Changed the title from Project 127 to Project Tooo Long


This is going to be an ultra low bugdet build....NOT

I started this build awhile back.

I've budgeted $10k for this build. The build will be taking place in my home garage but I own a Sign Shop soooo. I will have a lot of cool cnc work going into it.

Dont be to critical of my fab. work as this is my first project of this scope.

I'm "the guy" that bought a welder at home depot and now think I'm a "professsional fabricator"

My Plans include:
127" wheelbase
4 door 4 seater 4 wheel steering
OBD II 5.7 out of 97 pickup
TH400 out of an old chevy 3500
203/Lomax 205 (2.0/3.0 to 1)
2 steering Rockwells
47" LTBs
Triangulated 4-link front and rear
18" 2.5 fox rear
16" 2.5 fox front
Custom Chassis
Custom lexan "skin"
custom dash



Went to the Junk Yard and picked up a 97 tub and frame for $450
Stripped off all unneeded Sheetmetal, wires and brackets

Drilled out all the spot welds and removed the outside sheetmetal keeping only the firewall and floor.

Sorry, my pic quality sucks!!! its the host

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You can see the dash I built at work. When I was a kid, I had a 86 cj so this dash is a combo of cj/tj. Needs gauges and radio.

This is the DXF for the cnc

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The following is some cool equipment i've purchased over the years.
CNC router, metal shear, 20' welding table, 10' sheet brake

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Cut the Frame and Body in half!
Added 23" of 2" X 4" X 3/16" to the frame
and 26" of .080 5056 to the floor (attached with 3/16" POP rivets)

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holy badass tools!!! looks like a great project....subscribed.

By the way MY old Rig is for sale (http://www.pirate4x4.com/forum/showthread.php?t=617465)

SWWEEEET! More info on the dash!

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Dash was cut from .120" 5056 Aluminum
then bent and welded.
the radio and gauge "bazels" were cut from 3/16" acylic. as will be the glove box lid.
Then there's angle alum. inside the dash to mount to.

Completely forgot to incorparate speakers!:mad3:
gonna have to do 4*6s somewhere.

If you like it now just wait for paint!

That dash is defintely sweet. Should be a good build.

Subscribed:D
what are you doing about back doors?

All outside "sheetmetal" will be replaced will lexan (polycarb). so if I decide to include doors they will be cnc'd from polycarb.

After lengthing the body and frame, I reinstalled the body mounts with no lift pucks. Then cut all additional factory frame brackets off and started on the tube work.
The following are pictures of the new hood ($249)
front hood hoop
front tube fenders
front main hoop
rear fender wells
and rock sliders
also front and rear bumper
I plan on using 7-8 sticks of 1.75x.120 ERW for the jungle gym
tube cost-$200

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All tubing fits against the body very very tightly.
My goal is to have the buggy look very much like a factory jeep jk

Once it's "skinned" you won't be able to see the union of tube and sheet.

After doing the front hoop and fenders,
I started on the Middle and rear hoops
then bars between the hoop
then the rear "bed" area
then bars for seats and installed seats
then finished the rear cage
then front stinger

I used a tube notcher from harbor frieght $70
and went thru three hole saws

Next I ran up to the yunk yard and purchase a low mile (75k 98 c1500) vortec 5.7 and 32 spline turbo 400(late 70's k3500) -$800 for both

I also sourced a gm203 and ford 205 from a buddy -$300
Jedsmachining.com is providing the doubler kit -$495
Jbconversion.com is shipping the diy lomax 205 kit -$1100

I puchased the ford for the 32 spline outputs! plus they're damn near free compared to the gm 205.
Once the ford parts go into the lomax i'll have a gm 3to1 with 32 spline inputs and outputs
plus gear and case strength that make the altas look like a bitch!
(dont remind me about the wieght!!!)
I'll be triple sticking it myself.

Enough tech now on to the pics:eek:

OH and by the way the grill is a template i cut from card board.

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I know you are running rocks and big tires but why so long? I think 127" is too long even for 47's, 120" would be better IMO. Dig the tube work, looks good

looks real good, great tubing work!!!

127 is a little long, but if you haev the right skid i think you could manage

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I know you are running rocks and big tires but why so long? I think 127" is too long even for 47's, 120" would be better IMO. Dig the tube work, looks good

I want plenty of room to have 4 sus. seats and fuel cell, batteries, tool box, co2, & icechest

I know you are running rocks and big tires but why so long? I think 127" is too long even for 47's, 120" would be better IMO. Dig the tube work, looks good

Check out the pics, he stretched the middle section of the tub. It looks like a lot of material too (I'd say at least 20"). Most people stretch out their stock wheelbase rigs anywhere from 100-110". I don't think 128" is out of the question, it's just gonna have long legs.

is that aluminum drain around the steering column:D no, but seriously nice tube work.

The ERW tube rockers wont hold up so well to rocks. I did my last build like that and the tubes were smashed to hell when I tore it all off.

The ERW tube rockers wont hold up so well to rocks. I did my last build like that and the tubes were smashed to hell when I tore it all off.

is that aluminum drain around the steering column no, but seriously nice tube work.




I think you're totally correct!!!
i also was thinking the same
I have since built rock sliders out of 3"x3"x3/16 steel
The gutter you refer to is pvc not even Aluminum. I completly agree it's ace. I have replaced with better:homer:

Keep Following the build to see them installed


thanks for the constuctive criticism
KEEP IT UP!:smokin:

Hey Guys,
Got the "Skins" cnc'd decided on .120 lexan for all exterior sheetmetal and windsheild
I'll post up installed pic tomorrow.
Also Posted pics of my fuel cell Hope you likey

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Then fab'ed a fuel cell from .120 alu.
then ground and sanded the welds

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Next, I Cut a hole and use the top of pvc glue can for the filler.

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Then made my own fuel pickups and vent

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Then drill and tapped the top didn't like that so welded on a 1/4" alu. strap and redrilled and retapped

then paint gloss black

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I've gotten some PM's About the sign in the first picture
so here it is done.

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You are a fawkin' maniac.... I love it! :smokin:

got any pics of the motor mounts?

got any pics of the motor mounts?

no but i can get and post tomorrow
there no big deal made em the garage out of 3/16" steel and some tube:homer:

Looks good, but you sure you want to trust the top of a GLUE CAN for your cell in a rollover? I know I wouldn't....

Here's the pics of the jungle gym painted and skinned.
also ran a piece of 3/16 steel along the bottom.


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Very Nice Work :smokin:

I really like it.

OMG, I love this build up!

very cool

I know you are running rocks and big tires but why so long? I think 127" is too long even for 47's, 120" would be better IMO. Dig the tube work, looks good

Great looking project, you will love the 127" with the four wheel steer it will work great!

Got the radiator and grill in

Focus on the JEEP not the floor!!

:flipoff2:

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Got the Dash complete

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Spent some MONEY!!! this week
lomax 205
fox air shocks
tires
axles



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what are the plans for the rawks?

Got the motor wired and running
Also got the steering valve installed

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Check out the cool fuse and relay box on the firewall
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Next is transfercases and axles

That is fawkin awesome! Can't wait to see the beast finished....:eek:

Can you post a detailed picture of your radiator mounting? Thanks a lot, keep up the great work!!

How much have you spent so far??? Love the build... Keep the pics comin!:D

looks awesome. nice work

what are the plans for the rawks?

usa 6x6 pans
2.5" single ended rams
ouverson's lockers
usa 6x6 pinion brakes
wilwood 4 piston calipers

that's it!

How much have you spent so far??? Love the build... Keep the pics comin!:D

I had a 10k budget... that's now blown out the water!
I'm at 14K and i still need rams, custom wheel centers for h1's,
1410 t-case yokes, driveshafts, hydro lines, 6x9s, optima, and winch.

:(

Can you post a detailed picture of your radiator mounting? Thanks a lot, keep up the great work!!

Yes Check back later this week and i'll have it up

That is fawkin awesome! Can't wait to see the beast finished....:eek:

BIG THANKS to all you guys for your support.
It's not easy working all day then coming home and working all night.:mr-t:
I'm glad you guys like it...I was affraid it was gunna be u-g-l-y.

new fav. build right here.

Man looking great so far. It's gonna be awesome! More pics!:D

OK
this weekend I got the lockers installed and I got the Lomax 205 built


Unwire and remove cap bolts

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Unwire and remove bull gear bolts

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Remove spider gears and all shims

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NOW the HARD PART!!

No Locker

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aaaaaand...

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locker'ed

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Now put it all back together
No backlash No gear pattern It's that easy 30 minutes start to finish!!

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And Finally
Remove the nuts and washers from shipping.

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ALL PHOTOS ARE "BORROWED" FROM DANIEL @ USA 6X6

Ok

Got a ford 205 ($150) CUZ I wanted 32 spline outputs (and they're plentlyfull and cheap as heck!)

And the Lomax 205 DIY kit ($1100) comes with 32 spline input. (jbconversions.com

And the 32 spline 203 ($150)

Also Got doubler kit with 2" clock from Jedsmachining.com ($450)

Total $1850

Do not forget this is now a pass side drop!

Yea I could of purchased a Altas for $3000 +/-

And yea it would have been slightly lighter (and easier)

BUT...you cannot fawk with the strength of this combo!!!!!!:mr-t:
Check out pictures of gear comparisons at bottom of post.

And

All the parts from the lomax and ford work together except the shift rails. You must have gm shift rails.

And by the way for the ultimate E-brake leave the shift rail rods out!!!
There's no need to grind shift rails!
With this mod. when you shift the front in high
and rear into low (or visversa), it locks the gears together for the ultimate E-brake.

However, you can be a tard with this mod and potentily fawk stuff up.
(also only works with hubs locked and both driveshafts installed)

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For a Great "how to" on the doubler go here (http://www.pirate4x4.com/tech/billavista/Doubler/doubler_signed.pdf)

These new gears are twice as strong as factory which is twice as strong as atlas!!:D

Q: Is this gear set stronger than the Atlas II?

A: Yes. The NP205 is the undisputable King of strength when it comes to 4x4 transfer cases. Aside from some of

the bigger commercial designs, there is nothing that comes close to competing with the NP205 when it comes to

brute gear strength.



Q: Can the new case be inverted to produce a drivers side drop?

A: No.



Q: Does the LoMax design utilize the tapered roller bearing design for retention of the intermediate
gear?


A: Yes. The original NP205 uses a tapered roller bearing arrangement to achieve maximum thrust load capacity

as opposed to a straight roller bearing and thrust plate design found on lighter duty cases like the Dana 300 or

Atlas II.

Q: What is the intended application for the LoMax kit?

A: This kit is designed to be used in big, heavy, fullsize truck applications with high horsepower and large tires.

This gearset is not targeted for the Jeep or single-seat tube buggy market.

(Highangledriveline.com)


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Above images from jbconversions.com

rediculous build, i'm loving it. Keep up the good work.


Hunter

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What do you guys think about these wheel centers??

I think they look cool, but downside, they would be fairly heavy...and water/mud/slop would not drain out of them easily if you have an outer ring on your rims.

HOLY F@CKING SH!T !!!!!!! You are a PSYCHO! Love this build . I wish I had the balls and dollars to do something like this! Keep up the good work and pics coming. Very nice work.

not much to update...

built homebrew'ed triple stick after work yesterday

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this is going to be a tank with a jeep front end on it! great build!

this is going to be a tank with a jeep front end on it! great build!

Exactly!!

*why did i just now find this thread?*:shaking:

Sick buildup man, I may of missed it but how did you get the camo design on all your stuff?

TTT for a cool build

this is a sick jeep loving it so far.. keep up the good work.. still wondering about your rad setup... how tall you looking to make this one? with the HUGe tires your running I'd imagine it'd be a good 3.5' to the bottom of the frame.. 4 linking it? good luck.. looks great!

:smokin:

Sick buildup man, I may of missed it but how did you get the camo design on all your stuff?

LumberJack,
I'm a sign guy so I can get the Hardwoods vinal for cost.
Its a vinyl is applied to polycarb (lexan) then attached with pop rivets:)
Very easy, durable and cheap/quick to replace.

I think the tires will be out far enough that I will rarely rub the sides of the chassis.

this is a sick jeep loving it so far.. keep up the good work.. still wondering about your rad setup... how tall you looking to make this one? with the HUGe tires your running I'd imagine it'd be a good 3.5' to the bottom of the frame.. 4 linking it? good luck.. looks great!

I'm Keepin it as low as fesible.
bottom of skid plate is 31 and bottom of frame is 33
I'm running the factory tj skid plate
I've been waiting 7 weeks for usa 6x6 to ship rockwell pans!!!!
They came in Thurs. so I got the axles in now and the wheelbase worked out to 130" (thank god for 4 wheel steer!)
I'll post pics this week

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You may want to put a stainless steel isolator between the brass fittings and the aluminum tank to prevent galvanic corrosion.

First off, friggin cool build! Ive been wondering how it would look to pull off a 4dr wrangler done diffrently than the big red one on here. I like the looks of yours!

Can I go out on a limb here and make a few guesses? I see Texas plates hanging in your garage, Im guessing you are in Texas. And the sign, well, thats a local bank as far as I know, so are you in the Texarkana area? If so I would LOVE to come check this build out as it would probably give me a kick in the nuts to get something done on mine.

If not, dissregard this message as just another Pirate idiot.

Kyle

First off, friggin cool build! Ive been wondering how it would look to pull off a 4dr wrangler done diffrently than the big red one on here. I like the looks of yours!

Can I go out on a limb here and make a few guesses? I see Texas plates hanging in your garage, Im guessing you are in Texas. And the sign, well, thats a local bank as far as I know, so are you in the Texarkana area? If so I would LOVE to come check this build out as it would probably give me a kick in the nuts to get something done on mine.

If not, dissregard this message as just another Pirate idiot.

Kyle



I'm in dallas but i bought my rockwell's in texarkanna... red river surplus baby!

h1's recentered and reversed
(yea i know, But I hate the way the front looks!)

Front Axle mocked in
(yea i will be capturing the bolt on the upper and no it doesn't hit the frame)

Link mounts the axle
(yea i will be bracing the uppers alot)

Lastly, you will not find a panhard bar... why? because I haven't put it in yet.:flipoff2:

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looks good.. are you planning on moving the steering linkage up higher out of harms way?

looks good.. are you planning on moving the steering linkage up higher out of harms way?

no :( but i am going to sleeve it and bang the shit out of every rock i go over!!

Why didn't you triagulate the lowers? Then you don't need a panhard bar.

is that upper link bent???

a panhard bar will be interesting with that huge center section

This is a sweet build.

Why didn't you triagulate the lowers? Then you don't need a panhard bar.

This is the strongest link design
also I enjoy:
sliding on my lowers
Tire rub
having an unprotected transmission pan
:homer:

is that upper link bent???

a panhard bar will be interesting with that huge center section

The center chunk will have a rock cage in front of the brakes. The panhard will connect to the top of that and the bottom of the frame. Putting it uphigh gives me a high roll center for stablity.

I've done a horrible job of explaining this but i do have a plan so check back in for undates:smokin:

what's the deal with the pre-bent upper control arms? :confused:


i dig the sheetmetal work!

Nuthin' says "Big TexASS Redeck Jeep" like reclining nude trucker chick wheel centers and Realtree Hardwoods Camo :dustin:

All that sweet fab work and uses a PVC glue can lid...:shaking:
You know these are only $30...

336259

Awesome build, I've been watching this for a while.


Where'd you get the trucker chick gussets? I've been on the lookout for those for a while and haven't seen em yet.

Awesome build, I've been watching this for a while.


Where'd you get the trucker chick gussets? I've been on the lookout for those for a while and haven't seen em yet.


Had a buddy cut them and all brackets on his plasma cnc
I can email you the cad file if you're interested
also shawn
@ greatlake offroad (vendor section) can cut anything you want.

All that sweet fab work and uses a PVC glue can lid...:shaking:
You know these are only $30...


336259

Yea but where would the tech be in that!!
It might be ugly BUT
You can't accuse me of BOLT ON!!:laughing:
And nothing says redneck like building a gas tank from the shit in your shed.:grinpimp:

wow thats one kickass build. Keep on goin, im sure its goin to do great on the trail. I think you should paint everything to have a cool affect. Plus it would look clean.

Had a buddy cut them and all brackets on his plasma cnc
I can email you the cad file if you're interested
also shawn
@ greatlake offroad (vendor section) can cut anything you want.

Thanks!

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Hey guys
got the axles and wheels installed
here's a teaser photo
I'll get more pics when i get it out of the garage.
still got tdo brake lines and steering lines
also a million small things:massey:

looking good i like the green headlights

Looking good man. I like those trucker girls in your wheel centers!

someone left a 2x4 in your front suspension :flipoff2:


lookin good.

wow. if I live a million years I will never have a rig as sick as yours, couldn't find an ass kissing smiley . keep those updates coming

fawkety fawk ya baby

WOW this is a nasty build i can't get over it, if you bought a welder at home depot and learned to weld hell i all the sudden feel the urge to save up and buy one.

KICK ASS! Man that thing is nasty lookin. I wan to see that thing on the rocks:smokin:

SICK!!! enough said

should have bought a 4 door jk! :) looks awesome!

I DIG IT! NICE BUILD!
Scott

Just found your build, very nice work.

I'm just around the corner from you in Grapevine. I'll be mounting up my new 47" LTBs on my pig soon as well.

Keep up the good work.

That is sick... cant wait to see it finished

:smokin:

Awesome work man.

BFJ, that monster done yet? got any updates?

looking good dave!!! i need to come over and see this bitch.....

yea she's dun

just need to get mufflers and a few other things.
been busy with christmas and family
i'll get new pics up this week

IS it really gonna fit out the door?

any pics yet? I'd like to see the finished product

man i've been following this thread for a long time. btw way it looks great and really really big! i can't wait to see some pictures of it in action

That looks like one bad ass rig!!!! Keep up the photos.

updates?

updates?:p

yea she's dun

just need to get mufflers and a few other things.
been busy with christmas and family
i'll get new pics up this week

he said he would do it this week :confused:


but that was 6 months ago

maybe his digital camera broke......

:crickets: :crickets:

Updates???

Updates????

I would like to see what all you have finished.... Maybe you are out wheeling and forgot us.

Why not build the frame from scratch since it had to be extended?

What junk yard are you using? I am from Garland. Did you get your Rocks from Red River in Texarkana?

http://farm2.static.flickr.com/1387/895866764_958473b5cd_b.jpg[/QUOTE]

Sweet dash :eek:

updates? please!

SIKKKKKKK build man keep those pix comin. That is the nicest dash I have ever seen man

please dying of no updates.

I second that i read the build great work, love the build, alwsome machines more updates please

Looks like he's as busy in this economy as the rest of us

This guy has not been on line in over a YEAR!!!! I think he quit:mad3:..............or died:(.......I hope he just quit:D.

maybe he just couldnt get it out the garage :smokin:
http://farm3.static.flickr.com/2249/2069659779_417f228911_b.jpg

I need my updates, please.....

I saw him on the trails over a year ago, but haven't heard anything about him since.

Darn, I was enjoying the build.
If the OP ever gets back online, I hope you got your rig running, and running well!

I especially like the dash. I am likely going to be doing something similar to run a modified, but still relatively stock shifter in my 460/NP435 combo. I don't like the linkage idea which some guys have done, and I don't want to punch the radio on every shift.

Mark