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120 Posts
Discussion Starter · #1 · (Edited)
Project Tooo Long

Changed the title from Project 127 to Project Tooo Long

This is going to be an ultra low bugdet build....NOT

I started this build awhile back.

I've budgeted $10k for this build. The build will be taking place in my home garage but I own a Sign Shop soooo. I will have a lot of cool cnc work going into it.

Dont be to critical of my fab. work as this is my first project of this scope.

I'm "the guy" that bought a welder at home depot and now think I'm a "professsional fabricator"

My Plans include:
127" wheelbase
4 door 4 seater 4 wheel steering
OBD II 5.7 out of 97 pickup
TH400 out of an old chevy 3500
203/Lomax 205 (2.0/3.0 to 1)
2 steering Rockwells
47" LTBs
Triangulated 4-link front and rear
18" 2.5 fox rear
16" 2.5 fox front
Custom Chassis
Custom lexan "skin"
custom dash

Went to the Junk Yard and picked up a 97 tub and frame for $450
Stripped off all unneeded Sheetmetal, wires and brackets

Drilled out all the spot welds and removed the outside sheetmetal keeping only the firewall and floor.

Sorry, my pic quality sucks!!! its the host

You can see the dash I built at work. When I was a kid, I had a 86 cj so this dash is a combo of cj/tj. Needs gauges and radio.

This is the DXF for the cnc

The following is some cool equipment i've purchased over the years.
CNC router, metal shear, 20' welding table, 10' sheet brake

Cut the Frame and Body in half!
Added 23" of 2" X 4" X 3/16" to the frame
and 26" of .080 5056 to the floor (attached with 3/16" POP rivets)


120 Posts
Discussion Starter · #5 ·

Dash was cut from .120" 5056 Aluminum
then bent and welded.
the radio and gauge "bazels" were cut from 3/16" acylic. as will be the glove box lid.
Then there's angle alum. inside the dash to mount to.

Completely forgot to incorparate speakers!:mad3:
gonna have to do 4*6s somewhere.

If you like it now just wait for paint!

120 Posts
Discussion Starter · #8 ·
All outside "sheetmetal" will be replaced will lexan (polycarb). so if I decide to include doors they will be cnc'd from polycarb.

120 Posts
Discussion Starter · #9 · (Edited)
10/7 Update

After lengthing the body and frame, I reinstalled the body mounts with no lift pucks. Then cut all additional factory frame brackets off and started on the tube work.
The following are pictures of the new hood ($249)
front hood hoop
front tube fenders
front main hoop
rear fender wells
and rock sliders
also front and rear bumper
I plan on using 7-8 sticks of 1.75x.120 ERW for the jungle gym
tube cost-$200

All tubing fits against the body very very tightly.
My goal is to have the buggy look very much like a factory jeep jk

Once it's "skinned" you won't be able to see the union of tube and sheet.

120 Posts
Discussion Starter · #10 · (Edited)
10/8 Update

After doing the front hoop and fenders,
I started on the Middle and rear hoops
then bars between the hoop
then the rear "bed" area
then bars for seats and installed seats
then finished the rear cage
then front stinger

I used a tube notcher from harbor frieght $70
and went thru three hole saws

Next I ran up to the yunk yard and purchase a low mile (75k 98 c1500) vortec 5.7 and 32 spline turbo 400(late 70's k3500) -$800 for both

I also sourced a gm203 and ford 205 from a buddy -$300
Jedsmachining.com is providing the doubler kit -$495
Jbconversion.com is shipping the diy lomax 205 kit -$1100

I puchased the ford for the 32 spline outputs! plus they're damn near free compared to the gm 205.
Once the ford parts go into the lomax i'll have a gm 3to1 with 32 spline inputs and outputs
plus gear and case strength that make the altas look like a bitch!
(dont remind me about the wieght!!!)
I'll be triple sticking it myself.

Enough tech now on to the pics:eek:

OH and by the way the grill is a template i cut from card board.


120 Posts
Discussion Starter · #15 ·
I know you are running rocks and big tires but why so long? I think 127" is too long even for 47's, 120" would be better IMO. Dig the tube work, looks good
I want plenty of room to have 4 sus. seats and fuel cell, batteries, tool box, co2, & icechest

8,660 Posts
I know you are running rocks and big tires but why so long? I think 127" is too long even for 47's, 120" would be better IMO. Dig the tube work, looks good
Check out the pics, he stretched the middle section of the tub. It looks like a lot of material too (I'd say at least 20"). Most people stretch out their stock wheelbase rigs anywhere from 100-110". I don't think 128" is out of the question, it's just gonna have long legs.

120 Posts
Discussion Starter · #19 · (Edited)
The ERW tube rockers wont hold up so well to rocks. I did my last build like that and the tubes were smashed to hell when I tore it all off.

is that aluminum drain around the steering column no, but seriously nice tube work.

I think you're totally correct!!!
i also was thinking the same
I have since built rock sliders out of 3"x3"x3/16 steel
The gutter you refer to is pvc not even Aluminum. I completly agree it's ace. I have replaced with better:homer:

Keep Following the build to see them installed

thanks for the constuctive criticism
KEEP IT UP!:smokin:

120 Posts
Discussion Starter · #20 · (Edited)
Hey Guys,
Got the "Skins" cnc'd decided on .120 lexan for all exterior sheetmetal and windsheild
I'll post up installed pic tomorrow.
Also Posted pics of my fuel cell Hope you likey

Then fab'ed a fuel cell from .120 alu.
then ground and sanded the welds

Next, I Cut a hole and use the top of pvc glue can for the filler.

Then made my own fuel pickups and vent

Then drill and tapped the top didn't like that so welded on a 1/4" alu. strap and redrilled and retapped

then paint gloss black

I've gotten some PM's About the sign in the first picture
so here it is done.

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