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Old 01-02-2018, 06:10 PM   #1 (permalink)
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CJ Unlimited Buggy Build

The time has come to rework the buggy, 8 years ago i finished up my 2 seater TJ-7 build (see signature for link) and since then my wife and i have had 3 wonderful children, 2 boys and a baby girl so now i must make room to accommodate 3 in the in back. The plan is to use the existing TJ Frame, the 2.5" Kings in the front, replace there rear 2.0" SAW's with some 2.5" King IBP's, leave the 6.0/4L60E/Atlas 3.0 as well as the existing HP 60 front/14 bolt rear and build a new jeep buggy to drop onto the frame. I spent last weekend at my buddy Jeff Bate's house (Badbuggy) to get a solid, square, level & plumb platform to build off of in my garage. I'm going to build it to the LJ dimensions so i can use an LJ soft top, and skin the tube chassis with a YJ Tub that i plan to hollow out and do a fiberglass CJ Hood, CJ-7 Grill & Tailgate to give it the appearance of a bobbed scrambler...Hence the CJ Unlimited build thread...even though it's really a bit of a CJ/YJ/TJ???

Here's my "sketch" of what i was trying to accomplish....we actually came pretty close to hitting our marks surprisingly!


The base platform using 2 pieces of 2x4x1/4" square tube at the base of the door openings to act as a rocker guard for the boat sides to hang off of


Bending up some tube


Starting to take shape


Nearly comlete


Back home next to the buggy



Now the real question at hand, i'd like some feedback on how best to fill in the top of the cage. I'm going to do the spreader down off the eyebrow to the dash bar like my current buggy, but i'm struggling with doing the two X's over the driver/pass like i have in my buggy because i've had taller passengers have issues bumping their head on the X during a roll over or flop. Also looking for input on what to do over the rear seat (currently have a 36" bench will be ordering a 56" PRP bench)


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Old 01-02-2018, 06:29 PM   #2 (permalink)
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Do an X over the entire thing not two xs.

Glad to see you back in the buggy game.
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Old 01-02-2018, 11:07 PM   #3 (permalink)
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Definitely in for this donít fuck it up.
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Old 01-03-2018, 12:13 PM   #4 (permalink)
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Can't wait to see this one come together!
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Old 01-03-2018, 01:34 PM   #5 (permalink)
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For the x brace question, I'd recommend finding a way to raise your cage, or lower the seats to give your occupants a little extra headroom if you've had issues in the past, then do whatever you want as far as bracing is concerned. If they are going to hit their head with tube right above, then their head is too close to the roofline regardless. All of that is ASSuming their belts are always tight when they have hit their heads.

I say all of this having had this same issue with my latest Jeep build. I built it to fit my father who is much shorter than me, then he decided he wanted my old Jeep, so I got stuck with less than adequate headroom for myself. I'm going to fix my problem by raising the cage about 3-4", to match the headroom that I have in my other Jeep.
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Old 01-03-2018, 07:30 PM   #6 (permalink)
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I really the "sketch" I draw my stuff out too.
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Old 01-05-2018, 08:12 AM   #7 (permalink)
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Thoughts on this concept?
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Old 01-05-2018, 09:58 AM   #8 (permalink)
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I feel like the B pillar to windshield spreader overhead is overkill and not needed. I would run center of B to outer A, and center of B to outer C. Then just properly support it on the side back into the frame rails.


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Old 01-05-2018, 10:13 AM   #9 (permalink)
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Good feedback, so how about something more along the lines of this?

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Old 01-05-2018, 12:54 PM   #10 (permalink)
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I feel like the B pillar to windshield spreader overhead is overkill and not needed. I would run center of B to outer A, and center of B to outer C. Then just properly support it on the side back into the frame rails.


Something is wrong with your rear axle





I agree with Ronald. That is all you really need for bracing. Anything beyond that, while it doesnít make it weaker, isnít really necessary.
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Old 01-05-2018, 01:33 PM   #11 (permalink)
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Good feedback, so how about something more along the lines of this?

Still overkill where you want headroom. Get rid of the center A pillar to outer B pillar V.

One huge x and the center a pillar to center b pillar is more than enough.
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Old 01-05-2018, 02:41 PM   #12 (permalink)
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Looking good Wally.

Hopefully you'll keep it on tires more with the kiddos in there.... get them some nice harnesses, they're gonna need them.
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Old 01-05-2018, 04:37 PM   #13 (permalink)
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Still overkill where you want headroom. Get rid of the center A pillar to outer B pillar V.

One huge x and the center a pillar to center b pillar is more than enough.
Ok so something like this....keep the feedback coming it's been a while since i've built a cage and am no engineer by any means.

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Old 01-05-2018, 08:22 PM   #14 (permalink)
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Old 01-06-2018, 06:56 AM   #15 (permalink)
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Got your Facebook message thatís exactly what I did with my current buggy when I built it.



The issue was the cage buckled after a hard rollover in Rangely a few years later. Not opposed to it though as I am using thicker wall material on this cage. Itís not quit .188 wall 1-3/4 electric weld tubing.
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Old 01-08-2018, 09:22 PM   #16 (permalink)
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Awesome build last time, can't wait to see this one!

Are you going to do the same door bars by your hip? Did that seem to be the best compromise between protection and easy access? Would you have done it differently?
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Old 01-09-2018, 07:23 AM   #17 (permalink)
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Awesome build last time, can't wait to see this one!

Are you going to do the same door bars by your hip? Did that seem to be the best compromise between protection and easy access? Would you have done it differently?
Thank you, those door bars worked well, i'll be doing something similar this time that will also allow me to use a CJ/YJ Soft door for winter wheeling. Hoping to order up the new PRP seats this week and jump in and finish up the top of the cage this weekend, still looking for feedback on the cage
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Old 01-09-2018, 07:29 AM   #18 (permalink)
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Always loved following your builds Wally! .. I'll be watching!

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Old 01-09-2018, 08:59 AM   #19 (permalink)
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Wally,

I like your old buggy layout, very similar to how mine is built, how sleepsontoilet 's is setup, etc. That design is nice over the driver. If you feel that wasn't enough in your old buggy for strength, I would def go with what you drew in post #13. I think it's aesthetically good looking, not over tubed like the first one.
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Old 01-09-2018, 10:21 AM   #20 (permalink)
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What about a layout like this? Gives you good space for your noggin and keep proper triangulation.


[IMG][/IMG]
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Old 01-09-2018, 10:38 AM   #21 (permalink)
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What about a layout like this? Gives you good space for your noggin and keep proper triangulation.


[IMG][/IMG]
This is what Iíve done on the last couple builds.
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Old 01-09-2018, 11:40 AM   #22 (permalink)
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Thanks for the feedback, so hopefully this is the last attempt, i did add a few gussets. Would like to get this infilled this weekend, so i very much appreciate all the feedback you guys have been giving me.

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Old 01-09-2018, 08:37 PM   #23 (permalink)
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I feel like the roof tube that runs B pillar to C pillar is a waste as it dead nodes at the stern. The gussets don’t seem to do much other than add weight as you already have a double B pillar overhead. Most gussets are added where the A pillar and roof tube are connected in the front. Then they usually add them where the A to B roof tube meets the B pillar. Some gusset the other side too from B pillar to C pillar down tube. Other than my smooshed radiator, mine held flawless to this roll two weekends ago.

https://youtu.be/n4XQsZgROwc
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Old 01-23-2018, 02:18 PM   #24 (permalink)
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Any progress?
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Old 08-11-2018, 07:45 PM   #25 (permalink)
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Updates!!!! We were talking about your builds around the campfire on our latest wheeling trip
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