Cage construction

[Goatman]

I sorta like the way the back turned out. I like the idea of the vertical shear plane to increase the strength of the rear section, since so much of the original structure is gone. I saw the pic of the steel across the bottom of the rear crossmember, did you also plate inside the cross member, or the back of it? Did you weld or bolt the bumper to the the frame/crossmember? Since the bumper is now an integral part of the structural strength, I think it should be welded on and tied to the cage. Many of us have had cracks around the 8 rear bumper mounting holes, even with bumper mounts that ran down under the frame.

How about the original B and C pillars, are you going to run some plate tie ins to the cage? I think you'll be sorry if you don't.

 

[Jump This]

I sorta like the way the back turned out. I like the idea of the vertical shear plane to increase the strength of the rear section, since so much of the original structure is gone. I saw the pic of the steel across the bottom of the rear crossmember, did you also plate inside the cross member, or the back of it? Did you weld or bolt the bumper to the the frame/crossmember? Since the bumper is now an integral part of the structural strength, I think it should be welded on and tied to the cage. Many of us have had cracks around the 8 rear bumper mounting holes, even with bumper mounts that ran down under the frame.

How about the original B and C pillars, are you going to run some plate tie ins to the cage? I think you'll be sorry if you don't.

I needed to temporarily button up the project at this point, so some of what it will take to complete the Jeep won't be done until after I get back from vacation.
The factory bumper mounts are going to go, as will the factory shackle mounts. This will all be done with something with a bit more meat to it.
The bumper won't be welded on but with the additional stength I'm hoping to get out of the rear with replacing the mounts, that should be fine.
The cage will be tied into the body along both the A and B pillar nothing behind the drivers area though. There is no structural help to be found above the frame rails from just about a foot behind the front seats. That sheet metal is just for show.
After I build storage mounts in the old back seat area my attention will go to building some better crossmember work. I'll need a mount for an anti-wrap bar, some protection for the t-case and plating for the underside of the frame rails.

There is still much to do. I'll have it completed by Goatfest!

 

[Goatman]

Rick, I've talked to lots of guys who beat in their B and C pillars after cutting the bodys down and/or removing the doors. I'm just thinking that you like the lines of the body and the roof out to the C pillar area, if you also tied into the C pillar it would just make it last a lot longer.

If you want the bumper bolted on (not a bad idea), you could do what I did and weld a plate inside the C channel of the crossmember that ties to the shackle boxes, then you have a solid crossmember for strength and rigidity and for the bumper to mount to. Actually, I both welded and riveted the plate to the original crossmember, the rivets acting like little spot welds to add strength all over it.

Have fun on your vacation..........and you have to be ready for Goatfest.

 

[Jump This]

:cheers:

 

[Jump This]

......if you also tied into the C pillar it would just make it last a lot longer.

Here is my take on it, and we are just talking about the C pillar now.
If I do anything to make it more rigid, as it would be if I tied it (some how) to the rear hoop on the cage, the first boulder I lean on will dent it (I'm thinking that nasty lefty on Wrecking Ball) if I leave it the way it is and just fill the hollow area with a high density foam it will allow it to flex in and out of the way a bit. Really there is nothing there now to stop it from moving. I can take my hand and push it in two plus inches...
I know this could be a crazy ass dream but I want to give it a try. As a side note here, I will be picking up the buggy candidate on Monday and once I cut it all up I will have enough extra body to just replace the C pillar area and try again if it doesn't work.
Remember this project isn't about building the perfect XJ buggy, its about me learning how to build a real good XJ.

Anyway, as always I do appreciate the input and always take it into advisement...

Rick

 

[Goatman]

......if I leave it the way it is.....it will allow it to flex in and out of the way a bit.

I know this could be a crazy ass dream........

:cheers:

and just fill the hollow area with a high density foam

Not a bad idea. Just remember that you intend to brace the A and B pillar, so it won't flex like it does now. If you hit the trail with it able to flex 2" it will likely rattle and crack apart in no time. Quit being so stubborn and throw something on that C pillar. If you already have a buggy project rig, then wouldn't it be nice to make this one live?

 

[Jump This]

 

[Goatman]

What happened to the dimple die'd vertical panels in the back?


Bet it's real nice to get it driving again...... :cheers:

 

[XJ_ranger]

I think ive seen that rig before...




oh yea... about 2 years ago...

the next stage will look something like this -

 

[Rawbrown]

Hey Rick,
can you shoot me a few pics of the Tank mounting that you did. that looks pretty killer from what I can tell.

 

[Jump This]

Hey Rick,
can you shoot me a few pics of the Tank mounting that you did. that looks pretty killer from what I can tell.

No problem.
After sitting there looking over that part of the project, I don't think I could have paid someone to build a better tank for what I want to do.
It is light, it does have enough capacity for a Superstition run, built in fuel pump, and the gas gauge works.
Sweet.

 

[Mr.OverKill]

No problem.
After sitting there looking over that part of the project, I don't think I could have paid someone to build a better tank for what I want to do.
It is light, it does have enough capacity for a Superstition run, built in fuel pump, and the gas gauge works.
Sweet.

i have been thinking the same for my rig for a while now, i am just too lazy and the boss gave me a fuel cell i need to buy parts for so whitch way to go??

 

[TNT]

Hey Rick,
can you shoot me a few pics of the Tank mounting that you did. that looks pretty killer from what I can tell.

X 2

Thanks

 

[Jump This]

What happened to the dimple die'd vertical panels in the back?

They are getting chromed.

 

[Jump This]

X 2

Thanks

Let me just post up a few pictures of the tank swap.

I traced out the tank dimentions on the back. It will just clear without having to remove any of the frame rail spot welds. I moved it as far back as I could so I could use the bumper as a support.

I used the plasma to cut it out, very easy, could use almost anything to cut the pattern out.

Just another view. You can see the frame rails sit out about 3/4".

This is the picture most of you have already seen.

Used the factory straps and drilled and tapped the bumper and drilled and used doubler plates on the forward mounts.

 

[GrimmJeeper]

They are getting chromed.

'
NOOOOOOOOOOOOO

 

[Jump This]

I took the panels down to have chromed and the owner tossed me a sheet of stainless and told me it would be cheaper to make them out of it!



Anyway...
Started the front bumper this morning. Didn't have any 6" plate but I did have some 4" and some 2".

Its just too hot and humid right now. I should be able to finish it tomorrow morning.

Then off to fix some tail lights...

 

[Jump This]

I know this thread is mostly a picture showcase but I am having difficulty uploading to photobucket right now so....

I did finish the front bumper and it turned out nice.
Picked up the rear shocks today (14" travel Fox) along with ordering
my wheels ( Walker Evans beadlocks.)
Also picked up the seat belts (actually racing harnesses) and a bunch of misc crap........over 3K worth in one day.
Hey, I don't get out of Borrego Springs too often so when I do, its time to shop!
Tomarrow I'll tackle the tail lights, I think I've said that before!
Not every day goes as planned...
we will see about tomorrow....

Rick

 

[Jump This]

I was able to figure out my EasyShare problem. So.....I got more pictures!

That was a couple of days ago, I now have a filler hose and cap.
Give me a few and I'll dig out some other progress pictures...
(I'm sure you just can't wait....)

 

[Jump This]

The spacers ended up taking me half a day to build. I started out with some bar stock and cut 8 spacers with some some bevels, after I got back to my garage I noticed that the small bevels were not going to work, so I had to hand grind all eight of the bastards so the hiem could move....

Its not a great angle but the bumper turned out well and I still will be sheeting it along with mounting some recessed tow bar mounts.

I don't know why the damn fuel pump isn't getting any power to it!

Getting closer, the seat belts won't work with my cross brace, the brace is too high, gotta' lower it about 2"....or come up with a quicker solution...