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Project FIGJAM

97K views 548 replies 93 participants last post by  SkysTheLimit 
#1 · (Edited)
To start things off lets do a little back story. Bought the jeep back when I was 16 when it was more or less stock other than a tired small block Chev. Over the past 7 1/2 years I slowly built it into a more capable PNW style trail jeep. The last year of jeepin it started to become a bit of a hassle with tons of little things breaking/wearing out and I started to worry almost everytime I was gonna be "that guy". Never in its life having a full tear down, it was starting to show its age and I did my best to keep it together by strapping the frame after it broke, tied cage into frame, redid the suspension, etc. Anyways, here's the old girl.

TBI 350
Dana 44's F/R
t18
4.27's w/lunchbox lockers
Dana 20
Spring under rear with yj's
Spring over front front with toyota rears
Chromoly shafts
Redhead steering box
36 tsl's

[/url]jeep fenders by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20170225_170455782_HDR by Alex Velasquez, on Flickr[/IMG]

[/url]FB_IMG_1491176877168 by Alex Velasquez, on Flickr[/IMG]

Here was its final resting place after cracking bellhousing and fed up with working on old grimy parts.

[/url]IMG_20170830_164249355_HDR by Alex Velasquez, on Flickr[/IMG]
 
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#64 ·
So I kinda lied about update coming soon :flipoff2: Got sidetracked with life which put posting on the back burner. Made some progress with the coilovers, transfercase adapter showed up, messed with the grill a little, pushed motor/trans back, etc. Still slowly chipping away when the funds and time permits.

Rode along last weekend with a buddy to get some much needed motivation and picked his brain on his build.

[/url]IMG_20180331_113050104_HDR by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180331_121526344_HDR by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180331_131022392_HDR by Alex Velasquez, on Flickr[/IMG]

To get an idea for height at full bump its sitting at roughly 39.5".

[/url]IMG_20180323_183405630 by Alex Velasquez, on Flickr[/IMG]

Redid my coilover mounts to fit the Fox's. Still gonna have to clearance the front tube for spring clearance, but for the most part they have found their home.

[/url]IMG_20180324_143246566 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180324_143101546 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180324_144334665_HDR by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180326_155432231 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180326_104244875 by Alex Velasquez, on Flickr[/IMG]
 
#66 ·
Next was to mess with the grill. Ended up taking 3.5" out to get it to fit. Still need to metal finish the corners and what not, but you get the idea.

[/url]IMG_20180324_103641379 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180326_110651807 by Alex Velasquez, on Flickr[/IMG]

Pretty stoked on not having to cut holes in the hood to clear the coilover mounts.

[/url]IMG_20180326_115351653 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180326_130603317 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180326_133656535 by Alex Velasquez, on Flickr[/IMG]

Not much of a grill left, but pretty happy with the outcome. Plan on paneling in an cleaning everything up.

[/url]IMG_20180326_155304277_HDR by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180326_155633685 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180326_155334615 by Alex Velasquez, on Flickr[/IMG]
 
#67 ·
Clearanced the frame rail for the transfercase and went big with plans to most likely run an atlas down the road. Also, need to push everything back but the intake was limiting me so had to make a small hoop. Not my first choice and I'm not even planning to run the stock intake, but I want the option to be able to just in case. Plans are to run the Fitech Ultimate LS kit.

[/url]IMG_20180402_103524362 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180402_143636618 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180402_143544966 by Alex Velasquez, on Flickr[/IMG]
 
#70 ·
Short answer to your question is yes. My dilemma was that everything has been built to that hoop and the amount of effort it would take to raise the 1-1/2" just didn't make sense to me. Definitely not crazy on the aesthetics of what I did, but it will allow me to move forward. Looking at it today, I think I'm gonna ditch what I made and make it wider so it'll terminate at the bracing coming off shock hoops.
 
#71 ·
Ok, thanks. I've got a CJ5 and I'm loving how you're building yours. I'm very much considering copying yours, except also stretching the tub to CJ6 length.
 
#73 ·
Plated in the transfer case pocket and started in on some exhaust ports. Still waiting on front yoke before I can tackle the carrier bearing setup. Trying to stay busy with odds and ends.

[/url]IMG_20180408_133710756 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180408_134708412 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180408_141254829 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180408_141607622 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180408_141636339 by Alex Velasquez, on Flickr[/IMG]

Used some 3-1/2" tube for the exhaust ports

[/url]IMG_20180408_141736168 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180408_143101277 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180408_143252355 by Alex Velasquez, on Flickr[/IMG]
 
#74 ·
Cooked my Dewalt about halfway through so had to go by a new drill that was a little heavier duty and On Sale :D

[/url]IMG_20180408_152441655 by Alex Velasquez, on Flickr[/IMG]

Nothing like a hole saw grabbing every 2 seconds.

[/url]IMG_20180408_175255498 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180408_160543753 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180408_162408778 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180408_162351798 by Alex Velasquez, on Flickr[/IMG]

And random slider shot

[/url]IMG_20180408_160146416 by Alex Velasquez, on Flickr[/IMG]
 
#77 · (Edited)
Indeed.


I'm curious what kind of prep you do on the tubing for such pretty welds. Correct me if I'm wrong, they appear to be MIG welds, but I don't see even the slightest evidence of spatter...anywhere. I'm a decent welder, but I can't ever run that clean. I also haven't ever spent a tremendous amount of time prepping, cleaning the metal beforehand. Is that the secret?

What's your secret?
 
#83 ·
Still waiting on some parts to show up so keeping my hands busy with probably the least important thing possible... A new steering wheel :flipoff2: Made My last one about 3 years ago when bored on Summer vacation from school and was pretty happy with the way it turned out. However, since then I've definitely grown as a "Fabricator" and figured I'd retire the OG wheel as wall art and whip up something new. And just to clear things up, it was made entirely with a step bit and cut-off wheel. Literally about as simple of tools as you can get.

First, here's the Anti-spatter we use at work and its hands down the best I've used.

[/url]IMG_20180413_152241825 by Alex Velasquez, on Flickr[/IMG]

My grandpa was cleaning some stuff out of his garage and came across a sheet of 4130 and asked if I wanted it, that's what sparked the new wheel idea haha

[/url]IMG_20180410_172104238 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180411_120224907 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180411_120154282 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180411_120201100 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180411_120146834 by Alex Velasquez, on Flickr[/IMG]

First pass on the main spokes.

[/url]IMG_20180411_120827325 by Alex Velasquez, on Flickr[/IMG]
 
#84 ·
Trying to get better at a weave so figured why not. Definitely shaky and no "weld porn", but it was worth a shot haha

[/url]IMG_20180411_122148083 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180411_122159601 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180411_122232770 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180411_122215941 by Alex Velasquez, on Flickr[/IMG]

Scotch brite to dull it up and started laying out the slots

[/url]IMG_20180411_164326765 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180411_165322695 by Alex Velasquez, on Flickr[/IMG]

A lot of file and Dremel work

[/url]IMG_20180411_170746298 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180411_173807285 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180411_174126924 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180411_175142706_HDR by Alex Velasquez, on Flickr[/IMG]

Old wheel measured out to 13.50" diameter, while the new one I built to 13.00" even. The new one also was made with more offset to the hub.
 
#92 ·
Spent some time mounting the grill and starting to fit fenders. Plan is to have fenders be a part of the chassis welded to the firewall hoop and some supports off the shock hoops. On my old jeep the fenders and grill hoop/winch mount were all one unit. It worked pretty good, but was kind of a hassle when you need to pull the winch off or even just wanted to remove a fender you had to pull everything off making it a two man job. The plan this time around is to make just the grill hoop removable to made pulling the motor easier in the future.

[/url]IMG_20180416_115740039 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180416_122108099 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180416_130147692 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180416_130213465 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180416_130700872 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180416_133950413_HDR by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180416_140227499_HDR by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180416_165711726 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180416_165739872 by Alex Velasquez, on Flickr[/IMG]
 
#93 ·
fab work looks great, I have to say though that while I understand using that style of Warn on an old CJ its causing to major issues. 1) it looks to be blocking almost all the airflow through the grill. 2) and most importantly, its blocking our view of that beautiful grill.
 
#95 ·
The air flow is my biggest concern, but I'm not giving up the upright :flipoff2: Much more than just a look for me and with the terrain I'm building the rig for I really don't want to sacrifice neither line speed nor line capacity. I really hate running up on the cable mid hill when gaining traction and having to stop.
 
#97 ·
Put in some more shop time this weekend working on tying fenders into chassis and lowering the winch to hopefully help the airflow concern.

[/url]IMG_20180418_181658090 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180418_182018741 by Alex Velasquez, on Flickr[/IMG]

When I first built the fenders, I made the side panels removable to make getting to the bolts that tied into firewall easier. Since they are now gonna be a part of the chassis decided to ditch the removable idea and just stitch some new sides on.

[/url]IMG_20180421_112558639 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180421_112543830 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180421_112535048 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180422_093256669 by Alex Velasquez, on Flickr[/IMG]

Cut out the little gusset and realized it looked like shit so made a new one.

[/url]IMG_20180422_093238829 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180422_094821497 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180422_100247559 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180422_100252754 by Alex Velasquez, on Flickr[/IMG]
 
#98 ·
Then the whole winch lowering cluster f@!#... Absolute pain in the ass.

Ultimately, I didn't want to extend the front frame rails any farther forward because I like the idea on of driving up a straight ledge. When it came time to cutting it was very tedious and tried my best to make it not look like an after thought. I guess the pics will tell the story better, let me know what you guys think.

[/url]IMG_20180422_102549954 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180422_103813855 by Alex Velasquez, on Flickr[/IMG]

Had to push forward slightly to clear ram so notch tube and grafted in winch plate.

[/url]IMG_20180422_111820987 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180422_112444007 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180422_113819785 by Alex Velasquez, on Flickr[/IMG]

Back side of notched tube around winch plate. (Can't stand uncapped ends even if they're hidden)

[/url]IMG_20180422_115231947 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180422_120344402 by Alex Velasquez, on Flickr[/IMG]

Best part of the day was when I was starting to get irritated and my mom swung by out of nowhere and surprised me with food :flipoff2: "I know you won't stop to eat when working on this thing."

[/url]IMG_20180422_173453710 by Alex Velasquez, on Flickr[/IMG]
 
#99 ·
[/url]IMG_20180422_125448231 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180422_130431226 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180422_131545787 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180422_131719571_HDR by Alex Velasquez, on Flickr[/IMG]

Then I started to clearance front xmbr/core support and totally forgot to take any more pictures.

[/url]IMG_20180422_134605725 by Alex Velasquez, on Flickr[/IMG]

More or less laid the winch in there to get an overall width and just started trimming away till she fit.
 
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