Jealle o' cigano

[jpfrk2001]

Please stay with me on this Intro. It seems that all projects start with a story. Here is my story. I’ve always wanted a buggy. This entire project started in Mid July 2009 just prior to my deployment to Afgan. This project was born because of a drastic forced change in my life. On July 2nd my “Current” X-wife demanded a divorce. I was 3 months away from deploying. After 2 weeks of talking with my family (while all emotionally messed up as they come) with their strong advice, I hired my attorney. The same day I hired my attorney, I made a phone call to a chassis engineer, Rick Moonyham. We got to talking about the future of my situation, and I was able to guarentee a cash base project while I was playing in the box.

I deployed on schedule, the divorce decree was signed by me and my X, and I was off. The Divorce was finalized and signed by the Judge on Dec 22nd 2009. While I was gone for a full year, A car was being built. At times it took A LOT of coordination and phone calls with people across the country to supply Easy the needed componants. I finally arrived back in the states, Nov 2010. I then made a trek out west in Feb 2011 to attend KOH and drive a Camera Guy around for the upcoming DVD. I dropped my Jeep off at my parents house in New Mexico so I could bring back my current project. So with that in mind, I hereby present to you all, JEALLE O’ CIGANO. . .

Porn Star Dancing (Rock Version) - YouTube



The night prior after a 5300 mile round trip:



The following pics are all Easy's Craftmanship:











Here are the specs:

106 WB
Front HP Dana 60 up front from 89 F350
Rear LP Dana 60 out back from something.(I think a mid to late 70's ford F250)
2.5 liter MPFI Jeep motor from a 93 YJ
NV3550 5 speed from 2002 Jeep Rubicon
StaK Monster 3 speed.

The Drivetrain combo came out of a running buggy. So all works tits. Also, I plan on polishing the turd of the 2.5. I have some neet stuff being done right now in R&D in a secret location

First step in the build, get some material:


And one thing that needed done, the stock OEM lower alternator mount interfered with the Chassis. So I needed to Fab up a mount for the Alternator. I wanted to get this out of the way. Also, this was the VERY FIRST fabricated componant in my project:


Its very ugly, but it gets the job done.


Now this project will be built in a garage. I don't have all the super bling tools to work with, but I do have alot of local professional industries with the tools with amazing rates. I will throw NOTHING but the best at this project. So this will be a long drawn out project. NOTHING BUT THE BEST!! Also, this is my first attempt at a ground up from scratch build. But I have all the references here on PBB for assistance on EVERY detail required on the build. I am going to go SLOW and take my time and try not to fawk this thing up. I was given a VERY solid plateform to start with. I will NOT fawk this up.

More to come. . .

[rsqne1]

In...good luck Martin!!! You're gonna love this thing!!!

[jpfrk2001]

Next up was to start tracing lines for adding tubing and triangulation:






Start tube work:




Then started the jig up for the seats:





The seats are PRP Premiers. I purchased these at KOH at a special lakebed price only. I also picked up a seat harness at a killer price!
Before I could do the dash mount and more tube work, I needed to start the seat cradle:

[jpfrk2001]

Originally Posted by rsqne1

In...good luck Martin!!! You're gonna love this thing!!!

Thanks Nate. It just may take me 2-3 years to complete

[jpfrk2001]

seat cradle work starts:



The beginnings of the mount tabs:


building slider brackets:




sliders installed. still double checking everything here:


before on the mount tabs:


after:


Coming together here:


Not the complete cradle system. Still needs ALOT of work:


At this point, the seats are fully located. Now I can do the front dash bar and the rear seat hoop bar to mount the harness.

[spidr]

Fuckin eh.

[jpfrk2001]

At that point, I was able to mock up front dash bar:


Then I start mocking up for the rear seat bar:




and more mock up. measer many times so I know I can weld once:


rear seat bar tacked in:

[jpfrk2001]

Originally Posted by spidr

Fuckin eh.

This is just started. I plan to bring it on this one. And I am only working in a garage with limited tools

[spidr]

Originally Posted by jpfrk2001

This is just started. I plan to bring it on this one. And I am only working in a garage with limited tools

ETA? I'm stoked to see it coming together..

[jpfrk2001]

Originally Posted by spidr

ETA? I'm stoked to see it coming together..

Im hoping to drive it in about 2 years. The engine just got done with Engineering. I just have to give the "GO" to have it built. How does 220 hp / 300 trq WITH NO TURBO sound to you

I hope to have the engine delivered, built up, installed in 3 months. may take longer. I don't earn that much you know

[jpfrk2001]

So this post brings this up to date. I had to figure a bolt in system for the seat cradle just in case for trans/t-case removel for any situation. I don't have CAD or access to it. I do have a degree in Mechanical drafting/designe. So I had to go back to old school techniques:


Cut up some strip for the beginnings:


Set up the drill press:

[jpfrk2001]

So start makin some holes:


Its a start. Still needs some work:



Start working on the other tabs. Still alot of work to do:


This pic is of tonight where Jealle currently sits:


And this concludes my Introduction to my "New Beginnings"

[4Ruggyfamily]

Great Start buddy, i am going to love this thing come together.

[85blue4runner]

two questions:

What is the meaning of the name and how the hell are you getting 220hp and 300 TQ from a 2.5 four cylinder heep motor?

[rajincajingt]

great start!

[Roc Doc]

Good luck with the build Martin. Lookin' good.

[jpfrk2001]

Originally Posted by 4Ruggyfamily

Great Start buddy, i am going to love this thing come together.

THanks buddy

Originally Posted by 85blue4runner

two questions:

What is the meaning of the name and how the hell are you getting 220hp and 300 TQ from a 2.5 four cylinder heep motor?

The Name: I was going go with MILCPOS (Mid Life Crisis, Pissed Off Squirrels) but I came up with this name instead. As I was watching UFC fights while deployed, there is a fighter named the "Cigano" It comes from the Portuguese language. Translation is "Gypse" Well, I kind of think of my self as a gypsie kinda. I do wierd things, always going against the grain, and purposly finding ways to shake up the norm/traditional way of doing things. But I wanted to also give my new ride a female name. So I started researching authentic Portuguese Female Gypsie name, and I came up with Jealle. Translation is "Mountain goat".

So I think the translation of this would be "The Gypsie Mountain Goat"

As for the engine, I cannot disclose the secrets being used to generate this amount of power. All I can say, it WILL be wicked! And those numbers are even Naturally Aspirated, BEFORE throwing numbers using a turbo. Yes, I mentioned something about a turbo

Originally Posted by rajincajingt

great start!

Im going to attempt a delivery for you all

Originally Posted by Roc Doc

Good luck with the build Martin. Lookin' good.

Thanks Doc, Hopefully I can have this at the hammers for shakedown come around 2013!

[BrianDguy]

Its about time! Ive been waiting for this after following your jeep build. Should be interesting to see how the engine turns out.

Good luck

[jpfrk2001]

Originally Posted by BrianDguy

Its about time! Ive been waiting for this after following your jeep build. Should be interesting to see how the engine turns out.

Good luck

Thanks,

Well good afternoon ladies and Germs. I am now shutting it down after 2 days of non-stop burning metal. I did move slower then normal, as I did not want to make any mistakes or wrong choices. And with my work schedule, I just don't work on the rig during the week. So with that info put out, I did manage some motivation and started Friday evening after I got home from work. Here is Friday evening:


After clean up off to go drink a beer:


Next:

[jpfrk2001]

I hit it early Saturday morning (around 9:30ish)


Started mock up for my flange work:


Used my sawzall and placed the cradle on my welding table for work:


Sat night I got an idea for making those nasty square less of an eyesore. I started with some simple 1" strip. Cut up 8 pieces:


Set it up in my vice and started burning:

[jpfrk2001]

Ok, I don't believe Im going to post this. But here is to appease the welding nazi's. I am by far no where near like the pro's on here. But I feel I am getting better:


Another:


Final one:


I know I suck. But Im working on it. I concentrate on penetration and trying to keep it uniform.

[jpfrk2001]

This is what I have done for those nasty square holes:


Photo bucket is being a little bich right now. be back in a moment

[jpfrk2001]

finished the welding on the cradle and gave it a quick coat of primer just to fight the humidity here:


Did the same thing to on the square tubes on the other end:




Cradle back in place. It bolted in with limited force, but its in:


And that is all I got done. So here is a preview of next installement. Started mocking up for firewall frame/skeleton. This will also lead into the floor pan skeleton:


Material of choice. 24 feet of 1/2 sguare tubing. 1/16th thickness. I got it for free:


Next update will be about same time next week. You all have a great week to follow.

[jalbrecht42]

Originally Posted by jpfrk2001

As for the engine, I cannot disclose the secrets being used to generate this amount of power. All I can say, it WILL be wicked! And those numbers are even Naturally Aspirated, BEFORE throwing numbers using a turbo. Yes, I mentioned something about a turbo

I'm looking forward to seeing how you do this part! I'm glad to see this build finally posted on here--I've been wondering when/if you were ever going to post it. Looks like a great start, keep it up.

[jpfrk2001]

Originally Posted by jalbrecht42

I'm looking forward to seeing how you do this part! I'm glad to see this build finally posted on here--I've been wondering when/if you were ever going to post it. Looks like a great start, keep it up.

THanks man. Im going to read this thread this week:
/forum/general-4x4-discussion/833341-general-metal-fabrication.html

I need some ideas.