This place needs a buildup thread, dial up warning

[kwrangln]

Since I got the new heep in September, I've actually managed to get a couple things done in an effort to get it on the trail. It's a mostly complete project I purchased from a guy in Texas. Figured I could show the Tidewater gang what I've been up to between work and wedding planning.

The heep the way it looked when delivered to Jersey.


You may notice how far the tires stick out, I had to make at least a token effort to cover them since Jersey has this silly rule about stuff like that.
Before...

After installing Warn 7" TJ flares...

At least it looks like I made an attempt to cover them now. Dont think they look too bad, they're kind of growing on me. I know I need to clean up where the old flares were.


Of course new bumpers are in order since the ones I had on it were recently sold. Here's the front so far, still hanging for paint, just threw the fairlead on there for grins. Hard to tell scale with it just hanging there, so for refrence, its only 4" wider than the frame on each side. No more hitting the bumper on rocks that I'm trying to get the tire to climb.

2"x4"x3/16" wall tubing, 1/4" winch mounting plate and fairlead mount. Took a lil while shaping the fairlead mount to exactly match the Rockstomper aluminum fairlead.

The winch mount was origionally 2 pieces of plate that had that curved edge to em, so I joined them together to get a long enough piece.

Of course it needs a new back bumper too, so I started on that. Same tube as the front, had a hard time coming up with the mounting, so cut some 3/8" plate to match the shape of the ends of the crossmember, welded them to the tube, then drilled and tapped the mounts.

When I'm done it will have a reciever mounted up high in the center for my favorite pintle hitch, and a swing out tire carrier using a Rockstomper hinge.

On the inside I had a big hole in the floor to contend with. Since the previous owner had never finnished things off after the tranny and transfer case swap, you could look down and actually see the transmission and all the shift linkage. Lots of heat come up through a hole in the floor when its that big. Some 1/8" aluminum plate cut and formed to fit, lil more to surround the shift boots, and some self tapping screws makes it all better.
Before...

After...



To be continued...

[kwrangln]

Finally starting to make some progress on several projects, figured I'd share for those who are following the outfitting.

Last time I left off on the tranny tunnel cover, only got one shot of it since the disc for the camera was full, so here's another shot just for kicks. Still pretty pleased with how it turned out.


Another update from the last post is the front bumper actually installed. Looks alot better on the heep than it did hanging from wires in the shop.

The days of hanging up on the ends of the bumper should be over with this model. Still plan on adding some tube to it, most likely a radiator hoop for some protection if the heep forgets to keep the dirty side down.


Speaking of keeping the dirty side down, the new cage is done and ready for paint (I'm unleashing the painting goddess on it tomorrow, thanks Susan). A big thanks to Zach (from www.atozfabrication.com/) as well for taking the time to bring a bunch of tube over to my shop and getting all the bends laid out, I'd still be scratching my head staring at a bunch of scrap tube without him.
Here it is.

The plates tying the back two tubes together will get a matching plate under the fender well with tubing tying it into the frame. It will be tied into the frame at each mounting point, should make things nice and solid.

And from the rear. The bends at the bottom of the B hoop drove me about nuts. Looks simple, but I had to follow the bends of a factory cage in order to use the sound wedges I have (yup, this ones gonna have tunes).


I'm pretty durn pleased with the way all the angles worked out. The B hoop may look a little odd, but I wanted something a bit different, and following the angle of the seat back as well as the angle of the C hoop worked out nicely.


Everything lined up just fine. Still havn't got plates for it yet, keep meaning to send off for them. The one on there is the front plate off the black YJ, had to put it on there to go get gas after I ran it out in the parking lot driving it back to its spot.


I really like having one tube going from front to back, nice smooth line for occasions when the cage may come into contact with things like trees or rocks.


I think I just about have the starter problem taken care of, turns out the adapter was flexing when the starter torqued against the flex plate forcing the teeth out of alignment. I built a brace from the bellhousing to the lower starter mounting bolt and it works alot better now. Only hangup is the clearancing I did to the starter to try to shim it is letting it move around a bit so I have to get another one.

That finnishes up this installment of the ongoing mods to get this beast ready to abuse, tune in next time for more of Kens shop fun.

[kwrangln]

So what do ya think? Still got lots to do and build for this thing.

Continue posting longwinded photo intensive topics?

Questions, comments, concerns and criticism are all welcome.

I should be back down in Tidewater for a few days over the X-mas holidays to visit the parents, hope to get to see a few of the Tidewater gang as well.

Ken "More projects than time" B

[TheMaddRamm]

Its cool seeing all the work done to it!

I agree, there should be a link on here so that when we go through big projects like this, we can have an area to showcase it all.

[Lyle]

I agree too! How about here?

Ken, thanks for sharing the buildup! I LIKE that bumper!

[BIG J]

is that thing sittin on some dubs

[LILREDCJ6]

Why J you looking at getting something rims and tires like that.

Tony

[kwrangln]

DISGRUNTLED said:

is that thing sittin on some dubs

37's on 17's.

I'm not ready for dubs yet.

[PaulC]

Is that all your doing with it Ken? I know you have to have some more updated pictures.

PaulC

[kwrangln]

OK, here ya go, remember, you asked for it.


On to the pics.

See if ya can guess what its for before scrolling down to the next post.

First one, the pieces laid out for your inspection.


Next, partially assembled.


Fully assembled.


Last one, since I had to hold it on edge, you can get an idea of scale.


I just hope that when I try to install it, that it works out. I'll be a bit upset if I have to scrap it and go back to the drawing board. Wait, what the hell am I talking about, I didnt draw it in the first place, just started cutting metal, oh well, ya know what I mean.

[kwrangln]

Last update left me with a newly bent cage installed, well sort of installed. I wanted it mounted to the frame for security. The A pillar already has body mounts installed under the down bars. The B pillar comes down directly over a stock body mount, so that only leaves the back two bars. How the heck to connect them to the frame?

If you look at this pic you can see the 1/4" thick plate I used to connect the two downbars of the cage.


I had to make a matching plate for the bottom of the wheel wells that I could weld some tube to and then connect it to the frame.


Once that was done it was time to add some plates to the frame for the tie in.


With all that done, its time to bolt it all together.


You can sort of see in this pic how the tie in bars are right below the down bars of the cage.


With the full width axles there should be plenty of room between the mount and tire when flexing, I'll flex it with the forklift just to be sure, I'll have my fingers crossed.


And finally, all installed, with the cage painted (thanks Susan) next time I get her to go in to the shop with me will get the tie ins painted I hope. I better talk sweet to her or something.



Thats it for now, havn't had time to get anything else done due to work and holidays. Next up is to finnish the rear bumper/tire carrier, and rebuild the HS9500i since the power/free control lever has been sticking. I've set spring for a time frame for a complete shakedown/bashing run, probably Paragon.

I spent yesterday making link mount brackets for a buddies rear 4 link suspension and picked up another 30' of tube to finnish my cage. More pics to follow as I get stuff done.

Ken "I need more hours in a day" B

[KarlVP]

Looks real good. After I get done with all my skidplates, I am going to start fabbing up a cage for my TJ.

[PaulC]

I seen that over on Pirate. I see how it is. You tell them before us.

Just Kidding. Looks good.

Paul

[kwrangln]

Well, the origional post didnt get many replies, so I didnt think yall were interested. Dont want to bore ya with my lil project ya know. I'll do better from now on.

What are ya wheelin now? Seen the start of a few projects from ya.

[PaulC]

Ken,

We are interested, just don't want to pry. I know how short on time I get and how projects get done later then sooner.

Jenn, Connor and I mainly wheel her '95 YJ for now. I got the new '89 YJ we picked up ready to wheel so maybe we will take two Jeeps if we want to take the dog along.

The other three projects ('74 TLC, '67 M715 and bobbed CJ-8) are moving along. I'm trying to get the CJ-8 out of my garage before Christmas so I can work on my junk ('74 TLC and '67 M715). The TLC needs the exhuast finished and a new fuel pump and it will be on the road, the M715 need the lines done (wiring, brake, fuel and drive). I hate how the big stuff goes together quick and the little stuff kills you. Oh well.

When are you coming back down this way?

PaulC