Thread: Barn Door for JK factory hardtops

  1. #2941
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    When I was at the SEMA Show last month I posted that for a while now I've wanted to experiment with on board air system designs. At the show I talked with a compressor company and they supplied me with a compressor and tank to prototype with.



    I'm looking at several solutions for mounting the compressor in the Jeep. It fits very nicely inside a Jeep wheel, so it could be mounted inside the spare carrier on the tailgate to avoid taking up space inside the Jeep.



    In this photo it's sitting on top of the spare carrier to show the comparison in size, it could fit inside the carrier without too much trouble.



    I may also work up a mount to go in the inner fender ammo can trays, this would work in both my JKU and the LJ. Shown is the compressor sitting in the tray in the JKU.



    The company also gave me an air tank to experiment with. A tank isn't really needed if all the compressor is being used for is airing up tires, but if air tools are to be run it would improve the usability quite a bit. It turns out there's plenty of room underneath both Jeeps to mount the tank, in this photo I'm holding the tank in place under the floor of the LJ. The tank is above the bottom of the frame rails and driveshaft so it's a fairly safe place for it. The compressor could also easily mount underneath, but I'm not sure I'd want to subject it to the environment under there.



    I welcome any ideas or input you might have; I'm just starting this design project so any and all ideas for the design are welcome. What would you like to see in an on-board air system and where would you like to have it mounted?
    "Whether you think you can do something or you think you can't, you are right" - Henry Ford

  2. #2942
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    Quote Originally Posted by TrailBadger View Post
    Scherb, Good to see you're working on something of interested to us. We have the same system & have yet to determine where the tank & compressions should be mounted. One thing that you/we should make a note on, is that the compressor itself should be mounted in the center of the vehicle as the limited length of the hose restricts how far you can air up. IE: If the compressor is mounted towards the rear of the jeep as within your images, the hose would not reach to the front tires. Adding a second line would reduce the PSI from the compressor thus taking longer to air up. The next bit of info would be to mount the compressor anywhere on the jeep, yet create designated lines which branch off from the rear and front of the jeep, which the air line can quick disconnect from designated points about the vehicle. lastly, If you jeep has a pocket under the cargo floor mat, this could be cut out and a skid plate box mounted in it's place, this skid box could then hold the air tank and /or compressor with those hard lines branching off the box.
    The compressor does not have to be located in the center of the vehicle in order to reach all 4 corners, nor do you need complicated permanently installed lines to the corners of the Jeep. In this photo I've clamped a recoil air hose to the spare carrier, you can see it easily reaches the front of the Jeep.



    I picked up this hose for about $5. It recoils back to a size that's very easily stored.

    "Whether you think you can do something or you think you can't, you are right" - Henry Ford

  3. #2943
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    One benefit of mounting the compressor inside the spare tire carrier is that it's space that isn't used for any other purpose. Mounting it in the center console as has been suggested would take up space that I use regularly for storing other things.

    If I mounted the compressor inside the spare carrier, getting wiring to the tailgate is pretty easy - for the Safari cab barn door I had to run wires to the tailgate for the wiper and defroster and the washer hose, here's how those wires are run, it's the top set above the factory third brake wiring.



    And to get outside to the compressor, Jeep has conveniently provided a wiring hole through the tailgate:



    It would be a no-drill installation.
    "Whether you think you can do something or you think you can't, you are right" - Henry Ford

  4. #2944
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    While I'm working on on-board compressor and tank mounting designs, I'm also going to implement a portable air solution - I'll install the compressor in an ammo can. The idea is that I could use this air supply any of my Jeeps, just throw the can in the back and take it out when I need air. I've picked up all the bits and pieces I'll need, and everything will fit nicely inside a Fat 50 can.

    I've got an inexpensive jumper cable set which will be used to connect the compressor to the Jeep's battery. I'll cut the clamps off one end of it and make permanent connections inside the ammo can. A 25' coiled air hose will also fit inside the can. The main parts:



    I've got a pressure regulator to automatically turn off the compressor when it's not in use. Haven't decided if I'll include the pressure gauge in the design or not, or if it even needs a power switch - when it gets connected to the battery the compressor will run a few seconds until the air hose is up to pressure, then it will shut off. When air is being used, the compressor will start up, and when air is no longer being used it will shut off, so it may be that a switch is unnecessary.

    Comments and suggestions on this idea also very welcome.
    "Whether you think you can do something or you think you can't, you are right" - Henry Ford

  5. #2945
    Is the pressure regulator part of the pump, or is it something you added? I like the concept of being able to move it from vehicle to vehicle as needed.

    I found the answer. I’ll be following your project.
    Last edited by Dexter612; 12-07-2017 at 02:14 PM.

  6. #2946
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    Quote Originally Posted by Dexter612 View Post
    Is the pressure regulator part of the pump, or is it something you added? I like the concept of being able to move it from vehicle to vehicle as needed.
    I added it. It's the small part with two terminals in the photo, just to the left of the pressure gauge. It's a switch that turns the compressor on when the pressure falls below 90 psi and turns it off above 115 psi. Also required, but not shown in the photo, is a relay which controls the power to the compressor - the contacts in the pressure switch aren't rated for the amount of current the compressor requires.
    "Whether you think you can do something or you think you can't, you are right" - Henry Ford

  7. #2947
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    I liked the idea of having the compressor and tank under the rear rack on the back. What you have there looks like the perfect size.
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  8. #2948
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    Quote Originally Posted by akpostal View Post
    I liked the idea of having the compressor and tank under the rear rack on the back. What you have there looks like the perfect size.
    Thanks, nice to hear from you again after so long, I hope everything's been ok with you. Was just wondering about you yesterday since it's been several months since you've posted here.
    "Whether you think you can do something or you think you can't, you are right" - Henry Ford

  9. #2949
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    Out of curiosity Jeff, what are the dimensions on the tank? It might fit behind some after-market bumpers between the bumper and rear frame cross member. If so two of those tanks would provide a good supply of stored air in a place that is otherwise wasted.
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  10. #2950
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    Quote Originally Posted by Bullseye240 View Post
    Out of curiosity Jeff, what are the dimensions on the tank? It might fit behind some after-market bumpers between the bumper and rear frame cross member. If so two of those tanks would provide a good supply of stored air in a place that is otherwise wasted.
    The tank they gave me is 1.5 gallons; it's 17" long and 5.5" in diameter. The company has other sizes from 1/2 gallon up to 5 gallons but I chose the 1.5 because it's a size that shouldn't be too hard to mount somewhere in, under or around a Jeep. I posted this photo when I was at SEMA, it shows me holding the tank under the basket on the prototype Overland Rack MORryde had at the show.

    "Whether you think you can do something or you think you can't, you are right" - Henry Ford

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