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Old 04-21-2011, 08:16 AM   #1 (permalink)
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Project: Spare Parts and Scrap Metal

Like so many others I have an abundance of spare parts laying around my yard, shop, storage buildings, and many other places. Due to a slow down in my research and my impending graduation I decided it was time to do something or haul everything to the scrap yard. Prices are up you know. This build is hopefully going to be something different. I am going to be learning a lot along the way and hope to share some trials and tribulations with everyone.



Many didn't know this even existed, but this 2A body has been sitting next to my shop since about 2 days after I closed on my house. Before that it was in the back of my storage building in Raleigh, NC. The tub, hood, and grill were aquired by me from a guy in Winston Salem many moons ago. I had big dreams of a 2A buggy, but I already had way to many projects. Still, I am a dreamer so I bought the pile of rust and put it away for a day like today.

The idea of this project is that I, like most of my friends, have way to many parts laying around that would likely never find their way back onto a rig as my wheeling style has degraded to big tires and even bigger motors. We shuffle the parts around the yard to mow the grass, around the shop to make room for other projects, tools, or anything else that is shiney and catches our eye. This is going to be a project in which the design decisions are made by what parts are free/available/super cheap. The "body" is a perfect fit. I use body loosely as it has seen many better days.



Needless to say there is a lot of surgery in this things near future.
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Old 04-21-2011, 08:18 AM   #2 (permalink)
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I am not sure how many of you I have met, but I am 6'5" tall, 250lbs. So not a small guy by any measureing system metric or ISO. Even still I think the 2A is just to big for what I have in my mind. Just to make sure I rolled a set of 33's up to it in order to get an idea on size.



Those tires just aren't big enough so I am going to have to go with the 35's that are left over from the old ECORs XJ. Sure they are cut, shreaded, bald, and dry rotted. But they are mounted and stacked neatly under a tarp in my yard. Free... They will work for now.

The rest of the plan is as follows.

old 4.0L from my buggy. I know it works on the rev limiter and is a solid motor.
ax15 also from my buggy. Again, it takes the abuse and is just lieing there anyway.
dana300 or a NP231. Not sure, I don't have a complete one of either so it depends on what I find
Axles, are 44's front and rear from a waggy I parted out many many years ago, about two weeks after I bought this tub.
tires 35's
3 inch YJ lift springs
XJ driveshafts

As many of the parts will be fabricated in house as possible. The rest will come from a scrap pile, and if that doesn't work I will break down and buy them from someone. I have to justify all the money I spent in the last couple months on tools somehow.
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Old 04-21-2011, 08:20 AM   #3 (permalink)
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The first order of business is to get some solid metal somewhere on the tub to work with. The tub will be shortened approximately 22 inches to get it where I want it. Yes, trying for a clown car.

I would say around 80% of this tub is shot. I will keep about 40% of the firewall, the cowl, and a little of the door openings. The rest is swiss cheese or close enough to get rid of. Now I have a bender, but I don't have a bunch of dies. The new body will be built from 3/4" square tube, 1x3 rectangle tube, and some sheetmetal. To simulate the rear corners I need a way to bend the 3/4 to match the existing rounded corner. Like I said, I don't have the dies, but I do have tools and scrap metal.



I bolted down 2 pieces of 1/2" thick aluminum on my new mill and rotary table. (see comment about dumping money on tools) The local scrap yard has a bunch of these 7 7/8" diameter aluminum pieces so I grabbed a handfull when making my cnc table.(more dumped money).

I am not a trained machine operater, so I hack my way around and finally after some cussing, readjustment, and more cussing I had two halves of a die.



These two parts are not anywhere near perfect. They are only the second set of parts I have cut on the mill and the first ever on a rotary table. They do assemble to make a 3/4 square tube die for my JD2 bender though.



Like any square tube dies, there is some deformation in the bend. Overall I am happy though as the center line radius is really close to the tub and they work.



This catches us up from yesterday and today. Now I am back at school trying to finish up the dissertation so I can hopefully get the heck out of here. I should be back on this tomorrow afternoon. The goal before the end of the weekend is to wrap up the body metalwork so I can start on the frame.
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Old 04-21-2011, 08:21 AM   #4 (permalink)
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I got a chance to work on it some more today. I now remember why I built a cnc table. I can't cut a straight line with a guide with the plasma cutter. I still need to remove some more metal, but I got the basic shape of the body I plan to keep.



There isn't much left. I plan on taking the rest to the scrap yard and trading for some more metal. Like I said, I plan on shortening the body 22 inches. This is just about perfect.



Ready to load up and scrap. Won't bring much money, but it should buy a stick or two of square tube.

From here I started to actually build instead of destroy. The plan is to build a metal frame to attach what is left of the body to, and also wrap with sheetmetal.


This is the bulk of the frame minus the mounts to attach the body, some triangulation in the floor, and the tunnel. I ran out of 3/4 box so I picked some up this morning along with the metal to build the frame.
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Old 04-21-2011, 12:14 PM   #5 (permalink)
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If you ditch that much of the tub... what are you building? A wheelbarrow? sorry, bad joke.
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Old 04-21-2011, 11:21 PM   #6 (permalink)
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I am actually working on the next clown car for the circus. I am finishing school in a couple weeks and trying out new career paths. Really, I am just having fun with a bunch of parts that aren't worth crap to me anyway. This build is all about fun, friends, and playing with all the tools that I have wasted money on.

Tonight a buddy of mine, Evan came over and helped out for a while. We got the new metal frame connected to the body.



It is perfect. I couldn't have asked for any better. The end result was a 21.75 inch chop of the body. There is still more structure to add, but I will wait until it is mounted to the frame to worry about it. I don't want to put something in the wrong place. I am shooting from the hip on this one and running without a plan or real design. This is pretty new for me.

After the body got a little structure back, it was time to work on the actual frame for the thing. I have always wanted to try a double stack tube frame so this is a perfect opportunity. What I didn't think about is how much time I would spend notching all the little spacers. Luckily the trusty bridge came in handy again. (I love this thing and see many sleepless nights in my future)



This is the quick notching setup. A hole saw, chucked up in the collet and a piece of tube used to fixture everything so that all the spacers come out the same size. I spent way to much time doing this, but it will be worth it as all the notches will be perfect in the frame due to the added effort. To be completely honest, I think this took less time than notching by hand but it was really teadious. After over 30 notches the hole saw is missing a couple teeth, but it still cuts great. Up next is a little bending and then some welding to assemble the frame. Then I get to design some spring hangers and play with the cnc table. It will be a fun change of pace from the manual machining.

edit: if you try to notch like this, put the cut right next to the vise. This had a lot of chatter and had to be adjusted.

Last edited by DownNDirty; 05-02-2011 at 08:29 AM.
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Old 04-22-2011, 05:40 PM   #7 (permalink)
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parts

before you scrap the back of the tub..cut out the front face of the toolbox where the jeep stamp is....
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Old 04-22-2011, 05:49 PM   #8 (permalink)
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It is already cut out. Just trying to figure out where to put it. It was actually a little surprise. I didn't even know it was there until I seperated the two pieces.
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Old 05-02-2011, 08:27 AM   #9 (permalink)
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I am trying to be better about updating. I got a new camera last week, but I forgot the batteries so once I get some the picture quality will improve. In the meantime I have been working on it. The frame is tacked together. The axles are sort of in place. Free springs don't always include the bushings, so I need to order a ton of bushings.



I got the 4.0L, ax15, and NP231 installed over the weekend. I went to a you pull junkyard and found a 23 spline 231 on the ground that was already pulled so I picked it up. I also managed to find some monster lift shackles that I will be cutting down to work with my setup. The are 6" now and I will probably shorten them to around 4.5".



you can see that the hood will have to be stretched a couple inches. Shouldn't be able to notice once it is finished since the fenders will be custom built to match.



Here it is with the bed tilted up. I still need to build the mechanism to lift the bed. I am inbetween a hydraulic dump and a manual dump right now. The manual dump will be much cheaper, but not nearly as cool. The body is also on body mounts and bolted down. I have to pick up some more square tube for the fenders and sheetmetal for the floors. Then I should be ready to wrap up the metal work and get it to paint.
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Old 05-02-2011, 01:54 PM   #10 (permalink)
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Had this saved in my favorites. I plan on making defrosters like his.
http://whatareyouworkinon.com/conten...ys-cj2a-pickup
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Old 05-03-2011, 07:13 AM   #11 (permalink)
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Quote:
Originally Posted by 1946CJ2 View Post
Had this saved in my favorites. I plan on making defrosters like his.
http://whatareyouworkinon.com/conten...ys-cj2a-pickup
That thing is awsome. Needless to say, I don't think I will be even close to his build in both quality and price. I would love to build it that nice, but I have way to many other projects that I want to do. I might steal that bench seat idea though. I can't decide between a bench or two seats.
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Old 07-27-2011, 04:09 PM   #12 (permalink)
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Any progress? Ive been watching my bookmarks to see what happens with this. I'd love to jump into a build like this some day.
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Old 07-28-2011, 06:57 AM   #13 (permalink)
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Yea, I just got a new camera last week so I will have to put up some new pictures. My momentum has slowed as now I am hunting work, but projects like this keep me going.
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