98 Jeep ZJ "SHTFV"

[Recce01]

The only thing left was to add the struts and the locking system. I realized that the top was going to rattle unless I placed some rubber bushings in place to keep it from doing so. I picked up a couple of rubber bushings from the local hardware store and immediately threw them in the freezer

The reason for doing this is so when I drilled holes in them, and cut them down, they would retain the holes and be easier to cut without just melting them. They came out just right

I made 3 bushings, one for each spot the table could come into contact with the frame. I mounted each of them with self tapping screws after drilling small pilot holes for the screws

The screw pulls down the center leaving the outside rubber exposed to make contact with the aluminum

This should warn away any unwanted rattles

Now the fun part, figuring out the struts. I started with the top mounts, cutting 1/4" material, drilling and tapping it to hold the 1/4 20 threaded ball ends

Next I welded the tabs to the frame and painted them in place and installed the ball ends

I placed a square on the frame and the table to make sure the table hung level before mounting the bottom of the struts

After deciding to mount them at an angle I drilled the holes to mount the bottom mounts

The final step was to make the top mounts to hold the table shut during travel. I tried to cheat and cut up an old aluminum ruler and use that as a temporary mount, but the ruler failed during the breaking process. I guess that is what I get for trying to take a short cut. It was kind of nice having the measurements built in to the material LOL

I immediately pulled out some proper 5052 .090 aluminum and made versions that would not crack or be destroyed when breaking the angles

These were designed to be very basic over center clamps to hold the table until I could come up with some spring loaded pins to use as a permanent solution

The compress the rubber just enough to eliminate any chance of a rattle

 

[Recce01]

Addition to the Wife's Kitchen cont.

The end result offers the wife a place to put pans that come off the stove. Putting them on the wood would not work out so well. We are also thinking about adding a sink to this table area, likely the folding fabric version from Grub Hub. We will see how this plays out over time, but for now, this should come in very handy! You can never have too much counter space The next step will be to add some locking pins to the table and to the carrier so it locks in place when opened. The struts are quite interesting, they fling the table open quite quickly and then slow it down as it nears level. This will take some getting used to, because if you are in the way when it comes down, there will be blood. I guess after thinking this over, it is quite silly to have used the struts, but I am really into mechanical goodies like this and the fact that this addition is completely rattle free. If we had elected to use some basic cables to hold the table, then there would have been an element of rattling cables against the aluminum no matter what. For now, we are stoked!

All buttoned up.....

Completely clears the back of the rig even when flexed and pushed hard, no worries!

The struts are tightly nestled and clear of the table and the frame

The table up and in mobile position

And the kitchen in ready for service mode.... there is one decision left to make. Where do I put the stops on the carrier, paralell with the drawer system ? or pinched at the corner? ...hmmmmm

Whatever we decide, the wife is very happy at the moment

 

[88Xj]

Parallel for sure! Gives you a wee bit more space for manuvuring around, or incase you had 1 person at the drawer & 1 at the table for some reason. Looks better with it swung open a bit more in my opinion as well.
But man you deserve some praise for thinking EVERYTHING through & making everything come together so cleanly! You seem to have everything you would need on hand which makes things easier I'm sure! Those bumpers are spot on in every way! Seem pretty durn study but also fairly light weight for whats all there.

You fab & design on that bumper is amazing! Can you just be my personal fab/design guy..when you have time of course? Please please please

 

[rb70383]

Yes parallel for sure. Close enough to be useful and still looks good. Pinched makes it look a bit crowded.

 

[JacksonRally]

Looks damn good as always! Now I need to check out the new additions in person.

I bet you have an old AutoFab style hood pin lying around the shop somewhere....you could weld the pin onto the tube of the tire carrier and bolt the bushing into the table and use the supplied pin to secure the table up in travel mode, it wont make any noise and it quick and easy to use. I think you get the idea =)

 

[VanIsle_Greg]

Wow, nice design on the table. And these are going into production when exactly?

 

[Recce01]

Looks damn good as always! Now I need to check out the new additions in person.

I bet you have an old AutoFab style hood pin lying around the shop somewhere....you could weld the pin onto the tube of the tire carrier and bolt the bushing into the table and use the supplied pin to secure the table up in travel mode, it wont make any noise and it quick and easy to use. I think you get the idea =)

I picked up some spring loaded pins, but I am kind of happy with the over center clamps for the moment, simple, and rattle free!

Wow, nice design on the table. And these are going into production when exactly?

hahahah, I wish I could put some of this stuff into production. If only I had the resources to manage such an endeavor. Thanks for the kind words regardless

 

[Recce01]

Addition to the Wife's Kitchen cont.

Well all, I have taken your advice. I decided to mount the table paralell to the slide out. I am very happy to have listened to you all on this one, as I ran into a situation that I needed to squeeze in between the slide out and fold down table to grab some stuff off of the box. Good call! The first step to this project was to round up some spring loiaded pins.

This is what I managed to get ahold of......

This spring loaded pin should work great, I just had to figure out how to mount it. I decided to mount it to the swing out tire rack. First I had to make some brackets to mount it to the rack. So I disassembled the pin and welded some sides to the tube

Once the brackets were welded to the tube I found the ideal location on the rack in which to weld it

I tack welded it in place

Next I had to fill the gaps at the top of the brackets, I made a plate then welded it all in place

The next step was to drill the tab the right size so the pin would slide inside of it

In order to find the exact location in which to weld the tab, I had to make the table exactly paralell with the slide out drawer. I did this with some soft clamps, a square and a tape measure

The final step was to weld the tab in place on the bumper

I was very tempted to make a ramp for the pin to slide up and lock in place, but for the time being I just decided to do it manually. A little paint and the operation was complete!

At last the swing out carrier can be fixed in its position!

 

[rb70383]

Looks good. Where did you source those pins?

 

[nick_n_ii]

I just went through this whole build and WOW....

I keep tossing the idea of replacing my 2 door XJ with a ZJ or XJ and yours has given me way more idea's for a ZJ...

 

[jscusmcvet]

The welding is incredible. I just started welding this year and I find those welds, especially on the small parts to be just amazing. Nice work and very well thought out.

John

 

[Recce01]

Looks good. Where did you source those pins?

They were gifted to me by a friend, I'll try to figure out where to get some.

I just went through this whole build and WOW....

I keep tossing the idea of replacing my 2 door XJ with a ZJ or XJ and yours has given me way more idea's for a ZJ...

Thank you! I personally like the zj for the rear coil springs, but they are both great choices!

The welding is incredible. I just started welding this year and I find those welds, especially on the small parts to be just amazing. Nice work and very well thought out.

John

Thank you John! I have been welding for a lot of years, but I still have a long way to go I am confident that the welds will hold, which is most important to me. If you want to see "holy crap, I hate you welds", look at stuff built by this guy http://www.expeditionportal.com/forum/threads/77783-Jackson-Rally-FOZZWLR This is my man Kyle Jackson. He welds like this......

I hate him.

 

[GCRad1]

OK, to everyone reading Mr. Recce01's thread... I get to brag about him and his welding as I have seen his work for a bunch of years!

I will drop some expamples of his previous work in another life:






Sorry, I'm not trying to drag you back into fabrication at that level, just showing off your old work.

And yes, Kyle's work is AWESOME TOO!!!

 

[rb70383]

Ok so in the second picture why is there a space between the mounting plates? I suppose from Recce01's rally days?

Oh and thanks for the possible info on those pins.

 

[Recce01]

Ok so in the second picture why is there a space between the mounting plates? I suppose from Recce01's rally days?

Oh and thanks for the possible info on those pins.

The space is for the bed of the truck. It was raced in the "full size stock truck class" which required a bed. There are actually small bungs welded on each of the four corners of all the plates to sit down in the ribs of the bed. It was the cleanest way to make the rear section removable that I could come up with. That was one of my crazier builds, especially for a "stock truck class" LOL
A better pic of what it looks like

Way too many hours into this cage!

As far as the pins go, I have a call in to find out where to get them. Fingers crossed I get a response!