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Advanced Fabrication and Engineering For when your build is going off the charts. Wildly modified vehicles and straight up buggies welcome.

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  #1  
Old May 28th, 2014, 22:49
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Weasel Weasel is offline
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the sound of inevitability

Started as a rocker replacement. Planned on following Starboard's project.

Jeep started as this, the rockers were peeling out of the body where they were welded and really bent.



Turns out the 2x4 tube that I was told was installed was just angle iron welded to the body. Wonderful, I guess it last for 5 years.



So I started cutting, cutting and fitting of the 2x6 tube.



moved the door hinge up



testing the new rocker in



Fit pretty well, bummer that the sheetmetal is bent but I'm not spending time to straighten it.



Cut and capped the ends.



Driver side tacked in



Passenger side before and after. Driver side took a couple days but the passenger side was done in a Saturday afternoon.



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Old May 28th, 2014, 22:50
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Re: the sound of inevitability

Than I pulled the side glass out and Monday I took it over to the local shop with the plans of doing some tube work on reinforcing the broken a pillars and running sliders on the roof.



After some discussion plans changed.



Some quick discussion about back halfing the jeep and than deciding that sheetmetal is just sheetmetal and doesn't have much structure to it and the isn't much point in trying to weld dented sheetmetal to any kind of tube.









So the entire roof is coming off. The windshield was prefect and I wanted to see if I could get it out without breaking it for a buddy. So that's why the front half is still there. Another buddy pulled it tonight and the rest will be coming off tomorrow.

So we are starting on tube tomorrow. Will be using 2" tube. Roof will be dropped atleast 2" and raked with an aluminum roof skin. It will have a truggy look, not sure exactly what I will be doing with the b pillars, might try a double b skinned to look like the stock pillar.

The rear end is shortened to the gas tank skid and dove-tailed a few inches to the spring hangers.

And I ended up cutting off all of the rear half that I spend last week welding in. Eh that's the way it goes.

full album here:
https://plus.google.com/photos/11701...Pfeupvzn4_O7QE
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Old May 29th, 2014, 04:13
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Re: the sound of inevitability

Sounds sweet. Looking forward to seeing how it comes out.
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Old May 29th, 2014, 04:30
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Re: the sound of inevitability

Awesome! Easy part is done now.
What is the plan for the rear? I know you mentioned shortening it but with all that work why not move the tank to get it out of the way?
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Old May 29th, 2014, 07:18
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Re: the sound of inevitability

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Awesome! Easy part is done now.
What is the plan for the rear? I know you mentioned shortening it but with all that work why not move the tank to get it out of the way?
Still have leaf springs and the tank is skidded so I can't cut more just by moving the tank. Fuel cell might be in the future but the amount of body cutting would be the same.

Haven't quite decided how the rear ties up yet but should have a good idea later today.
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Old May 29th, 2014, 21:49
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Re: the sound of inevitability

slow day but got some stuff done:

The back end of the jeep trimmed out:


short as I can get it with the shackle boxes.


Better pic of the dovetail, just rough cut now:


welded in some pieces to tie the two sheetmetal halves together.


the new end cap and plug holes drilled. This is what the cage is going to tie to in the back.


and plug welded on


tacked to the floor:


the rest of the roof off


Working on the front a pillars and cross brace, triming around sheetmetal sucks balls.
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Last edited by Weasel; May 29th, 2014 at 22:17.
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Old May 29th, 2014, 22:11
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Re: the sound of inevitability

sub'd
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  #8  
Old May 30th, 2014, 13:32
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the sound of inevitability

Well that escalated quickly...
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Old May 30th, 2014, 21:39
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Re: the sound of inevitability

I blame it on the 35's.

Today's work:







I'm undecided on the 2 rear tubes. If they should be both vertical, the front one vertical and the rear one kicked back or both kicked back. Hopefully should be a bit clearer on the direction once the upper half is tacked on. Hard to judge tube placement with nothing but air around the tube.

The drivers tubes are tacked vertical and the passenger tubes has the rear most one slightly kicked back and the other one vertical.

Also still kicking around the idea of a double b pillar by the seat to give the shape of the stock b pillar, skinned with sheet steel.
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Old May 31st, 2014, 04:45
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Re: the sound of inevitability

What is the plan for getting in and out?
That tube up that high and straight will make it a royal pain, IMO.
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Old May 31st, 2014, 04:49
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Re: the sound of inevitability

If he makes a cutout in the skin for a step I'm sure it won't be that bad.

I'd bend up the a pillar and however you're going to do the rear before settling on a b pillar design.
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Old May 31st, 2014, 08:24
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Re: the sound of inevitability

Quote:
Originally Posted by RCman View Post
What is the plan for getting in and out?
That tube up that high and straight will make it a royal pain, IMO.
Quote:
Originally Posted by MoparManiac View Post
If he makes a cutout in the skin for a step I'm sure it won't be that bad.

I'd bend up the a pillar and however you're going to do the rear before settling on a b pillar design.
Everything is just tacked and hose will be checked before welding.

agree it's going to be a bit harder but it's also going to be the safest. With it up the high people don't stick their arms out when they look out the side. Well they can but it's uncomfortable. Couple of the buggiest there are similar and I like it while crawling.

But yes a step can be made and it is going to be a small opening. Also thought about making the top bar on the passenger side atleast hinged.
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Old May 31st, 2014, 08:30
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Re: the sound of inevitability

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Originally Posted by Weasel View Post
Everything is just tacked and hose will be checked before welding.

agree it's going to be a bit harder but it's also going to be the safest. With it up the high people don't stick their arms out when they look out the side. Well they can but it's uncomfortable. Couple of the buggiest there are similar and I like it while crawling.

But yes a step can be made and it is going to be a small opening. Also thought about making the top bar on the passenger side atleast hinged.
I'd feel more comfortable with a slightly larger opening and no hinge.

Looking good so far.
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Old May 31st, 2014, 20:57
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Re: the sound of inevitability

todays progress

driver's side upper still need quite a bit of fitment grinding, but the profile is there:



passenger side profile:


Front view:


side:


I realize the door bar is more of a personal thing, but I like the height. Several of the buggies at the shop have a similar height door bar proportional I and like it.

Probably going to skip the hinged door bar. The issue with the tube doors on the previous body was the lack of a place to grab and step. There will be no lack on this model.

Also going to skip the double B pillars, it just is too much tube in the area and I didn't realize this but most of the B pillars are looks only, no real support below them. With the upper we tried difference C pillar placements and found a new location that should look pretty good.
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Old June 2nd, 2014, 04:07
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Re: the sound of inevitability

That's gunna look awesome.
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