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Old 03-01-2012, 04:40 PM   #26 (permalink)
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got the rear door in and tacked at the top...... I am loving this and anxious to get it done !!







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Old 03-03-2012, 04:05 PM   #27 (permalink)
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nothing special to report ........ just some more welding.

after looking at the bed area ........ I decided to just keep it all together for now.

rear door is welded in ....... and my next phase is to go to tractor supply and get a pair of trailer fenders for the rear.
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Old 03-03-2012, 04:34 PM   #28 (permalink)
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That looks perfect. Going to be nice with the extra cab room
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Old 03-04-2012, 03:56 PM   #29 (permalink)
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I have run into a delima and can't figure out how I want to do this:

I want to stiffen up the walls of the extra cab area so it will not wobble...... I have some ideas:

1- build some rib stiffeners and weld them in
2- cut some thick gauge sheet metal in 3" strips and weld them in running front to back
3- use some 1x1 square tubing cut it to length from front to back

keep in mind that once the inner wall is welded in ..... the stiffeners will not be visable


uhhhggggg..........what to do.....what to do
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Old 03-04-2012, 11:53 PM   #30 (permalink)
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I`d use some 1x1 square
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Old 03-05-2012, 02:38 AM   #31 (permalink)
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Quote:
Originally Posted by ShuDuck View Post
I`d use some 1x1 square
yup..... thats what they are saying elsewhere also....

thanks Shu !!
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Old 03-10-2012, 04:00 PM   #32 (permalink)
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Got some more done today:

started flat fender truck bed & trimmed the front fenders. Liking the way the rear flat fenders are turning out.






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Old 03-11-2012, 07:08 AM   #33 (permalink)
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forgot to mention.......

inside truck bed measures....... 12"H x 36"L x 34.5W
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Old 03-11-2012, 05:20 PM   #34 (permalink)
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Little more done today..... got the bed floor cut away today.


PICS:



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Old 03-13-2012, 12:57 PM   #35 (permalink)
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That looks f-ing sweet! Cant wait to see this thing complete
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Old 03-17-2012, 04:54 PM   #36 (permalink)
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Thanks Buzz !!

Got what I wanted to get done today:

1x1 16 gauge wall tubing for bracing. I moved the triangle plate back and under the flat fender for protection.






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Old 03-22-2012, 04:19 PM   #37 (permalink)
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Looks good. thats a lot of work. How did the roof come out? What are you going to do for a cage? I was not a big fan of exo cages but after all the work on the body of mine it was a must.
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Old 03-24-2012, 02:47 AM   #38 (permalink)
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the roof came out good and I have no plans right now to build a cage.

I decided to cut 2 holes in the extended cab floor for dual battery storage.

got the holes cut and I have one of the boxes built out of 16 gauge sheet metal. I am going to use some 3/4" angle at the top edges so it will allow me to just drop the boxes in and bolt them to the floor.

Got some 30 gauge sheet metal to fill in the side panels on the body and will start that on Monday.


will have some pics Monday......
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Old 03-29-2012, 01:21 PM   #39 (permalink)
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30 gauge?

Seems really thin?

Nice work though!
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Old 03-29-2012, 03:56 PM   #40 (permalink)
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sorry.......I meant to say 20 gauge.
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Old 03-31-2012, 05:59 PM   #41 (permalink)
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Progress













- got the panels welded in
- expanded metal at the rear corners this will give a base for the fiberglass
the expanded metal is welded in on the back side
- holes cut in the floor of the extended cab and I have one of the battery
boxes built and done a test fit......... the bottom of the box is about 1"
from the frame
- got the front inner fenders made up ... I still have a little more to do with
these before they go in.
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Old 03-31-2012, 08:22 PM   #42 (permalink)
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Build looks awesome. gonna be watching the rest of this build for sure.
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Old 03-31-2012, 09:10 PM   #43 (permalink)
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Quote:
Originally Posted by norzuki View Post
Progress













- got the panels welded in
- expanded metal at the rear corners this will give a base for the fiberglass
the expanded metal is welded in on the back side
- holes cut in the floor of the extended cab and I have one of the battery
boxes built and done a test fit......... the bottom of the box is about 1"
from the frame
- got the front inner fenders made up ... I still have a little more to do with
these before they go in.
i dont understand... why would you do all this nice metal work and fiberglass the cab corners? dont sell yourself short... make some real cab corners....

looking really good otherwise.
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Old 04-05-2012, 01:37 AM   #44 (permalink)
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thanks for the comp's guys

got a little more done...... got the driver side fender installed and welded in. I had to trim the fender out to install the FJ-80 steering box. I will be starting on the passenger side fender later today.








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Old 04-07-2012, 12:47 AM   #45 (permalink)
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Passenger side inner fender done ........

next .....

inside wall under the extended cab..... gonna try and build a section on each inner wall to house an 8" speaker on each side









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Old 04-15-2012, 04:47 AM   #46 (permalink)
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Nothing exciting to report guys...........

been doing some fiberglass work and this is still continuing....

the only sheet metal work I have left is putting skins on the outer part of the flat bed tubing and boxing in underneath the rocker panels.

man I have a lot of sanding to do
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Old 04-29-2012, 05:07 PM   #47 (permalink)
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I got the outer sheet metal welded in on the bed. I need to re-do the sheet metal on the tail gate because the sheet metal warped a little and it will not look good with bed liner on it.

I might just do some heavy gauge expanded metal and call it done, but man the frenched licenses plate is going to look good.

I think I have an idea........... cut the 2 sections of sheet metal out on each side and re-weld them back in. I think what happened is when I started welding the whole piece of sheet metal I got it to hot.

I will try and have pics up about mid week.
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Old 05-13-2012, 12:03 PM   #48 (permalink)
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ahhhhh ..... the long awaited progress pics.

it might not look like much, but it took me a while to do what fiberglass work that has been done so far.





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Old 05-13-2012, 04:45 PM   #49 (permalink)
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Very cool...


(How did I miss this build up till now???)
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Old 05-13-2012, 09:24 PM   #50 (permalink)
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lookin real good . man thats a lot of work.
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