Barn Door for JK factory hardtops

[jscherb]

I know its not you, I just cant wait to get the slider kit.

Too bad you live on the other side of the country - if you were close enough we could install the pre-production kit as soon as it's in my hands, then your wait would be shorter than anyone else .

 

[jscherb]

As far as the method of the rear edge matching the bumper.

I prefer "E" angle trim.

Nice Job!

I like the "B" small radius the most as it preserves the "flatty" look, but also matches the rear bumper in as unobtrusive a way as can be done I think.

...I like the straight trim.

Thanks everyone for the input - I haven't decided which trim I'll install on my Jeep, but the good news is that it can be an installation-time decision. Since the fenders will come out of the molds with enough material to support any of the trim options, that can be decided when they go on. Also makes me think that if these became a commercial product maybe they should have the largest trim option (E), and the user could be supplied with templates and photos like this so they could decide which trim option they like best.

Can't help wondering what it would look like with the original side step running board as well. The way they both terminate now into open space due to the rubi rails makes me wonder if a heavy duty steel running board that matched the fenders (especially from the angle of picture 1) wouldn't look interesting and provide protection?

If you look back in the thread, I did the cardboard mockups and the mold masters for the front fenders back when I had the factory side steps installed, so maybe those photos will give you an idea. I sold the steps when I installed the Rubi rails, so I can't do any photos of the finished fronts or of the rears with the steps anymore.

 

[jscherb]

Hi Jeff,

I like the design. Matches the front fenders well, for a balanced look.
I also like the idea of them being nice and smooth coming out of the mold. It's easy to add texture. It's a pita to make textured items smooth.

Thanks! Personally I don't think texture is the way to go with these - the original Willys fenders weren't textured .

 

[jscherb]

Out of curiosity, what are your plans for the FSJ front end regarding the flat fenders? Last I remember, your plan of attack was new grill, new hood no change to fenders?

That's correct. The flat fenders will work with the Retro Rhino kit.

These fabrication projects of yours are extremely interesting and inspiring to watch. If you don't mind could you describe a little what your process looks like from the conceptual point of view? Where would you say you develop most of your plans eg. went to SEMA and saw a gap in X product line, or do you rely more on just the little "hey that would be cool if" type moments? Hope that doesn't come off as "fan-boyism", just genuinely curious on that step of the creative process through the myriad side-shoots that have stemmed from the original barn-door thread I started reading last year. Great Stuff!

I'll try to answer...

Most of my ideas start from one of three places - either I have a need or see a need that I think I can come up with a unique solution for (JK side mount jerry can carriers, for example), or I just think something would look cool (flat fenders) or I think of a way to do something very different than it's been done before and add functionality and/or styling to it (Safari Cab hardtop with barn door/removable sides/soft sides/etc.).

I rarely do something that's been done many times before, I like to be more creative than that. And if I do design something in a category that already exists, my design will be more functional/modular/easier to install/lighter/cheaper to manufacture - for example, my tailgate reinforcement design which includes HD hinges, the reinforcement and an HD spare carrier (and soon the Overland Rack). All of these components are at least as strong and as functional as the "big company" products, and they're less expensive and have features the big guys should be embarassed not to have included - the HD hinges are greasable and rebuildable, for example.

All of my designs start with concept drawings (I post only about a third of the concept drawings I do BTW), and I spend a lot of time in the detail design phase before I begin construction. I never "start cutting and figure it out as I go"... pretty much everything is planned before construction begins, even on a project as complicated as the Safari Cab hardtop.

But the designs often change as they're under construction, mostly due to input from forum members - for example, I had planned to do flip-out vent windows in the JK Safari Cab, but someone on the forum suggested that I power them. That was such a cool idea I wished I had thought of it myself, and it became part of the design.

I use most of my designs on the road and the trail, with the exception of the modular JK 2dr hardtop (I don't have a 2dr to test it on), although sometimes I'll design and build something as an "art project" just because it's an interesting design challenge and a fun construction project (example: the Jeepster Commando front end kit for the TJ - I made the molds and a set of parts and I've never used them on a Jeep, except for mockup purposes).

I have never done work for hire - I do all of this stuff as a hobby and it has to be something that interests me and I can be creative with. If I build something and it achieves all my design goals, then I'm happy. If something I design becomes a production product, that's nice, but it's not why I do it - I do it for my own satisfaction and enjoyment.

Sorry for the long response - does that answer your question?

 

[02rangeredge]

One of the details I'm still playing with is how the rear inside edge of the wheel arch gets trimmed - because the bumper wraps so far forward towards the wheel arch, the front of the bumper can be forward of the back inside edge of the fender wheel arch. There are a number of ways to trim the fender to accomodate this. Also, different aftermarket bumpers might look better with one of the trim options below or even a different one. I'm going to make the molds so that any of the trimming options below are possible so I don't have to decide this now, but here are a few ways it could be done...

either option C or D, the radius triangles don't quite fit with the angular fenders, and E just looks off with the nearly vertical interior but E does make the most sense for mass production because of the trimability of the fiberglass

 

[akpostal]

Ive got the EVO rear bumper delete so thats why Ild go with option A.

 

[akpostal]

Too bad you live on the other side of the country - if you were close enough we could install the pre-production kit as soon as it's in my hands, then your wait would be shorter than anyone else .

You have no idea how tempting it is to pack up the dog and trailer and start driving. Ive got a few relatives in NY as well as a number of friends I havent seen in a while.

Damn it, now I thinking about this and I can do it. How close are you to Long Island, NYC, or Syracuse?

Crap I need a passport.

ETA: I could even go down to Richmond and see my dad and get my sister to drive up from NC. Looks like the route will go through Minnesota, and Wisconsin where I also have a lot of family. I could even head to Baltimore for more family. Damn it this is something I want to make happen.

 

[jscherb]

Ive got the EVO rear bumper delete so thats why Ild go with option A.

That's exactly what I'd do in your case.

either option C or D, the radius triangles don't quite fit with the angular fenders, and E just looks off with the nearly vertical interior but E does make the most sense for mass production because of the trimability of the fiberglass

Like you said, if these became a commercial product maybe they should have the largest trim option (E), and the user could be supplied with templates and photos like this so they could decide which trim option they like best. What I'll probably do on my Jeep is install them trimmed as in E, drive it a while to see if I like the look, and if I don't, I'll trim them some other way.

 

[jscherb]

How close are you to Long Island, NYC, or Syracuse?

Syracuse, the nearest of those places is 90 northeast of here (Elmira). Elmira isn't near anything or on the way to anything.

 

[akpostal]

Syracuse, the nearest of those places is 90 northeast of here (Elmira). Elmira isn't near anything or on the way to anything.

Best friend/old girlfriend is in Syracuse Ild love to see her again, and meet her wife and kids. My brother is in LI and good friend/old roommate and cousin are in NYC.

A trip like this would be pretty epic for me, even without going offroad, though Ill have to look into a dirt everyday route. Ive got the time, I gotta get this planned out.

 

[jscherb]

Speaking of trips... I had to put some factory rear fenders back on for a weekend trip to Boston to do some cycling. The factory ones will come off as soon as I get home so I can begin work on the rear fender mold masters.

 

[rubicon91]

Speaking of trips... I had to put some factory rear fenders back on for a weekend trip to Boston to do some cycling. The factory ones will come off as soon as I get home so I can begin work on the rear fender mold masters.

I think it would have been way more beneficial to you Jeff if you just cycled to Boston instead lol then you would not have had to put the factory fenders back on. Hehehe. Enjoy I sure it is some insane mileage you are doing with your bike.

Donny

Sent from my SAMSUNG-SM-G890A using Tapatalk

 

[jscherb]

I think it would have been way more beneficial to you Jeff if you just cycled to Boston instead lol then you would not have had to put the factory fenders back on. Hehehe. Enjoy I sure it is some insane mileage you are doing with your bike.

Donny

Hey Donny,
Only did about 35 miles today, was riding with my son and daughter who both live in the Boston area.

Here's a bike/Jeep photo that I took in May when I was in Florida, you should recognize the location... I parked on the Sanibel Causeway and rode from the causeway to the Sanibel Lighthouse (visible in the distance) and then to the north end of Captiva and back...

Biked 48 miles on Friday, my other son has a summer job that had him in Watkins Glen NY that day so I rode from home to the Glen and back to have lunch with him.

 

[rubicon91]

Hey Donny,
Only did about 35 miles today, was riding with my son and daughter who both live in the Boston area.

Here's a bike/Jeep photo that I took in May when I was in Florida, you should recognize the location... I parked on the Sanibel Causeway and rode from the causeway to the Sanibel Lighthouse (visible in the distance) and then to the north end of Captiva and back...

Biked 48 miles on Friday, my other son has a summer job that had him in Watkins Glen NY that day so I rode from home to the Glen and back to have lunch with him.

You do love you miles and miles on the bike. Good for you. I could not imagine the ride to and from the north end of captiva. That's a haul. Good for you though. I could not do it in fact the first bar would have had me at it drinking lol

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[thechadwick]

Most of my ideas start from one of three places - either I have a need or see a need that I think I can come up with a unique solution for (JK side mount jerry can carriers, for example), or I just think something would look cool (flat fenders) or I think of a way to do something very different than it's been done before and add functionality and/or styling to it (Safari Cab hardtop with barn door/removable sides/soft sides/etc.).

Thank you for the in-depth reply, makes me want to get familiar with sketchup and get after a couple of projects myself! Excited to see how the rear fenders turn out, all the best from Fort Benning Georgia.