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Finished up some trimming and edge profiling. This is how the current test fit looks. Note the clamp/strap on the rear keeping the gutter edge pulled in. This was flexing out wider without the rear profile and will need pulled in as the new profile is glassed together. All else is looking...

Thanks! Glad to know the extra work of documenting it is going to good use. Nice rig! Dimensions are a little all over the place as I continue to change so much, but I’ll be putting together a more detailed write up when I wrap up this stage and have a moment to enter it into my site. I’ll have...

Trim template for even sides. The original chop was more of a “rough” straight with a jigsaw. Made a little hand tool with a drill bit to score a line into each side at an even point in reference to the top. Tape a line up to follow it then clamp metal for the trim template. The front of the...

Chopped out the old rear section. Yanked all the factory original rotting wood. Taking measurements for the new molded rear end. Filming everything as well so it takes a good minute longer on each task.

Drove across town today to get some supplies for reglassing the rear of the top. Different concept this time around. Depot run in the morning for a couple last things then prep work begins. More Details: Homemade Camper Builder Series: Episode 1

Scored some clean leather fold-flat seats out of an ‘03 Sequioa. Measures to just barely fit as a front set of seats and will work well with the bed platform system I have planned. Also pieced together a shop press with remnant metal from my local supply and a 20 Ton Jack.

Went to the parts yard this morning. Discount day. Planned to pull a 8.8 Rear End from a ‘97 Bauer Explorer but someone beat me to it. Finally found one with the 4.10 Limited Slip (Code# D2). First I’ve found in a good couple years. Regardless got a deal on a set of fiberglass fenders. Unsure...

Interested to follow along. Buy the Durango Box remanufatured through Oreilly. Comes lifetime warranty and they’ll swap it if the seal goes bad, internals get sloppy, etc. I’ve been satisfied. Get/fab an extra brace spacer in place of the stock as well. Nate on the dirt lifestyle YouTube...

Yep progress slowed a good bit. Worked full time + the full summer and been double shifting full time school/work the past couple weeks. Taking time off through the fall to get back in the camper and with some funds set aside now to do a few more things.

Blew out a pinion seal that never got replaced on the front 30 swap.

Got rid of the temporary mild cut-and-weld brace and bent up a link of tube to hold the front end in place.

Replaced a melted and shorted old headlight switch assembly and harness. Factory runs power all the way through, going to run a relay as an extra safety net. Also changed out the oil for the first time since break in (500 miles). 10w-30 Mobil 1. Picked up a 1.5” JD2 tube bender and drill...

Back to being a daily and “sand-crawler” around work. Chopped the exhaust up this weekend and refit it along with some new mounts I whipped up. Coat of VHT and it’s sitting pretty underneath. CARB compliant magnaflow catalytic mated up to a 50 series flowmaster. Good growl without being over...

Couldn’t agree more. Wishing I went with full stiffeners from the start, but this should do well for now. Thinking the trackbar might hit the brace tube at full flex but will articulate it to find out and adjust. For now it’ll be on the road for a while and not a issue.

Made a trackbar stiffener / unibody crossmember for the front end.

New glass is in.

Putting in new glass to replace the cracked windshield. First glass job; plenty of research and taking the time to get it done right. Pulled a clean windshield from the parts yard for $20. 3M Urethane for $25. Waiting on some specific primer to ship in and sourcing a 94+ moulding seal.

Axle is finished up and under the Jeep. The PCM board and casing is getting a coating and sealed. Tires on, torque it all again, then to drive it in for an actual alignment check. Full Injector Drive/PCM/ECU writeup

New seals installed and axle reassembled. Went to torque the unit bearing bolts and they began to strip more. Calling it a night, I’ll run and grab some new hex flange bolts in the morning.

Everything weld wise is burned and done. Pre/post heated the welds to cast steel in the center with a can of map, monitoring the different heating/ cooling rates with a laser thermometer and working to keep them the same. Carrier is pulled and ready to replace the seals. Spicer inner axle...