Project Geosynchronous Orbit

I don't regret doing mine nicely (initially), as it was a good learning experience in bodywork and paint:

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but this hurt a little bit.

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And looking at the possibility of that happening again, I'm pretty sure I'm not going to try and make it nice again (on this rig at least).
 
I would do it nicely. As long as you put a piece of good steel behind the seam to weld both to, it shouldn't be too hard to make it really clean. Hell, if you can get your hands on a spot welder and then just bondo what's left it would look decent - remember how much bondo got discovered on jordan's truck?

EDIT: oh yeah - only odd angle that comes to mind is the lower corners of the bed behind the tires, they taper. I figure you are plannning on cutting those and making wraparound bumper ends anyways though.
 
I'm pretty sure just tack welding the pieces together all over the place will be fine. Just grind it all smooth afterwards. I don't want to use any bondo. I dont care THAT much.
 
Yours definitely came out nice Chris, I just don't want to spend weeks bobbing a bed.

I'd like to have the two pieces ready to be welded by tomorrow night.
 
corey said he couldnt retain the tailgate if he wanted a nice departure.

i'd try to retain the tailgate. looks better and retains usefulness
 
Started by sectioning out about 8" and seeing how it looked.

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Here's the remains of the taillight / tailgate structure. I really want to keep this, maybe add some steel boxes in the future, but I really want the tailgate functionality.

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Also, for anyone interested, the stock MJ frame is basically two pieces of ~1/8" angle stacked on top of each other and then boxed in on the top.

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After measuring for the tires at full bump, I realized I would have to open up the wheel wells quite a bit more than previously planned. I'd have to cut beyond the pinch seam. I sectioned out the stock wheel wells so I can try to preserve them and just add a piece inbetween the cut down the middle I made.

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Mocked up the back structure. Take 1. This was with about 6-7" of frame sticking out.

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After speaking with Bill, he made a valid point that I should cut off as much as I can now since I don't want to have to redo this step.

Then came Take 2. Took out about another 4". This is where it's going to sit.

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Next step is cutting up the passenger side wheel well and then fitment. Having never done body work before, I'm sure it's going to be a PITA.

Even with taking careful measurements, things deflect and warp and it's tough getting everything situated again. Not to mention I don't have the steadiest hands.
 
Looks good.

If you don't have any, I have around 8 deep throat vise grips with sheetmetal welding jaws you can borrow. They make things easy, clamp it where you want it and tack around the jaws then remove.

I used them to do my replacement floor and the welds came out pretty ok except where I couldn't get them placed properly.
 
Thanks Ken.

Yeah I might have to steal those off of you if you don't need them for a while. Keep in mind, I have a feeling this step is going to take me a while.

I also still have your tire irons. :laugh:

I keep them in the back of my truck though, so if you need them in a pinch I can give them to you after work one day.
 
Doubt that's going to happen anytime soon :roflmao:

Actually, when are you working on it next? I gotta pick that 8.25 up from Ross and I need to mount the tires for the mj, so I can grab the vise grips from the house tomorrow and swing by some evening while you're working on it or meet at the usual place.
 
Not sure when I'm gonna have the time to work on it again this week. I have to give a capstone briefing this friday and choose a queuing theory project so probably not until the weekend.

I can meet you after work on Monday though if you want?
 
Looking good. That extra bit taken out makes a huge difference.
 
Not sure when I'm gonna have the time to work on it again this week. I have to give a capstone briefing this friday and choose a queuing theory project so probably not until the weekend.

I can meet you after work on Monday though if you want?

Sure, that works.

I actually don't mind welding sheetmetal when it is 16ga or thicker and isn't rusty. Hate it when it looks solid and I got a good bead going and then blam, it blows through and looks like arse because I hit a rusted paper thin spot without realizing it.
 
Parts parts gimme parts parts

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Got the extra return fitting on the reservoir along with an additional hose kit since I plan on running hydroboost brakes.

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