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Old 12-02-2008, 07:45 PM   #101 (permalink)
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Old 12-04-2008, 06:54 AM   #102 (permalink)
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thats a pretty sweet build what are your driveline plans?
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Old 01-04-2009, 10:39 PM   #103 (permalink)
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So are you going for an XVJP type of set up in place of the bed?
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Old 01-06-2009, 05:31 PM   #104 (permalink)
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Quote:
Originally Posted by jimbo92 View Post
thats a pretty sweet build what are your driveline plans?
Thanks! Everthing is up in the air at the moment. I'm working on getting a diesel from Brazil. That needs to go in before I get into the rest, but I am working with a company for some solid axles.

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Originally Posted by LRDisco View Post
So are you going for an XVJP type of set up in place of the bed?
Similar. The camper itself will be a custom flip-pac (to fit the bed) and the storage inside will be modular.
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Old 01-19-2009, 10:40 AM   #105 (permalink)
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Updates! Holidays are over and the shop has been moved, its back to work.


With the metal work now complete it's time to start prepping for body filler. I brought the truck over to a friends auto body business to let a pro have at it.




Although, the body filler would be done by someone else, that doesn't mean I can't be useful. Equipped with a dual-action sander I clean all the welds and low spots.




Spencer sands off paint to fix the tin can effect from me welding the roof.




This is where experience pays off. Spencer uses a fancy slide hammer to rework the roof to the correct curve. During construction the metal warped inward. By a push of a button, the tool welds itself to the sheet metal. Then you slam the metal weight upwards.

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Old 01-19-2009, 10:41 AM   #106 (permalink)
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Using a special body hammer, Spencer whacks in key locations to stretch the metal into the correct shape.




The side panels also had the "tin can" effect. This happens when metal stretches and/or contracts during the welding process.




Once Spencer finished banding and beating the body into shape, he sprayed all the seams with etch primer.




Here's is the etch primer used and the Kevlar fiber body filler he'll be adding next. That's right, Kevlar!

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Old 01-19-2009, 10:42 AM   #107 (permalink)
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Like any body filler, you have to mix it with the right amount of hardener. Which seems to be, about yay.




Next the filler is spread along the weld seems. The purpose of this is to reinforce the welded areas.




Now, it's time to wait a few days for the filler to harden.


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Old 01-19-2009, 01:39 PM   #108 (permalink)
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I think you should have converted that hearse in the background to 4x4, they already got tons of room in there

But seriously, your project is coming along nicely though
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Old 01-19-2009, 02:16 PM   #109 (permalink)
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cool project, good work! subscribed.
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Old 01-21-2009, 01:56 AM   #110 (permalink)
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WOW I don't even know what to say....
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Old 02-06-2009, 11:39 AM   #111 (permalink)
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Wow.

So you're taking care of the body work before delving into the drivetrain mods? Do you know what axles, engine, etc. you're going to go with?
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Old 02-07-2009, 06:56 AM   #112 (permalink)
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wow that is crazy good job man keep up the pics
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Old 03-13-2009, 10:08 AM   #113 (permalink)
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Haven't got much done on the truck the past few months. I will be finishing up the body work soon and get the truck ready for the Overland Expo in April. I've also been holding off doing any major work until I get the camper, which I received word I should be able to pick it up within a few weeks. So things are progressing. More news to come.
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Old 04-01-2009, 08:57 AM   #114 (permalink)
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Time to get some updated photos up!


With a delay in moving shops, both mine and the body guy's, we're back preping the body. Here Spencer sands down the kevlar filler.




After sanding down the first coat a second coat is applied.








After drying the second coat gets sanded

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Old 04-01-2009, 09:03 AM   #115 (permalink)
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After the kevlar coating a skim (thin) coat of body filler gets applied and sanded down.




Mixing the body filler.




Spencer applying another skim coat to fill in all the smaller dips.




Sanding down the second skim coat.

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Old 04-17-2009, 09:56 PM   #116 (permalink)
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Any updates!?!? This build is sick!
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Old 04-19-2009, 02:33 PM   #117 (permalink)
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First glimpse of our custom camper, which was installed yesterday.

With the Overland Expo looming I won't be able to go into details just yet, but here are a few more photos from yesterday.
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Old 04-22-2009, 08:28 AM   #118 (permalink)
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Thats badass! if you don't mind me asking what does one of those flippacs go for? I'd like to get one on the mj.
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Old 05-26-2009, 10:31 AM   #119 (permalink)
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Thats badass! if you don't mind me asking what does one of those flippacs go for? I'd like to get one on the mj.
Thanks! Mine was a special order since I have a shorter bed. I'll have to get a price list.
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Old 05-26-2009, 10:31 AM   #120 (permalink)
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Tons of updates coming up. Cab finishing, bed reinforcement, camper installation & demonstration, rear bumper build.





During the time bodywork was being done there were a few days I worked on the wheel well portion of the cab. To keep the tires from ever
rubbing against the cab I notched the edges with a plasma cutter.






After the rough cut I cleaned up the edges, then proceeded to create a paper template for a new edge.




Then I transfer the template onto a piece of 16 gauge sheet steel.




With a sheet metal break I bend the strait edges accordingly. Then I use a body hammer to beat each little tab into place then tack weld it.
As you can see by the number of small tabs this took a long time. The back of the cab has ridges making it very difficult.




Once fully in place I welded up every inch and repeated on the driver side.




When finished I sand blasted and smoothed the edges with seem sealer.




Once the truck was back together I took it out for a test run. Part of the test was to see if the tires would rub or even come close.




With the suspension fully compressed on the passenger side there is still three inches of clearance.

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Old 05-29-2009, 11:20 AM   #121 (permalink)
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Onto finishing the bed's supports. The last changes to the bed
only consisted of the exterior sheet metal and not any
structural support. I borrow a rolling frame to work on the bed
easily.




With heavy gauge sheet steel I form a new front support.




The front support will tie into the bed floor and the front portion.




With the sheet metal being rusty from swamp coolers I toss the new
support into the sand blasting cabinet.




After sand blasting I paint the inside to protect from future rust
since I won't be able to paint it after its welded on.

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Old 05-29-2009, 11:26 AM   #122 (permalink)
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Now I weld the bottom of the support into place.




Then with vice grips I clamp the sheet metal to the support and slowly weld all of the spots welds previously drilled out.




To create the rounded corners of the wheel wells I cut strips of steel and bend them into the rough shape.




Then I go crazy with spot wells to fill the area with material. Kind of ugly, but neccesary.




After the welding madness I grind everything to the correct shape.

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Old 05-29-2009, 11:31 AM   #123 (permalink)
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Now its to extending the wheel wells to reach the front of the bed. I create two paper templates that fit the curves.




I then cut sheet metal to the templates pattern.




Using a rubber mallet and a hole dug in sand I beat the sheet metal close to the correct curve.




Then I slowly weld into place.




And repeat with the second half.

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Old 05-29-2009, 11:43 AM   #124 (permalink)
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Same process gets repeated for the other side.




Standing the bed on end I clean the area with a sand blaster.




Using a plasma cutter, I remove the excess material.




Creating yet another paper pattern for the small remaining piece of the wheel well.




New piece created then welded into place.

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Old 05-29-2009, 02:39 PM   #125 (permalink)
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How is the front of the tent supported when it's folded out? I see the two rods coming down to the front fenders, but is that area reinforced? Does the tent actually support itself in the down position?
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