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Topic Review (Newest First)
Today 08:45 AM
Originally Posted by Diablo169 View Post
^ You're a dick, it's only been a little over 5 1/2 years
You mean 5 years 8 months

Think it will be ready for pismo this year?
Yesterday 01:48 PM
Diablo169 ^ You're a dick, it's only been a little over 5 1/2 years
06-30-2015 03:02 PM
Originally Posted by sleepsontoilet View Post
That's pretty darn clean imo, wanna do mine after the motor swap?
Do you have 6 years to wait?
06-30-2015 02:10 PM
sleepsontoilet That's pretty darn clean imo, wanna do mine after the motor swap?
06-29-2015 10:27 PM
Diablo169 Update 2:

I was worried about my rivnuts, so I did some destructive testing. My main concern was them spinning in place. In theory the tighter you tighten the bolt, the tighter the crimp gets. None the less I wanted to test their strength.

I used a 1/4-20 Grade 5 and Grade 8 bolts.

On the left, Grade 5 snapped at about 20-25lbs, yet I was able to untread the broken piece by hand. The rivnut did not slip at all.

On the right the Grade 8 bolt survived and pulled the threads out of the rivnut. Note though, it was so strong I actually slipped a gear on my 3/8" Craftsman Ratchet Wrench! I had to switch to my 1/2" drive and even then I had to crank on it in order to strip the threads Even with the threads stripped I was still able to back out the bolt, and then reinstall it with enough torque to secure the panel again.
Pretty impressive!

06-29-2015 10:27 PM
Diablo169 Update 1:

Still working on the floor, pretty much done now.

Sorry if I'm boring everyone, but it seems that most builds skip over the flooring, so maybe I can help someone learn what not to do

I had some 1/16" x 3/4 Aluminum Angle Stock laying around (Yes, I had to look up what it was called, I almost called it Aluminum Angle Iron), and it came in pretty handy for making 90* angles with the flooring. At $7.99 for 4' it was a pretty cheap solution from having to weld up a bunch of additional tabs, basically I can attach panel to panel

Here you can see the Angle Stock is attached to the same mounting bolts as the floor panel, and then I added rivnuts to the sides so that a panel can be mounted.

And Panel attached. Floor is not water tight, but it's tight enough that a 1/4" washer won't fall through.

Underneath looking at one of the 90* corners.

This is the storage area I was trying to create next to the seat. It will come in handy for tow straps, gloves, but most likely empties When the UHMW rockers are installed it is almost water tight.
06-27-2015 10:32 PM
Originally Posted by spyder05 View Post
that came out awesome...been following along silently since the beginning. keep up the good work and get this thing done...I wanna see it on the trail
Thanks man, I'm pushing, I don't want to miss wheeling season.

On a side note, next time I design a floor, it's going to be flat. There is way to many pieces!

No pics, but only two pieces left! Then its on to the cowl
06-26-2015 12:59 PM
spyder05 that came out awesome...been following along silently since the beginning. keep up the good work and get this thing done...I wanna see it on the trail
06-25-2015 11:32 PM
Diablo169 Well not much to update. Just trying to get the floor done. It's a slow process of making tabs and fitting the panels. It's moving along pretty well.

Here is an example of a tab with the rivnuts, and the rivnut gun in the background. Rivnut tool works awesome $65 Amazon Amazon.com: Astro Pneumatic Tool 1442 13" Nut/Thread Hand Riveter Kit: Automotive

Made a ton of these. Tabs were .25 a piece from A&A manufacturing, rivnuts were $16 for 100.

Seats dip down a little so the panels under the seats needed to be mounted below the tubing.

Plenty of leg room.

Getting there.
06-10-2015 11:14 PM
Diablo169 I fitted quite a few pieces tonight. I'm starting to get the hang of it. Not looking forward to installing the mounting tabs.

I bent the passenger floor plates so that they will bolt to the firewall plate to help seal it up a little better.

I think I have a good plan for the back half of the floor.
06-10-2015 11:39 AM
Diablo169 ^My main concern with the cowl is I don't want water dripping on my feet when it rains.

I don't have to much to update. I have about 5 pieces of the floor that I need to get new Jig Saw blades in order to trim them to properly fit.

I did get the upper tunnel cover piece cut and bent up. I don't know what grade aluminum I got, but it is incredible hard to bend. I tried using my HF bender to bend a 27" piece, and no way, I even tried heat, wouldn't budge I've never really worked with aluminum before. I picked up my sheets as scrap at the local Sims Metal, so I have no idea what type it is.

Paper Template.

Finished piece after some major trimming. The aluminum did not bend nice like the steel. Hopefully tonight I can get the other pieces I have cut, fitted and taped into place.
06-04-2015 10:39 AM
FordFascist Agreed. Fiberglass is way more effort than required.
06-04-2015 08:23 AM
MtnYota I have an idea on the cowl, forget fiberglass...ask Jeff.
06-03-2015 10:06 PM
Diablo169 ^ Thanks!

Originally Posted by Tazer15 View Post
I was going to buy those shears and that brake but I got a bunch of 16ga almost givin to me cheap.Both say their rated to 18ga worried 16 be too much
The shears I got are good to 14ga!
14 gauge 4 Amp Heavy Duty Metal Shears

The Brake says it's good to 17ga steel, which is about what I have.
30 in. Bending Brake

Both are working great. I finished the passenger side in about 30min.

I think I'm going to leave them tacked in. They are the only solid mounted panels, and I can easily get to everything with them in place.

If anything I might make this piece removable for easy drive-shaft and shifter access.

I still have no idea what to do with the Cowl I might look into fiberglassing. It's a weird shape where a TJ or aftermarket Cowl will not fit.
06-03-2015 08:24 PM
Dan K Great build and nice work!
06-03-2015 07:51 PM
MichaelMaxim Gotta love Harbor Freight. I think Jeep owners keep them in business. :-)
06-03-2015 06:02 PM
Diablo169 Thanks all.

I was planning on it being removable, but I didn't really see where I would need it to be. The top of the tunnel and the floor is going to all be removable aluminum. The only thing I was thinking was to maybe make one of the panels that I just installed removable so that I can easily get to the drive-shaft and shift levers.

I'll think about it, I would only have to remove a few spot tacs to remove the panel in one piece, add some tabs and then bolt it in.
06-03-2015 07:06 AM
tjjared413 Good trick on the floor I use full sheets and it was not that much fun!

X2 on not making it removal?
06-03-2015 06:10 AM
Tazer15 I was going to buy those shears and that brake but I got a bunch of 16ga almost givin to me cheap.Both say their rated to 18ga worried 16 be too much
06-03-2015 06:02 AM
vogelj That floor trick is super impressive! It coming out really good. Are you concerned about not making it removable?
06-03-2015 05:00 AM
hitman_1b Been following along and is coming out great! Floor is taking shape nicely
06-02-2015 10:40 PM
Diablo169 Update 2:

Well I ran out of things to work on to avoid the floor, so I figured I'd try to get something done. Honestly, it was one of the more fun things I've done on the Jeep in a long time. It was really easy and went very fast.

A few weeks ago I was talking to MtnYota about the floor and he mentioned cutting a bunch of strips of paper and taping then on the seams. It worked flawlessly, every piece fit about 95% and just needed a little massaging from a flapdisc. For the tunnel I used 1/8" plate, just kidding, sheet metal measured out to 17ga.

The first one, I cut the strips a little wide. By the end I cut them to around 1/2" wide. I used heavy construction paper. I basically did single bend pieces, I probably could of done two bends, but it was my first sheet metal project since High School. The 3/8" rod made it easy to shape the pieces.

Then I trimmed my template and traced it onto the sheet metal. The $44 Harbor Freight Sheers made incredibly nice straight lines with no deformation.

Then it was over to the $30 Harbor Freight Mini Brake to add the bend. For $30 it was worth it.

The piece fit perfect. Then it was time to shape out the next piece.

I still need to fully Tac it in, and then I'll seal it up with some seam sealer.

06-02-2015 10:39 PM
Diablo169 Update 1:

I got the grill mounted. It came out really solid. I used some 1/8" plate and lightened it up with some speed holes

Some new metric hardware

I also purchased new longer rear wheel studs. I thought I would be ok running Steel wheels, but the 3/8" centers are pretty thick. I did read on another thread that the countersink on the TWF beadlocks sometimes isn't deep enough. I forgot to check my wheels out, but either way I got 16 Dorman 610.194.1 studs shipped from autoplicity for $56, cheapest I could find.

05-26-2015 08:03 AM
Diablo169 I didn't get to much done this weekend, but I did make some progress on the front end. I have not started on the floor yet, I figure I'd get the cage completed first. I did buy the 14ga Sheer and 30" Brake, so I'll have the tools when I get around to it.

Its getting roomy up there! I finish welded most of the front, and added two fender/ shock hoop support bars. I also removed the Bumper Plate. I realized I didn't leave myself enough room to get to the winch mounting bolts, so I'm going to have to make something removable. I'll worry about that later though. Surprisingly the Grill Assembly weighs in at 48.6lbs!

I also trimmed the hood to fit.

I've been using a digital Crane Scale to see what various items weigh. Wheels and tires came it right where I figured they would, 200lbs! That's 800lbs of tires! I think I'll leave the spare at home.

Note to self, Mobile Imgur is aweful!
05-19-2015 09:54 PM
Originally Posted by MichaelMaxim View Post
What's your frame rail height off the ground. Is it sitting at ride height now?
Right now it is nowhere near ride height. Rear is 2" low, and front is like 5" too high. I haven't really decided how I'm going to have it sit. I'm thinking 7" up travel in front and maybe 5.5" in the rear to give it that BroCal fast look.

Originally Posted by tjjared413 View Post
this is where i had the same issue! keep at it and it will all work out!
Thanks A little here, a little there, as long as I keep moving forward.
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