man. Hopefully you continue detailing upgrades of yours in the same manner. I think I speak for most when I say there's some departure from the norm going on here, and certainly some unique stuff here for us XJ sluts to gawk at. Keep it up.

That's some insanely good work!

man...that's some good work

I'm usually not into XJs but the cage you did on that thing looks so bad I'd never put the top back on anyway

http://inlinethumb05.webshots.com/900/2950360580032428117S600x600Q85.jpg

That looks real slick :grinpimp:

I'll pass on some experience :p

I had a toyota truck that I made into a convertable with a kit.

[booty fab version] During the winter run a strip of black duct tape across that seam and fold it over the drip rail and you'll stay dry.

[fancy version] get a "carson" top put over the roof with buttons at the windsheild to do the same thing as the tape.

Either way your still going to have to sillicon the joints to make them water proof (just cut to remove)

Hows it look with the full doors and no top?

That is probably the best mod ive seen done to an xj. You have any plans for the windows?

I think it would have looked better on a 2dr...:flipoff2:
nice sheet metal work though.

Arctic - the flares will be black, still don't know about the rest of the rig. I am resisting going black with the body because I was something that won't show the scratches and the trail beat body panels. Was thinking about LineX but if I ever change my mind that stuff is all but impossible to remove.


Krylon - I still have the original full door but haven't touched them except cutting the hinges. They go back on, seal up OK, and the power windows still work but they are still the factory color and only use them in the harshest of weather... prefer the half doors or none at all.


Ash - A 2dr would have been less work :flipoff2:

Nice work, looks like a really nice xj.:jeep:

:eek: im speechless

incredible

In response to some back channel Qs... additional bracing to the unibody besides the cage includes three crossmembers. One that replaces the stock tranny mount xmemeber
http://inlinethumb06.webshots.com/2629/1068052915032428117S600x600Q85.jpg

One that braces the control arm mounts for the rear suspension...
http://inlinethumb06.webshots.com/389/1099870781032428117S600x600Q85.jpg

The third functions as the upper coil mounts and adds quite a bit of rigidity to this new stress point...
http://inlinethumb28.webshots.com/2075/1088493679032428117S600x600Q85.jpg

http://inlinethumb44.webshots.com/363/1403517527032428117S600x600Q85.jpg

damn that is nice great job

Not related to the removable top but figured this would be an overall build thread.

Pictures show it but basically cut up the stock ARB bumper to mount a couple of transmission coolers...

http://inlinethumb34.webshots.com/4257/2497363630032428117S600x600Q85.jpg

http://inlinethumb38.webshots.com/5349/2405860130032428117S600x600Q85.jpg

http://inlinethumb03.webshots.com/2882/2483166390032428117S600x600Q85.jpg


Here is what was cut...

http://inlinethumb11.webshots.com/2570/2262840600032428117S600x600Q85.jpg

Side fluid cooler...

http://inlinethumb45.webshots.com/4844/2429097620032428117S600x600Q85.jpg

Center cooler, mounts where the winch should sit... winch is in the plans so this spot is temporary.

http://inlinethumb28.webshots.com/3675/2982005390032428117S600x600Q85.jpg

Absolutely beautiful work man! Very impressed!! GREAT JOB:beer: :beer: :beer:

if i knew u man id shake ur hand props.

Nice work, You stepped outside the box on this one.

Been working on relocating the battery to the passenger side rear cargo area. Replaced the battery with a Odyssey 1700 w/ metal jacket... if weight is any indication of battery performance this one should be a beast.

http://inlinethumb10.webshots.com/3849/2764177230032428117S600x600Q85.jpg

http://inlinethumb16.webshots.com/2575/2909459770032428117S600x600Q85.jpg

http://inlinethumb15.webshots.com/4046/2666886320032428117S600x600Q85.jpg

Here is the wiring in the engine bay... all cables are fine strand welding wire in 1ga and 1/0 with soldered connections.

http://inlinethumb25.webshots.com/3672/2604690840032428117S600x600Q85.jpg

I have more pictures to post but didn't have time to pull them in right now... more to come...

that its a ver good work Quality

Awsome and thats a bad ass XJ

Unbelivable rig you got there. You do awesome work. :smokin:

i live in knoxville and know some xj guys that re always up for hottong trails or whatever. i have a tj myself i am rebuilding. you should def pm me when u get to knoxville. im only here on weekends and in nashville during the wee. holler if u want to wheel or help use some of ur amazing fab work lol thank josh

Finished the battery relocation...

http://inlinethumb48.webshots.com/5167/2229159650032428117S600x600Q85.jpg

http://inlinethumb31.webshots.com/2974/2481646170032428117S600x600Q85.jpg


Disconnect switch

http://inlinethumb62.webshots.com/2429/2629927520032428117S600x600Q85.jpg

ummmmm..... wow.

I've never seen the Odyssy battery before. It might just be the pictures but it looks big enough for a D9.

The odyssey PC1700 is a nice piece... its actually a bit smaller than an optima and weighs in at ~60lbs and puts out 1700 cranking amps... wasn't cheap at ~$250 shipped but should last for 10 years or so. Was going to run dual PC1200s but decided to just run a big single and see how it works... future winch plans may change my thinking but its good for now.

Thats awesome. Good work!

That is the most awesome XJ I have ever seen. Never heard of Odyssey batteries how about posting a link. Again super build. Can't say enough about your work.

Very nice battery install! I love it when people take the extra time to get everything together in nice and clean rather than a really bad hack job! Keep up the great work!

For odyssey battery info...
http://www.odysseybatteries.com/batteries.htm

They sell a lot of motorcycle and ATV batteries because they cram a lot of cranking amps into a small package. You can get a battery that fits the stock battery tray that puts out something like 2150 cranking amps... compared to 1000 or so from a typical lead/acid battery.

I have to admit in the past most of my wiring has been hack job, but since coming across http://www.delcity.net/

I have found so many OE type components that its easy to do it right. The funnest part of the whole job was soldering the ends on the 1 ga wiring... real easy as you can order solder slugs for the wire size and connector type. Also got some real nice triple wall adhesive lined heat shrink and rubber covers that made a very nice tight seal on all the lugs. Order one of their free catalogs... very handy for any wiring projects.

Thanks for that link flexy! That is going to definility help out on my build! I can't wait to get back to wrenchin on my shit!

That is some AWESOME work.

THanks for sharing it, gives me some ideas for the fenders of my ZJ.

Dirk

Are you concerned about rocks and mud and crap filling up the coolers behind the bumpers? I know I fill that area up with mud and crud just driving around. Maybe weld a few tabs in and put a sheet metal shield with camlocks there so you can pull it out when you want/needed to?

I ordered some pieces of rubber sheet that will screw into the bumper to keep mud and rocks out of the bumper. I want to keep as much out of there as possible but don't want to restrict air flow through.

You've done some really nice work, great job!

Bump :mr-t:

Extremely impressive work!!! Excellent ideas and great fab!

After finishing the battery relocation I decided to work on finishing the other side of the cargo area. Its going to be lockable and it is very stout so it should keep my stuff safe with the top off.

Just some progress pics for now...

http://inlinethumb11.webshots.com/5322/2161221810032428117S600x600Q85.jpg


http://inlinethumb46.webshots.com/3629/2112445140032428117S600x600Q85.jpg

http://inlinethumb09.webshots.com/2440/2990156130032428117S600x600Q85.jpg

http://inlinethumb07.webshots.com/4550/2653836900032428117S600x600Q85.jpg

http://inlinethumb32.webshots.com/6175/2588325320032428117S600x600Q85.jpg

Finished up the driver side storage area...

http://inlinethumb59.webshots.com/3002/2150082900032428117S600x600Q85.jpg

http://inlinethumb23.webshots.com/6550/2183345490032428117S600x600Q85.jpg

Stainless piano hinge is from Mcmaster Carr...
http://inlinethumb01.webshots.com/2944/2494912660032428117S600x600Q85.jpg

1/4" aluminum plate held on with 3/16 stainless rivets...

http://inlinethumb49.webshots.com/4016/2374461570032428117S600x600Q85.jpg

http://inlinethumb35.webshots.com/3362/2042460290032428117S600x600Q85.jpg

http://inlinethumb04.webshots.com/3587/2922959670032428117S600x600Q85.jpg

Havent seen a post in a while. Nice to see you back. Hopefully when I get my axle project done I will be pulling the top off my XJ too.

great work keep it coming

very nice work, please keep the pics coming

You mentioned that you used a HF bender to do your cage. which one? The Hydraulic one or the manual? and how did you modify your dies?

Griz, I used the 16 ton HF bender... see post #41 for how dies were modified

mmm... just reread #41 and it really doesn't say much about the dies.

Basically what I did was take a die grinder to the 1.5" pipe die (1.5" pipe is 1.9" OD) to open it up so the 2" tubing nests well in the die. A tight fit on the sides of the tubing helps keep it from flattening as it bends.

The die mods combined with packing the tubing with sand kept the kinking to a minimum. Also when making bends greater than 30* or so you can't just throw the tube in the bender and start pumping away on the jack in one spot. I would mark the center of the bend and several marks an inch away on either side, make a little of the bend in the center, release pressure and move to one of the outer marks and continue, etc... spread the load.

If the tube starts to dent under the outer "rollers" just cut a couple sections of exhaust tubing to put between the tube and rollers, spread the load.

Start all bends with the outer rollers at their furthest point from the center and move them inward as you need sharper bends, this minimizes the pressure at the rollers and denting.

Very labor intensive but it does work and is a good route to go if you can't afford a nice bender.

Thanks for the info!!!

Was checking out the rig after wheeling and noticed that the rear unibody was cracking at the upper rear shock mount. Also needed to repair some rust above the oval port that is for the gas filler hoses.

http://inlinethumb54.webshots.com/4597/2823705540032428117S600x600Q85.jpg

http://inlinethumb40.webshots.com/6695/2366554560032428117S600x600Q85.jpg


Cutout all the rust and made cleared some space for the new upper shock mounts.

http://inlinethumb19.webshots.com/4370/2430021410032428117S600x600Q85.jpg

http://inlinethumb23.webshots.com/6870/2777880220032428117S600x600Q85.jpg


Here is the upper shock mount, it runs from between the C & D cage supports and is welded to the floor and wheel well. Made from 2x2x3/16" angle steel and some 3/16 flat bar, probably beefier than it needs to be but I dont want to do this again.

http://inlinethumb48.webshots.com/5935/2195007490032428117S600x600Q85.jpg

http://inlinethumb59.webshots.com/4474/2517186110032428117S600x600Q85.jpg

I put three different mounting bolts for some adjustability on length... used the middle one for the shock and made some aluminum spacers for the other two, should keep it from drawing the U channel together too much.

http://inlinethumb07.webshots.com/6278/2651537470032428117S600x600Q85.jpg

http://inlinethumb02.webshots.com/5569/2281785400032428117S600x600Q85.jpg

http://inlinethumb21.webshots.com/4756/2925142120032428117S600x600Q85.jpg

wow your jeep looks amazing. keep up the good work

any new updates?

Not really anything to update... been out wheelin too much lately and breaking things. Most of my jeep wrenchin time has been spent fixin. :(

Next items on the list are going to be a bikini top, sheetmetal center console, completely new dash that will tie into the cage.

http://inlinethumb27.webshots.com/4634/2509336510032428117S600x600Q85.jpg

http://inlinethumb46.webshots.com/4525/2340579780032428117S600x600Q85.jpg

http://inlinethumb53.webshots.com/8436/2803332000032428117S600x600Q85.jpg


Did I mention that I need a bikini top... third trip in a row that it has rained.

http://inlinethumb49.webshots.com/5552/2512478570032428117S600x600Q85.jpg

Awesome job!

When ya gonna build mine? :D

Been working on some smaller details... finished up the rear storage area on the driver side, redid the upper shock mounts on the pass side.

http://inlinethumb10.webshots.com/18889/2294017180032428117S600x600Q85.jpg

http://inlinethumb56.webshots.com/19127/2619105680032428117S600x600Q85.jpg

http://inlinethumb31.webshots.com/18334/2768926920032428117S600x600Q85.jpg

http://inlinethumb44.webshots.com/16683/2006858920032428117S600x600Q85.jpg

http://inlinethumb16.webshots.com/17551/2967533470032428117S600x600Q85.jpg






Also added limiting straps and Daystar shock bumpstops to all 4 corners. The daystar bushing work well and have held up to being completely compressed numerous times without issue... putting them on was tough but the install tool helped, to bad it was extra $.

If your adding limiting straps don't go cheap... you can see in the pic what cheap ones will get compared to some decent double layer straps, much less stretching so they are easier to setup correctly.

http://inlinethumb09.webshots.com/16904/2321587470032428117S600x600Q85.jpg

http://inlinethumb45.webshots.com/16428/2579490290032428117S600x600Q85.jpg

Bikini top...

http://inlinethumb08.webshots.com/29639/2638749430032428117S600x600Q85.jpg

http://inlinethumb42.webshots.com/30057/2850860170032428117S600x600Q85.jpg

http://inlinethumb44.webshots.com/29739/2882512860032428117S600x600Q85.jpg

http://inlinethumb56.webshots.com/29175/2413107760032428117S600x600Q85.jpg

http://inlinethumb63.webshots.com/31230/2484961900032428117S600x600Q85.jpg

New dual diaphram booster and WJ master cylinder...

http://inlinethumb22.webshots.com/32085/2760559470032428117S600x600Q85.jpg

http://inlinethumb13.webshots.com/29708/2891930940032428117S600x600Q85.jpg




Removed factory proportioning valve and installed mechanical line locks and a Wilwood prop valve for the rear...

http://inlinethumb07.webshots.com/32198/2540328030032428117S600x600Q85.jpg

http://inlinethumb23.webshots.com/30678/2913561120032428117S600x600Q85.jpg

http://inlinethumb24.webshots.com/30295/2293012610032428117S600x600Q85.jpg

http://inlinethumb38.webshots.com/31269/2049415440032428117S600x600Q85.jpg

http://inlinethumb39.webshots.com/29798/2873631410032428117S600x600Q85.jpg

http://inlinethumb29.webshots.com/31388/2647728820032428117S600x600Q85.jpg

wtf?




Your fab skills, and you go out and BUY a bumper?
Haha jk, thats some amazing work you do!

Outstanding fab skills. This has been an interesting build to follow. Based upon all I've seen here you do an outstanding job of thinking things thru and detailing around the final product.

My question has been simply...how did you reinforce the garage roof when you cut the hole for the top and what did you mount the winch to?? Still own the home? That was also an a feat that deserves some recognition.
:)

The ARB bumper was the only aftermarket piece on the jeep when I bought it so no need to fab one up... could resist not cuttin into it tho! :D


As for the garage it definitely took some thinkin to get it reinforced well... guess I did learn somtin gettin my mech eng degree :)

Funniest part was it was in a condo and I shared part of the garage structure with my neighbor. I tried to keep him in the dark until it was done but hard to hide all the construction noise.

I went overboard really because not only was I cutting a 6'x9' hole out of the floor and hacking out the lower A brace of the trusses but trying to build in a factor of safety for the 1300lb hoist. Hows that saying go... engineering is just brains and materials, the more you use of one the less you need of the other.... I tried to go with a lot of both!

The real bitch is that we have since moved and all the work was pretty much wasted.... gonna have to redo it in our new place. :shaking:

Here are a few shots of the framing...
http://inlinethumb10.webshots.com/10953/1343806202032428117S600x600Q85.jpg

http://inlinethumb57.webshots.com/30712/1343806275032428117S600x600Q85.jpg

http://inlinethumb26.webshots.com/32665/1343806358032428117S600x600Q85.jpg

http://inlinethumb24.webshots.com/30103/1348124405032428117S600x600Q85.jpg


Removable platform...

http://inlinethumb22.webshots.com/30165/1348124257032428117S600x600Q85.jpg

http://inlinethumb37.webshots.com/32676/1348124282032428117S600x600Q85.jpg

http://inlinethumb13.webshots.com/29772/1348124307032428117S600x600Q85.jpg

Very cool job. I really like the garage hoist. I am about to do an addition on mine and might have to do that!!

Any updates on this thing?

Freaking sweet fab and body work on this thing. I like it.
How are you holding the hard top on the XJ when you're running it?

I'm trying to figure out how to do something similar with my ZJ but just doing the rear chop only.

wow did you go to a school and learn all of this or did you just learn from friends and family. You are doin a awsome job, if I had a shop I would hire with out a doubt

Been working on relocating the battery to the passenger side rear cargo area. Replaced the battery with a Odyssey 1700 w/ metal jacket... if weight is any indication of battery performance this one should be a beast.

http://inlinethumb15.webshots.com/4046/2666886320032428117S600x600Q85.jpg



is the batter on its side?

is the battery on its side?

yes it is...you can mount that type of battery any way you want, he could put it upside down if he really wanted to. :smokin:

damn good fab skills, and damn nice XJ, makes me want to build one like it

hi! awesome fab work!!!! I was wondering, can you drive with the top off where you live? I am going to the smae thing(well i'll be trying) to my 90xj next summer but i live in quebec and i'm going to bring it in the trails on a trailer:shaking:....

bye
Dave

hi! awesome fab work!!!! I was wondering, can you drive with the top off where you live? I am going to the smae thing(well i'll be trying) to my 90xj next summer but i live in quebec and i'm going to bring it in the trails on a trailer:shaking:....

bye
Dave

I think it depends on the officer.
I drove all over the GTA with the doors off my old ZJ and never had any issues. Touch wood.

WOW! saw this thread and my jaw hit the floor, sickest XJ in existence. that is some incredible fab work, love the attention to detail keep up the great work

Finally got a chance to ditch my well worn ARB air compressor in favor of a York... 210 model.


http://inlinethumb59.webshots.com/35386/2988038640032428117S600x600Q85.jpg

http://inlinethumb61.webshots.com/35836/2385868540032428117S600x600Q85.jpg

http://inlinethumb53.webshots.com/36788/2565776480032428117S600x600Q85.jpg



Factory AC compressor and hoses removed...

http://inlinethumb22.webshots.com/33045/2840069640032428117S600x600Q85.jpg




Won't fit sideways... hits the hood... doh!

http://inlinethumb23.webshots.com/35286/2635751900032428117S600x600Q85.jpg




Compressor sitting at ~45*

http://inlinethumb02.webshots.com/36737/2723412140032428117S600x600Q85.jpg

http://inlinethumb30.webshots.com/36253/2024790720032428117S600x600Q85.jpg



Engine bracket cutline...

http://inlinethumb48.webshots.com/33327/2040877180032428117S600x600Q85.jpg




http://inlinethumb28.webshots.com/35867/2573767700032428117S600x600Q85.jpg

http://inlinethumb40.webshots.com/36583/2957245290032428117S600x600Q85.jpg


http://inlinethumb49.webshots.com/35440/2779882840032428117S600x600Q85.jpg


3/8 UNF drain plug welded to 1/8 NPT threaded bung and drilled for oil return...

http://inlinethumb13.webshots.com/36876/2102165950032428117S600x600Q85.jpg





http://inlinethumb04.webshots.com/35459/2889313920032428117S600x600Q85.jpg

http://inlinethumb20.webshots.com/35667/2666807550032428117S600x600Q85.jpg



Manifold for pressure switch, blow off valve, etc...
http://inlinethumb39.webshots.com/18854/2279768270032428117S600x600Q85.jpg


Plumbing for ARB locker...
http://inlinethumb24.webshots.com/36951/2689136990032428117S600x600Q85.jpg




Rear Manifolds mounted... lower will run ~150psi and upper regulated for ARB to 90psi...
http://inlinethumb11.webshots.com/2954/2120632110032428117S600x600Q85.jpg

Any tips to some one who is going to start a very similar removable top project. Im more interested in knowing about things you would have done differentially, problems you ran into, or any little things you wish you had known.
The only part Im having trouble visualizing is how and exactly where to cut on the quarter panels, and how to wrap it to keep it looking clean. I also noticed that it looks like your cut here wasn’t perfectly straight, im assuming it was to compensate for the way you built your hatch.

My general plan is to cut the roof the same, brace the roof invisibly with strap under the head liner to keep the top ridged, modify a MJ tail gate and keep my hatch complete and connected to the top, use 1 set of full power doors and 1 set of half doors, do a some what similar 8 point cage (I think im going to go all DOM because I do plan to roll/tip mine more than once), some inside bracing (I already have a 3/16th frame and 4 cross members underneath), and I found some awesome camper shell weather stripping I plan to use to seal the top.

Thanks a lot of putting the time into doing a write up and posting pictures. It’s definitely going to help me with my project.
-Andrew

Did you use a lift "KIT" or did you put that together yourself. What size springs and shocks did you use??

Didn't use a kit just pieced together and fabbed up the control arms and all the frame bracketry. Front springs are 4.5" from Rusty's (don't recall spring rate but they are soft and have sagged), rear coils are stock WJ front coils... shocks are Pro-comp MX6 all around, 6 way adjustable is nice to help tune the ride. For the road I run a front 28mm sway bar and in the rear is the stock sway bar from and Explorer.


Haven't had much time to spend on the XJ lately due to a recent move, hope I'll get some good projects completed over the summer.

I've just been through all 5 pages and I'm more than impressed. your attention to detail is amazing. this is one of my favorite XJs that I've ever seen.

top notch work homeslice:D

Amazing work.

Very impressive. Keep up the good work.

what kind of coil springs did you use on the rear suspension? and how many inches of lift do you have...?

subscriped...holy crap. Your fab skills are sick but your ideas are better.

My XJ might just have to start looking like yours some day.

Looks awesome, I've been contemplating doing something like this but going a different route with the top. Was thinking of making it a full convertible soft top using the top off one of the new 4 door wranglers. Need to find one locally that I can get some measurements from to see if they're even close in size.

The rear coils are from the front of a WJ (stock height).




Finally got some new rubber... 35x12.5 BFG MTs

http://inlinethumb04.webshots.com/41987/2044183010032428117S600x600Q85.jpg

http://inlinethumb01.webshots.com/43456/2258471930032428117S600x600Q85.jpg

New steering linkage... 1.25" DOM tube, 3/4" heims.

http://inlinethumb10.webshots.com/41353/2753424570032428117S600x600Q85.jpg

http://inlinethumb20.webshots.com/32339/2742655660032428117S600x600Q85.jpg

Front Axle Truss...

http://inlinethumb53.webshots.com/40628/1450951852032428117S600x600Q85.jpg

http://inlinethumb64.webshots.com/18495/1450951963032428117S600x600Q85.jpg

This is by far the BEST build I have ever seen. And I spend alot of time looking at XJ builds, GREAT job. But I have a question, Im not sure if it's been asked or answered but I will ask. Do the cops ever bother you? Being when you drive around without your top on or doors on? In my state (PA) the only cars that can drive around without doors or tops are Trackers, CJs, and Wranglers (because they were meant to come off).

Im sorry if Im asking a stupid question or if I worded it wrong. But Im just wondering how that works out for you.

I've never had a problem with the cops... doors on or off they just cruise on by (luckily).

Last weekend wheelin in Harlan, KY...

http://inlinethumb40.webshots.com/14055/2813868410032428117S600x600Q85.jpg

http://inlinethumb52.webshots.com/12403/2075596020032428117S600x600Q85.jpg

http://inlinethumb17.webshots.com/18128/2866894570032428117S600x600Q85.jpg

http://inlinethumb59.webshots.com/17210/2932487170032428117S600x600Q85.jpg

where did you get the latches and hinges for the bottom of the rear hatch

My favorite source for all kinds of raw materials and hardware is McMaster Carr... easy to use website, decent prices, fast shipping.

http://www.mcmaster.com/

I fawking love this build. Any more "little details" to share?
Billy

cool build! Glad I ran across this. Nice to see someone being creative with a full-unibody! Cheers:beer:

:eek: I just have to say that your fab work and ideas kick ass. I wish that I had the time, money, and place to do all of that work. Being garage-less sucks. Very well done on the top and the cargo storage!:cool:

I am a fan. Nice work.

Got a killer deal on a new smittybuilt XRC8k winch...

http://inlinethumb37.webshots.com/24164/2208680240032428117S600x600Q85.jpg



Mounted the winch controller plug to the header panel...

http://inlinethumb36.webshots.com/41699/2898443840032428117S600x600Q85.jpg




Wiring inside the engine bay...

http://inlinethumb42.webshots.com/34473/2680053540032428117S600x600Q85.jpg

This is by far the BEST build I have ever seen. And I spend alot of time looking at XJ builds, GREAT job. But I have a question, Im not sure if it's been asked or answered but I will ask. Do the cops ever bother you? Being when you drive around without your top on or doors on? In my state (PA) the only cars that can drive around without doors or tops are Trackers, CJs, and Wranglers (because they were meant to come off).

Im sorry if Im asking a stupid question or if I worded it wrong. But Im just wondering how that works out for you.


go to your elected state lawmakers office and demand him to loosen the vehicle code.

http://www.pacode.com/secure/data/067/chapter175/s175.77.html


§ 175.77. Body.
(a) Condition of body. All items on the body shall be in safe operating condition as described in § 175.80 (relating to inspection procedure).

(b) Fenders. The wheels of a vehicle specified under this subchapter shall be equipped with fenders of a type used as original equipment. A tire may not come in contact with the body, fenders or chassis of the vehicle.

(c) Hood and hood latches. The entire motor compartment of a vehicle specified under this subchapter shall be covered by a hood. The hood shall be equipped with a double latch system to hold it in the closed position if the hood was originally so equipped.

(d) Protruding objects. There may be no torn metal, glass or other loose or dislocated parts protruding from the body of the vehicle.

(e) Fender flares. A vehicle may be equipped with fender flares not to exceed 3 inches.

(f) Doors. A vehicle specified under this subchapter shall be equipped with doors of a type used as original equipment. The doors shall open and close securely unless the vehicle has been manufactured or modified to the extent that there is no roof or side. Tailgates, except on vehicles where the tailgate gives access to the passenger compartment, may be replaced with wood planking, nets or other material that will prevent loss of load. Tailgates may be removed when optional equipment, for example a truck camper, is added.

very nice work. I didn't see this answered previously, but how to you keep the top on, are there latches on the inner body that holds it on, and also, how does the top hold up on the highway, if you had to drivve on the highway?


anyway, sweet ride.:mr-t:

Rolled it again... sucks...

http://inlinethumb10.webshots.com/42057/2104487150032428117S600x600Q85.jpg

http://inlinethumb54.webshots.com/41845/2493859840032428117S600x600Q85.jpg

http://inlinethumb57.webshots.com/34360/2230576210032428117S600x600Q85.jpg





The cage took the brunt when hitting this rock...



http://inlinethumb61.webshots.com/41468/2903264960032428117S600x600Q85.jpg


http://inlinethumb07.webshots.com/44358/2291703990032428117S600x600Q85.jpg

http://inlinethumb50.webshots.com/15857/2147964110032428117S600x600Q85.jpg

http://inlinethumb58.webshots.com/32057/2173207590032428117S600x600Q85.jpg

time to start over...

was every one ok

I took a bottle jack to the head and got a 1.5" long gash and my passenger got a cut on his chin... his kneed himself in the head during one of the flops.

4.5 barrel rolls... luckily a tree was there to stop it or it would have been a few more to the bottom!


The cage barely moved at all in the roll so I'm pretty confident that the unibody is ok and relatively straight.

The body on the other hand is pretty banged up... at a minimum it needs some new A pillars and upper windhield frame so I can get a new windshield and make it road worthy.

Rear upper suspension arm bent and the axle shifted a few inches so that will have to be remade... thinking about going to a standard 4 link instead of the 3 link wishbone setup on it now.

Holy shit! 4.5 rolls? That must have felt like a 1 hour disaster, time seems to slow down when stuff like that happens.

Good to hear you are ok, cant wait to see whats in store for version 3.0

Glad you're ok. I think I'll make sure everything is secure in my jeep.

glade to here your OK flying gear can be worse than the roll. when i rolled mine luckily every thing was strapped down. Jeeps can be replaced people can't

glade to here your OK flying gear can be worse than the roll. when i rolled mine luckily every thing was strapped down. Jeeps can be replaced people can't

x2. I am building boxes in the back of mine just because of this.

Glad you are ok.

x2. I am building boxes in the back of mine just because of this.

Glad you are ok.

X2

was making it part of my gas tank relocation, but don't want fumes in the cab cause of the new baby.

X2

was making it part of my gas tank relocation, but don't want fumes in the cab cause of the new baby.

As soon as I finish the floor this weekend I will be doing the tool boxes in the back. Ya i dont have to worry about the baby thing. I dont have kids yet....that i know of :evil:

I had this in the back.

http://i85.photobucket.com/albums/k51/hadfield4wd/My%20Jeep/fatty001.jpg

I took it out for weight. The box was very functional, but wieghed a ton and I had the tendancy to just put stuff in it. I keep everything strapped to the floor now.

Damn... that sucks!

Glad you're gonna be ok though!

Billy

Any updates on the repair?

Head is mostly healed up after taking the hit from the jack...

http://inlinethumb16.webshots.com/42639/2473783090032428117S600x600Q85.jpg




Started doing a little on the XJ... replaced leaky water pump, pulled off the mechanical fan that got bent during the roll and replaced it with an electric fan out of a Taurus.

This fan is awesome, much better than any aftermarket fans... 2 speed and flows 4000+cfm on hi.

http://inlinethumb07.webshots.com/37190/2327169990032428117S600x600Q85.jpg

It was a pain to fit in the xj and I actually moved the radiator forward about in inch for cleance between the fan motor and serp pulleys.

http://inlinethumb09.webshots.com/1544/2888037580032428117S600x600Q85.jpg

http://inlinethumb10.webshots.com/4297/2760579640032428117S600x600Q85.jpg

http://inlinethumb44.webshots.com/43307/2603134040032428117S600x600Q85.jpg



Waiting on an 85 amp relay before I can finish up the wiring.

http://inlinethumb52.webshots.com/41203/2658423800032428117S600x600Q85.jpg

Finished the top storage hoist... pics are from before the roll... not sure if the top will ever fit back on! :shaking:

http://inlinethumb07.webshots.com/42118/2672528800032428117S600x600Q85.jpg

http://inlinethumb23.webshots.com/43030/2967101010032428117S600x600Q85.jpg





Next I'm hoping to get working on the rear suspension and fixing the bent linkage mounts... after that its on to figuring out what to do about the windshield and trashed A-pillars.

The rebuild has begun...

http://inlinethumb11.webshots.com/23434/2237261360032428117S600x600Q85.jpg


3/16" steel armor, 12ga for the tailight housings...

http://inlinethumb45.webshots.com/25452/2790480260032428117S600x600Q85.jpg

http://inlinethumb55.webshots.com/29814/2570998500032428117S600x600Q85.jpg

http://inlinethumb32.webshots.com/20831/2841248330032428117S600x600Q85.jpg

http://inlinethumb35.webshots.com/41314/2780257410032428117S600x600Q85.jpg

http://inlinethumb22.webshots.com/43541/2581603550032428117S600x600Q85.jpg

http://inlinethumb22.webshots.com/43541/2581603550032428117S600x600Q85.jpg
Why not use a hole saw? :confused:

I'm excited to see this thread back at the top! http://www.slicky.net/smilies/cool.gif

Billy

I didn't have the hole saw sizes I need and didn't want to drop $15/ea for them... plus the material I was cutting through was 12ga stainless and would be a bitch... mostly just trying to save a buck.

More pics...

http://inlinethumb52.webshots.com/44531/2444628460032428117S600x600Q85.jpg

http://inlinethumb25.webshots.com/34584/2271115550032428117S600x600Q85.jpg

http://inlinethumb43.webshots.com/22378/2506090650032428117S600x600Q85.jpg




The tailgate got ejected during the roll and hit hard on this corner

http://inlinethumb12.webshots.com/21579/2960168840032428117S600x600Q85.jpg

http://inlinethumb43.webshots.com/44714/2849888830032428117S600x600Q85.jpg

http://inlinethumb30.webshots.com/42525/2368348280032428117S600x600Q85.jpg

More pics...

http://inlinethumb52.webshots.com/44531/2444628460032428117S600x600Q85.jpg

http://inlinethumb25.webshots.com/34584/2271115550032428117S600x600Q85.jpg

http://inlinethumb43.webshots.com/22378/2506090650032428117S600x600Q85.jpg




Wait... how do those attach? :confused:
Looks good!
Billy

The rear corner guards/tailights are BOLT ON... the bolts were countersunk, welded and ground smooth to give it a more stealthy look.

I was going to weld them straight to the rear quarters but I couldn't get the sheetmetal to pull tight enought to get a decent weld.

I love the build. Keep up the good work.:smokin:

The rear corner guards/tailights are BOLT ON... the bolts were countersunk, welded and ground smooth to give it a more stealthy look.

I was going to weld them straight to the rear quarters but I couldn't get the sheetmetal to pull tight enought to get a decent weld.

http://www.slicky.net/smilies/cool.gif
Billy

Been working on fixing the rear suspension after the rollover... trashed the upper wishbone arm and decided to make a new one that should handle much more abuse.


Here is what the old wishbone arm looked like... high side loads caused problems at the bends, even with the gussets.

http://inlinethumb44.webshots.com/363/1403517527032428117S600x600Q85.jpg

http://inlinethumb06.webshots.com/44229/2076205130032428117S600x600Q85.jpg




...in with the new

http://inlinethumb18.webshots.com/42257/2377136650032428117S600x600Q85.jpg

http://inlinethumb55.webshots.com/44342/2246995980032428117S600x600Q85.jpg

http://inlinethumb08.webshots.com/44231/2843344290032428117S600x600Q85.jpg


Had to redo the frame mounts...

http://inlinethumb26.webshots.com/5721/2476689080032428117S600x600Q85.jpg

Decided to cut out the rotting floor and rockers and move the rockrails up a few inches...

http://inlinethumb62.webshots.com/44861/2905922690032428117S600x600Q85.jpg

http://inlinethumb57.webshots.com/41528/2880086950032428117S600x600Q85.jpg



Boxing the "frame"...

http://inlinethumb55.webshots.com/44278/2539942690032428117S600x600Q85.jpg




Welded the 2x6x3/16 tubing into the cutout rocker areas...

http://inlinethumb60.webshots.com/44603/2172313920032428117S600x600Q85.jpg


http://inlinethumb55.webshots.com/11446/2209767490032428117S600x600Q85.jpg



Gotta fix the A pillar, windshield and front fenders next.

keep up the awesome work! wishin i had enough time to complete a project like this.

Did you consider getting a steel hatch? IIRC the late model XJ had them.

I'm a little sick and tired of your fancy fab work and your patience. Can you rush through something and make it "just work for the upcoming trip?"

Project looks great man, mad props for the good work and innovative thinking!

Damn dude, I just read through your entire thread from start to finish. I nearly cried when I got to the page w/ the roll. My jaw still hurts from hitting the desk.

I can't wait to see how the rebuild turns out, you've got some amazing skill man.

Man that sucks about the rollover but you probably needed something to do anyway, right? Glad you are OK. Dude, that attic storage could have doubled for a panic room!

Some more updates on the repairs...

http://inlinethumb61.webshots.com/43836/2921346990032428117S600x600Q85.jpg


Inner fender braces for the steel flares:
http://inlinethumb40.webshots.com/45159/2487614450032428117S600x600Q85.jpg

http://inlinethumb28.webshots.com/43611/2818944150032428117S600x600Q85.jpg

http://inlinethumb31.webshots.com/44958/2968715920032428117S600x600Q85.jpg


Windshield frame beefed up to handle another roll...

http://inlinethumb58.webshots.com/42873/2620275890032428117S600x600Q85.jpg

A pillar rebuilt with a 1.5" tube running down to the rock rail...

http://inlinethumb62.webshots.com/29949/2060734780032428117S600x600Q85.jpg


http://inlinethumb42.webshots.com/44649/2133186500032428117S600x600Q85.jpg

http://inlinethumb27.webshots.com/12442/2496243860032428117S600x600Q85.jpg




Hood Pins...

http://inlinethumb60.webshots.com/45307/2889496600032428117S600x600Q85.jpg

http://inlinethumb46.webshots.com/10349/2331844660032428117S600x600Q85.jpg

http://inlinethumb60.webshots.com/42747/2352173740032428117S600x600Q85.jpg

http://inlinethumb49.webshots.com/43568/2806708700032428117S600x600Q85.jpg

More pics of those fenders! We can see they're done! http://www.slicky.net/smilies/biggrin.gif
Billy

incredable jeep man. the fab work is amazing. i wish i had a 10th the talent you do. killer work man

Finished Pics....


http://inlinethumb22.webshots.com/45397/2849674340032428117S600x600Q85.jpg

http://inlinethumb60.webshots.com/44411/2339295520032428117S600x600Q85.jpg





fender flare to inner fender attachment...

http://inlinethumb26.webshots.com/41305/2021790650032428117S600x600Q85.jpg

Finally got a chance to get it back out on the trail, well worth all the effort!!

http://inlinethumb31.webshots.com/42078/2513027510032428117S600x600Q85.jpg

http://inlinethumb25.webshots.com/42776/2618501040032428117S600x600Q85.jpg

http://inlinethumb10.webshots.com/42505/2295617400032428117S600x600Q85.jpg

http://inlinethumb55.webshots.com/41846/2249235890032428117S600x600Q85.jpg

what brand of hood pins are those? i like those alot

Hood pins are made by autofab...

http://www.autofab.com/hoodpins.htm


I was very pleased with the quality of the hardware and the poly "bushings" eliminate any rattles and don't squeek, not bad for $30, would go the same route if I had to do it again.

I was wondering if you had the design plan to make the roof into a hard top that you can put back on? Does anybody have any ideas on how to do that. Im getting a 2 door and would love to have that ability to have a soft top and a hard top

Definitely no plans/drawings for making the top removable... plan on lots and lots of hours of cutting, welding, & tweaking to get it right.

Oh... don't think about cutting the top without a good cage or the unibody may sag and it will never line up again.

i noticed you're wearing a helmet this time. :smokin:

I could only dream to have your skill. Definitely an incredible build. When I get my new house I plan to build me a hoist like that as well.

You have an incredible eye for detail. Simply amazing man

Not much of a jeep guy, but this is a kick ass build.

I just re-read this thread... I knew it was coming, but I still cried at the rollover post!






So... any updates?
How's this working out for you?
http://inlinethumb63.webshots.com/31230/2484961900032428117S600x600Q85.jpg

Have you got to that custom console you mentioned?

http://www.slicky.net/smilies/cheers.gif
Billy

INSANE!!

I simply don't have the time...or the skills. Mad props.

Appreciate all the positive comments, been a long road but its worth it!!

As for the bikini top mounting... working very well, the windshield channel seals against water coming in better than snaps and makes it very easy to put on quickly.

Plan on starting the center console next... stay tuned...

Subscribed!!! This build is :smokin:

Fabbed up a steering box brace, nothing big all the pieces came from salvaged "junk"

http://inlinethumb56.webshots.com/43255/2193248820032428117S600x600Q85.jpg

http://inlinethumb11.webshots.com/45194/2275241440032428117S600x600Q85.jpg

http://inlinethumb07.webshots.com/45638/2784594020032428117S600x600Q85.jpg

sweet man, definately beefier than mine.

Redid the trac bar to get better angles and to keep the spherical joint from over rotating... 1.25" OD x .25" wall DOM

http://inlinethumb01.webshots.com/45440/2609985630032428117S600x600Q85.jpg

http://inlinethumb17.webshots.com/44240/2812663270032428117S600x600Q85.jpg



Machined some Delrin bushings for the axle mount UCA, was wearing the bushings out way to quick. I am only running an UCA on the driver side radius arm so it takes the full load under power. The delrin works great!

http://inlinethumb31.webshots.com/24478/2896243270032428117S600x600Q85.jpg



XJ vs ZJ pitman arms... just needed a little bit of drop.

http://inlinethumb61.webshots.com/40828/2422341740032428117S600x600Q85.jpg

Started work on a new overhead console... the old one was pretty busted up and none of the lights worked.

THE OLD...

http://inlinethumb52.webshots.com/42547/1147705315032428117S600x600Q85.jpg


what needs to get cut from the old setup...

http://inlinethumb64.webshots.com/44927/2739774670032428117S600x600Q85.jpg




WORKING ON THE NEW...

http://inlinethumb44.webshots.com/44459/2157091540032428117S600x600Q85.jpg

http://inlinethumb61.webshots.com/43708/2056542860032428117S600x600Q85.jpg

http://inlinethumb28.webshots.com/20507/2212467270032428117S600x600Q85.jpg



I have been very impressed with the quality and fit&finish of these Carling Contura switches... the ones with screen printed labels are very slick but tought to find all the different versions I need.

http://inlinethumb63.webshots.com/12798/2736378020032428117S600x600Q85.jpg

http://inlinethumb64.webshots.com/44543/2487175150032428117S600x600Q85.jpg

http://inlinethumb36.webshots.com/12515/2673139280032428117S600x600Q85.jpg


Some labels I picked p for the other switches that weren't screen printed...

http://inlinethumb27.webshots.com/42714/2286260740032428117S600x600Q85.jpg


...more to come, hope do some wiring this week or next. Also plan on putting some speakers and led cabin lights in the new console as well as other places in the cab.

http://inlinethumb27.webshots.com/42714/2286260740032428117S600x600Q85.jpg


:eek: You've got a frying pan for cooking bacon in that thing???



(second to the last row, in the middle) :D
Billy

Bacon frier to come! :D

Was your flop in Harlan? It sure looks like the trail next to the lower rock garden.

Your right on... the roll was at the lower rock garden at Harlan... good eye.

More progress on the console...

http://inlinethumb47.webshots.com/45678/2236146640032428117S600x600Q85.jpg

http://inlinethumb11.webshots.com/1418/2816775710032428117S600x600Q85.jpg

http://inlinethumb44.webshots.com/43307/2549191100032428117S600x600Q85.jpg



Waiting on LED lights for the console and then need to finish up the wiring.

Your right on... the roll was at the lower rock garden at Harlan... good eye.

I thought that was where it was at. I almost flopped at the same place. Glad you didn't get hurt too bad. Hope the jack is ok. HAHA. Keep the pictures coming. Very nice work.

Now that I have read the entire thread, start to now....

Top notch work!

Can I get you to work on mine?

It's give you the chance to chop a 2door......

Finally got the overhead LED lights and finished up the console. The amount of light is adequate but definitely not overpowering... planning some additional lighting around the perimeter to help insterior visibility.

http://inlinethumb62.webshots.com/43901/2653293550032428117S600x600Q85.jpg

http://inlinethumb34.webshots.com/12833/2827309650032428117S600x600Q85.jpg

~$30 each

http://inlinethumb26.webshots.com/35289/2927574580032428117S600x600Q85.jpg


took a scotch brite pad to the polished 316 stainless ring for a more brushed look...

http://inlinethumb44.webshots.com/42603/2382336550032428117S600x600Q85.jpg

I may have missed it but where did you get the decals, switches and switch panel? That overhead console looks great.

The rocker switch labels/stickers I got here:

http://www.mudstuff.co.uk/Carling_Legends.shtml

THE brushed look looks awsome.

Started working on a new center console...

http://inlinethumb40.webshots.com/42471/2589720690032428117S600x600Q85.jpg

http://inlinethumb35.webshots.com/45986/2447149640032428117S600x600Q85.jpg

http://inlinethumb25.webshots.com/42840/2675235090032428117S600x600Q85.jpg

This build is ridiculous! I wish I could do half the shit you can....looks i've got a lot of learning to do and a lot of work to do on my jeeps

Got my rail shifter today... the shifting action leaves a little to be desired (sticky) but overall it appears to be a solid product... we'll see how it operates, waiting on a couple more switches.

http://inlinethumb58.webshots.com/43001/2520769850032428117S600x600Q85.jpg

http://inlinethumb61.webshots.com/32828/2289514170032428117S600x600Q85.jpg

Made the panels to the console bolt on for access to wiring and the shifters themselves...

http://inlinethumb15.webshots.com/31502/2451347250032428117S600x600Q85.jpg

http://inlinethumb20.webshots.com/44371/2683082540032428117S600x600Q85.jpg

http://inlinethumb63.webshots.com/32254/2104869380032428117S600x600Q85.jpg

Transfer lettering I got from a hobby store...

http://inlinethumb40.webshots.com/45415/2941133020032428117S600x600Q85.jpg


Put a few coats of clear over the letters to seal them...

http://inlinethumb02.webshots.com/36225/2538624140032428117S600x600Q85.jpg

Masked off the labels and coated the rest with bedliner...

http://inlinethumb24.webshots.com/22807/2676288890032428117S600x600Q85.jpg


Strip brushes cut to fit for the shifter gates, keep the dirt out of it and just give it a finished look...

http://inlinethumb44.webshots.com/43307/2289380880032428117S600x600Q85.jpg


Tcase shifter got the same treatment...

http://inlinethumb29.webshots.com/31324/2615821670032428117S600x600Q85.jpg



Finished except for the wiring... I gotta do sumptn with that dash...

http://inlinethumb50.webshots.com/44145/2840216690032428117S600x600Q85.jpg

http://inlinethumb08.webshots.com/17799/2655105790032428117S600x600Q85.jpg

That looks great! Where did you get the brushes for the shifter openings? And the pad for the arm rest?
Thanks,
Billy

WOW! That overhead console and center shifter console is came out awesome :grinpimp:

Got the brushes and foam from www.mcmaster.com

Finished up the wiring today and took it out on the road. Overall the rail shifter functioned as advertised... BUT... do not expect the shifts to be fast or crisp, or have much compression braking.

I also came to the realization that there is no real good way to hook up my "manual" or "auto" lights... seemed like a no brainer until I got into the wiring of the rail shifter... oh well.

If I use this shifter 1% of the time it will be a lot but having the ability is nice.

Got the brushes and foam from www.mcmaster.com
Awesome. Thanks.

Finished up the wiring today and took it out on the road. Overall the rail shifter functioned as advertised... BUT... do not expect the shifts to be fast or crisp, or have much compression braking.

Do you have a TC lockup switch? Is there still little compression braking with the TC locked up?

I also came to the realization that there is no real good way to hook up my "manual" or "auto" lights... seemed like a no brainer until I got into the wiring of the rail shifter... oh well.

So, that must mean that you don't need to flip a switch to activate the rail shifter? I've got the same one that's been waiting to be installed for months and I had planned to do a setup very similar to what you did. I was hoping to have LED indicators for the different gears too, but maybe that's not an option.

Thanks!
Billy

Top Knotch Work!!! True Quality. I like the looks of the cage even without the top!!!

I did wire in a switch for the torque converter... SPDT switch allows to run it TCU controlled, off, or locked. One thing that this allows that the TCU will not do is lock in 2nd gear, no lockup allowed in 1st. Haven't tried compression braking in 2nd with TC locked but there is ZERO compression braking when downshifting to 1st... not like a manual at all. Haven't tried it in 4LOW yet.

Having lights for each gear may be tough to do since the control is for two solenoids that switch independently to give 1-4 gears... not a simple hookup.

Basically use a DPDT switch with the center posts of the switch going to the trans, the top posts come from the rail shifter and the bottom two come from the TCU... switch it forward and its in manual, center position and its off (trans still functions tho) and down is TCU auto mode.

Finished up all the wiring for the trans controllers and winch... lovin the winch controls in the cab!

http://inlinethumb56.webshots.com/44471/2335319190032428117S600x600Q85.jpg

http://inlinethumb20.webshots.com/21587/2251929350032428117S600x600Q85.jpg

where did you get the cup holders. i love the lower center console. I also like the fender flairs, and the rear boxes on the side great build.

Looks more like the center console of a hummer H1 now, very nice! only problem with reading this post is that now I'm seriously considering this. I've tossed the idea around in my head for years now, but having seen how it turned out I really like it!
Love the looks with the cage with doors and top off.

That thing is beautifyl man! Your skills are the stuff of unibody legend...keep up the fabulous work.

Whats the latest on this build? this rig is supa-sick

Wow that's a really nice project man. Serious patience

Been working on replacing the driver side fender, fixing the metal flare, and boatsiding the driver side.


http://inlinethumb20.webshots.com/19923/2984846410032428117S600x600Q85.jpg


http://inlinethumb10.webshots.com/17097/2201734380032428117S600x600Q85.jpg


http://inlinethumb33.webshots.com/5024/2613231330032428117S600x600Q85.jpg


http://inlinethumb49.webshots.com/45616/2542019370032428117S600x600Q85.jpg

http://inlinethumb33.webshots.com/35104/2588726800032428117S600x600Q85.jpg


http://inlinethumb60.webshots.com/43067/2314081180032428117S600x600Q85.jpg

Been working on putting in a couple of seats that I had kickin around. It was a tight fit and had to trim a bunch from the cage, floorboards and even some from the unibody rails.

The cage is pretty low so to keep from smacking your head the cutting had to be quite extensive.

The seats are comfy and angles seem good.

http://inlinethumb31.webshots.com/44190/2962442970032428117S600x600Q85.jpg



http://inlinethumb14.webshots.com/7309/2971121860032428117S600x600Q85.jpg



http://inlinethumb02.webshots.com/18497/2598400970032428117S600x600Q85.jpg



http://inlinethumb36.webshots.com/26275/2452074480032428117S600x600Q85.jpg



http://inlinethumb13.webshots.com/43276/2743037880032428117S600x600Q85.jpg


http://inlinethumb15.webshots.com/45518/2885366540032428117S600x600Q85.jpg

Working on building a sub box in the space where the driveshaft tunnel was... cut it out as not needed with steeper driveshaft angle. Gonna put an amp over top of the sub, not looking to win competitions with this system just looking to a get a little more bass than receiver driven speakers can give.

Planning on running a 8" sub and 500W 4 channel (2 for front speakers and bridge the other two and power the sub, was looking at this amp...
http://www.crutchfield.com/p_113KAC6404/Kenwood-KAC-6404.html?tp=115

and this sub..

http://www.crutchfield.com/p_204ELW8014/Bazooka-ELW8014.html?tp=111

I will be dynomating the inside panels of the sub box to help with vibes... what about poly fill, should I use?? Also what are the benefits of putting a port in the sub box vs leaving it sealed like I have it now??

http://inlinethumb61.webshots.com/44604/2575495630032428117S600x600Q85.jpg

http://inlinethumb55.webshots.com/43830/2612169330032428117S600x600Q85.jpg

http://inlinethumb04.webshots.com/24963/2131111580032428117S600x600Q85.jpg

ported boxes are designed for a small frequency. So they are good for listening to one type of music. I had a sealed box with a 15" in it and it didn't hit hard but was cleanish. I did like how it wasn't clean enough so i bought two 12" with a ported box. I hate my two 12" right now the ported box works great for hip hop but rock, metal, classical, and blues there is too much bass for me. It also is less clean than my 15".

That looks like a good use of space, placing the sub where it is.
The Bazooka sub has a really low sensitivity at 83 db. For every 3 db increase, the speaker sounds twice as loud at the same volume. If you can find a sub that has a higher sensitivity, you'll hear more bass from it.
I've played around with subwoofers a lot, and I've found that when I reflect the speaker off a solid panel (rear gate, side panel, etcetera), I get more volume. Someone explained it to me as a flash light. If you shine a flashlight directly into the night sky, it doesn't illuminate as much as if you shine the same flashlight at the ground and the reflective light brightens everything up.
I've read in the Car Stereo Cookbook that you don't need poly fill for sub boxes, and since I read that and stopped using baffling in my boxes, I haven't noticed any differences.
You've put together an incredible rig so far, I can't wait to see how your stereo turns out.

Every time i check on this thread you do something new that is super cool.

I am not convinced this is the best family wheeling vehicle.

Now it is just time for some big boy axles and 38"+ tires.

Awesome fabwork on the seat mounts/ box!

As others have said, skip the poly fill, skip the port, definitely do the dynamat! A sealed box will have a cleaner sound than a ported one will; I hate the sloppy sound of a ported sub enclosure. If you can afford it, definitely get a better sub ( this (http://http://outlet.crutchfield.com/p_109GTO804/JBL-GTO804.html?cc=07&tp=111) is only a little more $ but a lot better unit) An underpowered good speaker sounds 100x better than a max powered cheap speaker any day of the week.

As WTF? said, a higher quality sub will sound better under powered than that POS bazooka. I'm not sure what your budget can handle but you should definitely be dishing out more than $30 and you should definitely steer clear of Crookfield... Their stuff is way over priced!

Here's some stuff that the last guys haven't mentioned:
1) It's pretty hard to make a small ported box, getting the port the right size and length with enough clearance at the back of the port is just too hard in that small of a spot. Stick with sealed. Tighter, more even bass response.
2) The best approach to building a box is to first, estimate how much room (cu.ft.) you can dedicate to your enclosure, don't forget to account for wall thickness, you need to figure for interior space. Start searching for a sub that has an optimal sealed enclosure size in your range. buy that sub and build you box to that exact size :smokin:. When your talking about 1.0cuft (or less), you don't have much room to play with. Since your box is complete already, figure how much interior space it has and find a sub that works best with it.
3) It appears that your box walls are sheet metal. Good luck getting anything to eliminate the resonance in that bad boy. :shaking: Might want to add in gussets to each of the walls :rolleyes: Anyway, make sure you seal up all of the edges of the box from the inside with your choice silicon... oh and then pray that thing doesn't end up sounding like you're dragging "just got married" tin cans down the road...

Don't skimp on the system!

I like your build, you've got some great tube work.

Great feedback, thanks!!

For the sub I'm really looking for bang for the buck but also realize you get what you pay for... needs to be 8", .6 cu ft sealed box volume, under $100.

I'm gonna skip the poly fill and porting based on what I've heard here and from a buddy... dynomat will definitely go in. The sub box is made from 14ga, its fully welded and sealed with silicon from the inside so hopefully with the dynomat the vibes will be minimal. Another good thing is that there are not a lot of large flat pieces to the box so the bends and welds gave it a lot of rigidity.

Anyone have a source for a good deal on stereo equip?

You never want to under power a speaker. The voice coil won't cool itself w/out enough power, and is the biggest reason speakers blow out.

I'm looking for inexpensive Kicker Solo Baric L5 8" subs. They are built for very small cabinets, have a higher sensitivity, and really move air.

Definately use some dynamat on the inside to help with the resonance since the majority of your box is sheet metal.Don't throw out the idea of poly fill just yet.If your box ends up being to small for your sub of choice it can help to slow down the soundwaves efectivley making the sub sound like it's in a larger box.Speaking from experience it does help.
It just takes a shitload of the stuff.

some more progress...

http://inlinethumb58.webshots.com/46393/2086142840032428117S600x600Q85.jpg

http://inlinethumb38.webshots.com/12517/2045374940032428117S600x600Q85.jpg

http://inlinethumb29.webshots.com/15836/2712367250032428117S600x600Q85.jpg

http://inlinethumb29.webshots.com/43164/2584775780032428117S600x600Q85.jpg

http://inlinethumb56.webshots.com/45175/2448193130032428117S600x600Q85.jpg

That looks like a great amp location.

I've gotten some really good deals from http://woofersetc.com/. Sales on components and generally good prices on dynomat, etc. Haven't looked at sub prices, but I've been satisfied with their service & delivery.

Fab work is now finished on the sub box and amp enclosure. Gonna apply Dynomat, paint and do some wiring today.

http://inlinethumb46.webshots.com/36589/2863441690032428117S600x600Q85.jpg

http://inlinethumb09.webshots.com/46536/2191245440032428117S600x600Q85.jpg

hows the front of the sub going to breath? Just looks like its sealed on the face of it now too, which wont sound very good.

The upper part of the sub box/amp enclosure is not sealed so that the sub can breath and also to keep air moving around the amp. The enclosure has an opening into the arm rest portion of the console and it also has an opening at the rear most portion of the console (backcut portion is covered with a metal mesh).

Tried to keep it as water tight as possible without overheating the amp... might have to add a computer fan to keep the air moving.

All I can say Is WOW! I have been following this build since I joined and WOW! You are awesome.

Got everything painted and buttoned up.

Ran the power & ground cables for the amp as well as coax and speaker wiring... gonna wait to install the amp & sub when I do the rest of the stereo in the dash.

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top notch as always man. love watching this one come together!

Started tearing apart the dash... what a mess of wiring. Go figure I had to start with a "Limited" version which has every option available... the security system wiring is a pain.

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Put together a 3D CAD model to get the layout concept... lots of work ahead...

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wow man, top notch

wow I love it, like a YJ hybrid dash. Looks super clean.

man your work is meticulous and incredible this is one of the most well thought out projects I have seen! keep up the good work!

that CAD model looks sweet! Can't wait to see it completed. I've been daydreaming of doing something like this to mine. Never was really happy with the factory dash setup

I forgot that I basically made the heater box impossible to remove when I did the cage... soooo... had to trim a "little" from the box and rebuild it so the heater core can be accessed.

The blower motor housing will be seperate from the heater core box... gonna be connected by 2x 2.5" OD pieces of hose. More updates to come.

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