57/53 Willys Wagon Build, Need help from Hardcore TJ folks - Pirate4x4.Com : 4x4 and Off-Road Forum

dimmwatt · 02-07-2009, 04:49 PM

I have poked around Pirate for a little while and some of you may have hopped on over to my Cardomain page where I have been documenting the build.

More here;

http://www.cardomain.com/ride/2415963

I'm at a point where I need to make some decisions on designing a few things and figured I need Hardcore experiance. Midnightburns build has been a help in some areas, but we dont have all the same issues because I started with a Rubicon driveline and frame.

The overall final use of this rig will be an expedition/camping rig/daily driver. It wont have more than a 2 inch lift on 32-33's, will have adjustable short arms all around (needs it because frame isnt perfect...stretched...F'd up alignment)

It will have a reciver built into both bumpers that will cary a single winch and a 30 + gallon tank, 2 big gel cells, on board air, everything cool that comes on a Rubicon.

2 areas I need help with

1. Flat Belly. I have a Teraflex Bellyup, but want to build my own that will be higher and incorporate boat sides, engine skid and sliders in the skid. Please post pics of yours if you built one. Looking for ideas
Q1- if you raise the belly to be level with the lowest part of the TJ frame, (approx 4 inches) how far does the engine need to be raised? The Belly up kit only raises the engine 1/4" or so.
Q2- Whats your feeling on alluminum skid? I was planning on building framing from square steel tube to mount the trans to and carry the weight of a hard hit, then skin the underside with a fairly thin sheet of aluminum to keep weight down. The framing will extend to the outer edges to act as sliders/boatsides. Not true boatsides at a 45, but just enough angle to go from the bottom of the frame to the bodys edge.

2. Tank construction. If you check out the last pages of my cardomain site you can see what mods I made to the TJ frame. The tank hangs WAY too low for my tastes and there is tons of room on the sides and behind the tank to expand. Based on the area available, I can get over 30Gal easy. I want to build the tank for a reasonable price but will spend as much as it takes to ensure a reliable rig. Weight is another concearn. My thought was to build a heavy skid out of 3/16 plate then fill the void with an aluminum tank This is a heavy and expensive option though.
Maybe I should continue the theme of steel angle iron framing and alluminum plating??? Not sure if it will take the hit though??? That area will be heavy with fuel and take the most off road abuse. Has anybody tried this method?

All help is appreciated. Thanks, Casey

Magnum_Willys · 02-07-2009, 06:03 PM

You might check out http://www.mtscompany.com/ for their polyurethane tanks. On my 52 Willys PU I run a 35 gal Poly tank mid-frame ( out of a Ford Van) and a 14 gal. poly tank behind the axle ( CJ-7). You don't have this kind of room on the wagon but worth looking into. Though the Poly tanks are 1/4 inch thick I run a 3/8" aluminum skid plate under them ( a little thick but I had it handy )

dimmwatt · 02-07-2009, 06:33 PM

There isnt much room between the frame rail and the drive shaft on the driver side. There might be just over 1 cubic foot. 10 galons maybe?? I dont think that small of a tank justifies the complexity of 2 tanks. I was planning on putting the air compressor and tank in that spot anyway.

Those Poly tanks are a great idea if I can find one that fits the hole. Its not a square hole though. Have you seen the shape of a TJ tank? The front is pointed to fit into the cross member. Next time I'm working on the Willys I'll take some measurements and look at those again. Maybe I'll fab a cardboard version of what I want too.

So you dont see any problem with Alluminum skids? You said 3/16 was thick, Think I could get away with 1/8? Granted it would depend on the steel structure behind it...

Magnum_Willys · 02-07-2009, 07:27 PM

Quote:

Originally Posted by dimmwatt

Think I could get away with 1/8? Granted it would depend on the steel structure behind it...

I think my 3/8 is overkill... The poly tanks will take a beating if not cut so if you don't puncture the skid plate you will be ok. I wouldn't go less than 1/4" in aluminum myself, but if you are not rock crawling 1/8 aluminum would probably be fine.

dimmwatt · 02-09-2009, 09:53 PM

Thanks Magnum That helps with the tank.

Anybody got pics of their TJ with a home brew flat belly?

Additional pics/ideas of home brew tanks welcome too.

02-07-2009, 04:49 PM	#1 (permalink)
dimmwatt Registered User Join Date: Jan 2008 Member # 106465 Posts: 80	57/53 Willys Wagon Build, Need help from Hardcore TJ folks I have poked around Pirate for a little while and some of you may have hopped on over to my Cardomain page where I have been documenting the build. More here; http://www.cardomain.com/ride/2415963 I'm at a point where I need to make some decisions on designing a few things and figured I need Hardcore experiance. Midnightburns build has been a help in some areas, but we dont have all the same issues because I started with a Rubicon driveline and frame. The overall final use of this rig will be an expedition/camping rig/daily driver. It wont have more than a 2 inch lift on 32-33's, will have adjustable short arms all around (needs it because frame isnt perfect...stretched...F'd up alignment) It will have a reciver built into both bumpers that will cary a single winch and a 30 + gallon tank, 2 big gel cells, on board air, everything cool that comes on a Rubicon. 2 areas I need help with 1. Flat Belly. I have a Teraflex Bellyup, but want to build my own that will be higher and incorporate boat sides, engine skid and sliders in the skid. Please post pics of yours if you built one. Looking for ideas Q1- if you raise the belly to be level with the lowest part of the TJ frame, (approx 4 inches) how far does the engine need to be raised? The Belly up kit only raises the engine 1/4" or so. Q2- Whats your feeling on alluminum skid? I was planning on building framing from square steel tube to mount the trans to and carry the weight of a hard hit, then skin the underside with a fairly thin sheet of aluminum to keep weight down. The framing will extend to the outer edges to act as sliders/boatsides. Not true boatsides at a 45, but just enough angle to go from the bottom of the frame to the bodys edge. 2. Tank construction. If you check out the last pages of my cardomain site you can see what mods I made to the TJ frame. The tank hangs WAY too low for my tastes and there is tons of room on the sides and behind the tank to expand. Based on the area available, I can get over 30Gal easy. I want to build the tank for a reasonable price but will spend as much as it takes to ensure a reliable rig. Weight is another concearn. My thought was to build a heavy skid out of 3/16 plate then fill the void with an aluminum tank This is a heavy and expensive option though. Maybe I should continue the theme of steel angle iron framing and alluminum plating??? Not sure if it will take the hit though??? That area will be heavy with fuel and take the most off road abuse. Has anybody tried this method? All help is appreciated. Thanks, Casey

02-07-2009, 06:03 PM	#2 (permalink)
Magnum_Willys Registered User Join Date: Dec 2003 Member # 25643 Location: Longview, WA Posts: 797	You might check out http://www.mtscompany.com/ for their polyurethane tanks. On my 52 Willys PU I run a 35 gal Poly tank mid-frame ( out of a Ford Van) and a 14 gal. poly tank behind the axle ( CJ-7). You don't have this kind of room on the wagon but worth looking into. Though the Poly tanks are 1/4 inch thick I run a 3/8" aluminum skid plate under them ( a little thick but I had it handy ) __________________ [url]www.RainierVisitorGuide.com[/url] [url]www.MountStHelens.com/offroad.html[/url] 51 Willys PU, 502 Chev, 60/80, Alloy/CTM, Hydroboost, 44" Boggers, 205, T400.

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02-07-2009, 06:33 PM	#3 (permalink)
dimmwatt Registered User Join Date: Jan 2008 Member # 106465 Posts: 80	There isnt much room between the frame rail and the drive shaft on the driver side. There might be just over 1 cubic foot. 10 galons maybe?? I dont think that small of a tank justifies the complexity of 2 tanks. I was planning on putting the air compressor and tank in that spot anyway. Those Poly tanks are a great idea if I can find one that fits the hole. Its not a square hole though. Have you seen the shape of a TJ tank? The front is pointed to fit into the cross member. Next time I'm working on the Willys I'll take some measurements and look at those again. Maybe I'll fab a cardboard version of what I want too. So you dont see any problem with Alluminum skids? You said 3/16 was thick, Think I could get away with 1/8? Granted it would depend on the steel structure behind it...

02-09-2009, 09:53 PM	#5 (permalink)
dimmwatt Registered User Join Date: Jan 2008 Member # 106465 Posts: 80	Thanks Magnum That helps with the tank. Anybody got pics of their TJ with a home brew flat belly? Additional pics/ideas of home brew tanks welcome too.