Barn Door for JK factory hardtops

[akpostal]

I like the rack, your stuff is top notch. I dont run a spare on the rear so could this rack be made to where the tray is just above or right at the top of the gate?

 

[Comanche Scott]

It's funny you mention the CMHSL because just this morning I picked up some plugs to match the JK's wiring so I could implement a plug-in CHMSL on the rack.

The rack is something I've been discussing for a while with the company that manufactures the HD hinges and tailgate reinforcement, I've wanted to do something like this to take advantage of the extra strength the hinges and reinforcement provide. If they like what I've built they'll probably show it as an engineering proof-of-concept in their booth at the vendor show at Easter Jeep Safari. It won't be on my Jeep, I'll be driving the LJ for that event, but it probably would be on one of their Jeeps - which is why I got the plugs to make the CHMSL plug-and-play.

Today I put a few finishing touches on the rack, including Molle grids on the sides. As soon as I get the CHMSL done and get the parts reinstalled I'll post some photos.

That's perfect! :victory:

In other news...
Any updates on the tire covers?
Inquiring minds need to know.

 

[jscherb]

I like the rack, your stuff is top notch. I dont run a spare on the rear so could this rack be made to where the tray is just above or right at the top of the gate?

Thanks. A rack based on this design could definitely be built to have the tray at or near the top of the tailgate. It would probably have to be built as a one-off, I doubt you'd ever see one like that available commercially - how many people out there could there be that don't carry a spare on the tailgate and want a rack at that height?

 

[jscherb]

That's perfect! :victory:

In other news...
Any updates on the tire covers?
Inquiring minds need to know.

The company received the 37" pre-production sample from the sewing place about two weeks ago and they reported it fit their 37's fine and looked good.

The last I heard was that the company was all set on the black fabric for production, but was reviewing a few sources for the Coyote fabric - apparently there's a wide range of colors called "Coyote", some of which are closer to brown and some of which are closer to tan. The color the company wants to use is a Coyote Tan that's fairly close to the old Jeep Spice color. I think as soon as they get the source for that fabric nailed down, the first production run will be done and won't take long.

 

[akpostal]

Thanks. A rack based on this design could definitely be built to have the tray at or near the top of the tailgate. It would probably have to be built as a one-off, I doubt you'd ever see one like that available commercially - how many people out there could there be that don't carry a spare on the tailgate and want a rack at that height?

Could you modify the plans to put the tray a little above the gate? I think I can find someone local to make it. Of course Ild have to get your hinge setup, would this work without the tire mount?

 

[jscherb]

Could you modify the plans to put the tray a little above the gate? I think I can find someone local to make it. Of course Ild have to get your hinge setup, would this work without the tire mount?

At this stage of the design process I haven't done final plans. I've done a set of preliminary mechanical drawings that I used to make the prototype parts, but the drawings are far from being final.

This rack requires the HD hinges and the tailgate reinforcement. It does not require a spare tire mount.

 

[akpostal]

I know Im in the minority wanting a low rear rack version of what you built, but I cant be the only one. I have an idea for mounting the spare inside my JK and putting the lighter recovery gear and maybe a cooler/fridge out back works for me. That and it would make better room for my dog.

 

[jscherb]

I finished up the last few details on the prototype Overland Rack this morning. One of the details I added is a plug-and-play third brake light - it plugs in to the factory with a plug that's compatible with the factory third brake light wiring. I also finished up the step for climbing up on top, and I added Molle grids on both sides. You can see the third brake light in these photos.

This morning's sewing project can also be seen in the above photos - an ACU camo cover to protect the jack mechanism from the elements, I thought it would be nice to match the ACU Tactical Spare Cover and the military surplus Molle pouches.

A Molle pouch on the driver's side (there are also two on the Tactical Spare Cover):

And a 2.5-gallon Rubican on the passenger side. You can also see the step in this next photo.

I also redid the 225-lb. gorilla test video with the finished rack, this time the gorilla is being a little rougher on the rack:


The complete rack weighs just under 39 pounds. Light weight + high load carrying capacity were main design goals for this project, I don't believe in using up cargo capacity by having unnecessarily heavy cargo racks.

 

[Yuke]

Jeff,

Random question on the window slider kits. If desired could the windows be flipped to the other side so the opening was towards the front? I think this would work best if I decided to use them as a access panel.

Are they able to be opened from the exterior?

 

[jscherb]

Jeff,

Random question on the window slider kits. If desired could the windows be flipped to the other side so the opening was towards the front? I think this would work best if I decided to use them as a access panel.

Are they able to be opened from the exterior?

The windows are side specific - because the factory windows slant forward and the sliders are fitted specifically to those angles, the windows only fit on the side they're intended for.

If the window is latched inside, they cannot be opened from the outside. Even unlatched it would be a bit difficult to slide the window from the outside because there's no grip on the outside.

BTW the first production windows are out of the window company shop, a pair is on the way to me and is supposed to arrive Wednesday. I'll post photos of the windows as they come out of the box and I'll also install them in one of my test hardtop panels. Photos to come later this week...

 

[Yuke]

The windows are side specific - because the factory windows slant forward and the sliders are fitted specifically to those angles, the windows only fit on the side they're intended for.

If the window is latched inside, they cannot be opened from the outside. Even unlatched it would be a bit difficult to slide the window from the outside because there's no grip on the outside.

BTW the first production windows are out of the window company shop, a pair is on the way to me and is supposed to arrive Wednesday. I'll post photos of the windows as they come out of the box and I'll also install them in one of my test hardtop panels. Photos to come later this week...

Thanks for the speedy response. I am eager to try and get a set on my JKU

 

[jscherb]

I received an early production test slider window retrofit kit today; this one is for late model JKU factory hardtops.

A window just out of the box:

The windows come with screens; these can be removed easily if they're not wanted.

The fit of the windows is great and the overall quality is excellent. There are one or two very minor tweaks I'll ask the window company for before approving these for full production, but the changes are very minor and won't delay the startup of production.

In this next photo the slider is inserted into the retrofit kit mounting ring, which fills the window opening in the hardtop and provides a flat mounting surface for the window.

Tomorrow I'll do an install in one of my test hardtop panels, photos to come.

 

[Yuke]

Looks awesome.

They appear tinted. What percentage?

 

[jscherb]

Looks awesome.

They appear tinted. What percentage?

It's a match for the factory tint.

 

[jscherb]

The slider and retrofit kit installed in a test hardtop panel.

A factory window for comparison: