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Old 03-01-2011, 02:51 PM   #176 (permalink)
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I finished cutting the sheet metal. Now, since it has been changed, there is too much missing so I will be filling it back in as close as I can to the CO, and enclose the trunk.



I also put a piano hinge on the bottom of the tailgate so it will now open down, cheap and easy, just the way I like ‘em.



Still need to add some cables.

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Old 03-01-2011, 05:21 PM   #177 (permalink)
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good job man. I like the piano hinge idea is cool, If I still had a tailgate I would totally steal it
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Old 03-03-2011, 04:50 PM   #178 (permalink)
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Started on the front. Cutting the mounts off so I can rebuild them.
Got one cut off and then I trashed my last sazall blade and since I needed some wire and gas and other stuff, I went to get supplies and didn’t get much done.



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Old 03-04-2011, 03:43 PM   #179 (permalink)
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I got the other side in the front cut off.



Then I started hanging the rear tailgate.









Not done yet.

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Old 03-09-2011, 04:59 PM   #180 (permalink)
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After deciding on the location of the front components, I got buy building.
I want a single bar across the front for the shocks and so I bent up this jewel.



And when I test fit it, I nailed it the first try. Then I marked to cut the ends and took it down about 3/4” too short. I tried to fix it but ended up remaking it.
So here is the second one I made, and the start of the bracing for it.





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Old 03-09-2011, 08:23 PM   #181 (permalink)
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Damn nice rig. Keep it up, I want to see it on the rocks!
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Old 03-09-2011, 11:05 PM   #182 (permalink)
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Not done yet.

whats with the china tools



Just jokin weve all got em. Keep pluggin away its coming along nicely.
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Old 03-10-2011, 03:36 PM   #183 (permalink)
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I went and picked up an XJ rad.
I think it will fit the bill.
I was thinking 3 smallish electric fans.



Then I started making the rest of the CO bracing.



Then I burned it all together.



Still got more bracing to go.
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Old 03-11-2011, 02:44 PM   #184 (permalink)
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Before I finish bracing the front, I needed to get the steering valve mounted because the bracing will go around and protect the valve.
So I needed this.



To couple to this.



The coupler on the Charlyn valve is made to mate to the OEM TJ shaft, so all I needed to do was shorten it.



I spaced this end up some to make it as short as possible.



And just cut this end off where the pinch comes together.



All cleaned up.



Done.



Painted with the notch for locking with the bolt.

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Old 03-11-2011, 02:45 PM   #185 (permalink)
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Then I started on the mount. This is what I came up with.



Fits like this.



Welded in.



I had to make a little notch to clear the valve mounting bolt.

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Old 03-12-2011, 07:00 PM   #186 (permalink)
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good job man, the tube work up front looks solid
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Old 03-15-2011, 03:41 PM   #187 (permalink)
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I believe I am going to have to tear the knuckles of this axle apart and do a fix on the king pins.

Some research tells me the bushing coming out like this will cause a failure.

See how the under side of the joint is flush.



And this one isn’t.




Any way, I will do that when I am done with the build.
So I finished up the bracing for the front.

Driver’s side had to go around the steering valve.







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Old 03-15-2011, 03:42 PM   #188 (permalink)
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Then I had to deal with some braces that were not used any more.
They were cut off like this.



And ended up like this.



So I could do this.





Started painting it and ran out of flat black rattle can stuff so I stopped.



Started on the other side.









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Old 03-16-2011, 03:32 PM   #189 (permalink)
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Got going on the CO brackets.
After cutting them out of .25” plate I profiled them.



Ended up with these.



Here is a trick I learned on PBB.
To easily find the center on a home made bracket, use a washer.



Another is; to make clean bolt hole in your cardboard mock up, if you don’t have a punch, or don’t have the right size, use a spent cartridge.



I welded the bottom ones onto the inner knuckles.





I boxed in some for strength.



I got one, top side done before I ran out of time.



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Old 03-17-2011, 02:31 PM   #190 (permalink)
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Finished up the welding on the upper mounts and some boxing in.





Covered it all in some flat black.







Then I started figuring out how to mount the grill and new rad. I had to make sure I had enough clearance at the tire when stuffed and turned so I did just that.



Since the grill fits I am going to install the new rad into it and then fit it into the tubing.
It looks like it will be a perfect fit.



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Old 03-19-2011, 05:02 PM   #191 (permalink)
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I worked on the grill some.

Cut it up to fit the rad.



It was already kinda cut up, but not much left now.



Then I fit it and marked to shorten it.



Chopped some out and started prepping it.



I will put it back together later.

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Old 03-22-2011, 11:42 AM   #192 (permalink)
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I got the grill finished up. The front came out pretty good if I do say so my self (I am no body man).









My wife helped me cut out a pic of Scooby and I spray painted it on the rad.



Then I made these big holes in my hood.

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Old 03-22-2011, 11:43 AM   #193 (permalink)
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And because of reworking the rad core support, there is no room for the safety latch in the center so I made this center pin.
Cut off, drilled, and turned a bolt. Then just welded it on.





And I made some brackets to mount the grill.



Then I started on the winch mount.



Some test fitting.

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Old 03-22-2011, 07:22 PM   #194 (permalink)
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hey man its Jeremy. jeeps looking good. what size tube are you using?
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Old 03-23-2011, 10:40 AM   #195 (permalink)
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hey man its Jeremy. jeeps looking good. what size tube are you using?
what's up Jeremy?
I am using 1.5" OD x 1.20" wall DOM throughout.
and thanks.


Cutting, bending, notching, grinding, and fitting the winch mount.



The pieces donít exactly line up in these picís, but they will after I hit them with a flapper wheel. I was real particular about the notch tolerances because this part takes to much force.





The winch will straddle this and the center part will be open to use as a suck down.



I havenít ever needed a stinger and since the approach is so much better now, I donít see needing one in the future, so I am not adding one. I will be protecting the winch more though.

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Old 03-23-2011, 08:37 PM   #196 (permalink)
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tubing is turning out nice. i decided to keep all that flatty stuff and going to build a lil buggy out of it. since i already had the 4.3 and adapter to a yota tcase. picked up a set of yota axles and some 37" stickies for it this week. when i get around to the cage part of it, you wanna help me bend some pipe up for it(im needing a bender and a good hand to help show me some tricks on bending it).....
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Old 03-24-2011, 10:55 AM   #197 (permalink)
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Thank you.
Its good about the flatty, I decided to only use the sides and cowl.
Sure I could show you the limited bender tech that I know, prolly be pretty busy for a while though.
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Old 03-25-2011, 09:52 AM   #198 (permalink)
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Welded up the frame and started on the plate.



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Old 03-26-2011, 01:14 PM   #199 (permalink)
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Thank you.
Its good about the flatty, I decided to only use the sides and cowl.
Sure I could show you the limited bender tech that I know, prolly be pretty busy for a while though.



im in no hurry, still got the steering to finish up on the yota then the flatty starts. but i still will have a bunch of lil things i can do to it before i can start on the cage. going to try and make the cage the last thing i need to do, other than brakes.
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Old 03-30-2011, 12:26 PM   #200 (permalink)
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I got the winch mount done and painted.













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