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Topic Review (Newest First)
07-26-2015 11:31 PM
Diablo169 ^Will do, that is always a nice local maiden voyage. Hopefully I can get her smogged. Last time Hollister wouldn't let me in because I didn't have a current sticker
07-26-2015 10:22 PM
vova Looks like it's coming along nicely! Let me know when if you do a Hollister shakedown run.
07-26-2015 12:17 AM
Diablo169 ^ Yeah, I'm all about saving weight, now. After weighing some of the major components, I'll be lucky to be under 5,500 empty
07-25-2015 11:53 PM
Originally Posted by Diablo169 View Post
I used a mixture of 2", 1 1/4" and 1/2" .120 Flat Bar.
Trying to keep it under 6k?
07-25-2015 10:01 PM
Diablo169 Well its been a shitshow of production, well maybe a tornado of production. I've made a massive mess of my shop. Metal shavings, Jeep parts and tools, make it nearly impossible to navigate through. The cords, hoses and cables are like a damn snake orgy. But I'm finishing up a lot of stuff, not really picture worthy, but lots of little stuff like tabs, plating, caping and finish welding. I also have a few other things 1/2 done. I'll update tomorrow if I make any more progress.

I decided rather than get it running to pull the engine. I'm glad I did because there is a lot that needs to be done that I couldn't get to with the engine in place.

As I pulled everything I decided to weigh it. Pretty interesting what things actually weight.

Skidplate: 65lbs
Atlas II: 105lbs
NV3550: 110lbs
4.0 with intake, two cats, flywheel and clutch: 542lbs

Getting roomy in there.

Here is what I'm doing for the corners of the cowl. I gave up, I'm welding the corners on solid. I used a mixture of 2", 1 1/4" and 1/2" .120 Flat Bar. Worked well to match the shape of the hood. Went very fast as well. Once it's all welded up I'll use my massive 4.2HP 7" DeWalt grider to smooth it out

07-25-2015 10:00 PM
Originally Posted by stan o View Post
Man, stuff is getting done and looking nice in the process. Keep your head down and you'll be done before you know it!!
That's good advice. I'm trying to just keep busy, and not stop and think, just work!
07-13-2015 07:09 PM
stan o Man, stuff is getting done and looking nice in the process. Keep your head down and you'll be done before you know it!!
07-12-2015 10:10 PM
Diablo169 Cargo area is pretty much complete. Tabs are welded and drilled for 3/8" Bolts. I just need some aluminum for the bottom and then its done.

3 major things left; Cowl, Bumper, Engine / Trans Skid Plate. Then finish up the small things and it should be ready for paint and to finalize plumbing

Fuel Cell mounted finally. I used 1/8"x2" flat bar. I might add some 1" speed holes, but didn't feel like it today.


07-12-2015 06:05 PM
Diablo169 Yeah, 80 Proof got a new garage buddy. I traded the Black R/T in for a 15' SRT I would of tried selling it, but I didn't want to deal with the Bay Area clientele that would be into a blacked out Challenger. I thought 24k was good trade in, seeing local dealers offered me 19k. The dealer turned around and sold it in 4 days for 36.6 Buyer added leather seats and nav

I need a good car cover ASAP! I'm looking at California Car Cover, they have a cover that has a special dust layer that blocks out very fine particles, and has a fleece lining, but it's almost $300!

07-12-2015 05:26 PM
over's tj The Challenger is blushing..??
07-11-2015 09:07 PM
Originally Posted by gtxracer View Post
Yup, run it. Looking good, hopefully you can finish it up in next 8 weeks
Thanks, I'm hoping 4 weeks tops!

I've been working on finishing minor things, problem is I keep running out of material. I ran out of aluminum, body tabs, 1/8" Flat Bar, so everything is half done!

I sat it down at full bump to make it easier to work on the body tabs and lay out the plumbing and electrical. It looked pretty cool at full bump so I snapped some pics.

Everything clears nicely

These are the Ballistic Fab Tabs I'm using for the body panels, I think I used to many, but I wasn't sure how much support 1/8" Lexan needs. The side and rear cargo area used 38 per side yeah I ran out and need to order more. I still need to add tabs for the fender liners, roof and windshield.
07-11-2015 10:14 AM
gtxracer Yup, run it. Looking good, hopefully you can finish it up in next 8 weeks
07-06-2015 10:17 PM
Diablo169 Well, I ground down and rewelded my front lower links, and I warped the $hit out of them. I had to use my 24" Crescent Wrench to get enough leverage to run the tap through them, but I guess that means I burned them in hot

I also fully welded the Front Upper Link Bracket. I think it will survive?

07-04-2015 02:46 PM
Diablo169 You guys are both dicks I'm hoping to have it running soon. Chassis is almost done.

Happy 4th, I'm off to go party with a bunch of single moms form my daughters Pre School... Hopefully wifey doesn't read that, but she's the one making me go.

I just placed an order for a bunch of bolts from McMasterCarr, I also ordered some hood pins, so I can get the hood finalized. I received my UHMW panel so now I can finish the passenger side rock slider.

More boring floor pics. Floor is almost 100%

These Alu Angle brackets make it nice and clean to attach the panels. I drilled and tapped the frame to 1/4-20 because I wasn't able to get the rivnut tool in there.

Cab rear panel.

Center panel installed.

Front Bump Stop Brackets almost done.

I did have one rivnut fail, but it was kind of my fault. I kind of welded the bolt to the nut When I tried unscrewing it, the bolt snapped. One of the reasons I'll be using Grade 8 Bolts.
07-04-2015 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?
07-03-2015 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.
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