Clutch
<---Pass
Could make the prototype out of wood then cast a mold from that. Have any boat builder buddies?
JK 4-door to 2-door long wheelbase conversion.....
- Thread starter Metcalf
- Start date
Could make the prototype out of wood then cast a mold from that. Have any boat builder buddies?
Metcalf
Expedition Leader
Nope, no boat builders here. I know a few river jet boat fabricators up north.....
I do have to wonder if fiberglass is the best answer? I think an aluminum top if properly fabricated could be VERY cool. The JK is pretty boxy....but also doesn't really have a straight panel on it. Aluminum with a double wall top for insulation and the inside sprayed with a bed liner material could be interesting......
I suspect the top could be hand carved out of foam......or cnc machined if you had the means/cad data. Then that used for a composite mold plug or whatever.
Carbon fiber/kevlar/honeycomb composite anyone?
I do have to wonder if fiberglass is the best answer? I think an aluminum top if properly fabricated could be VERY cool. The JK is pretty boxy....but also doesn't really have a straight panel on it. Aluminum with a double wall top for insulation and the inside sprayed with a bed liner material could be interesting......
I suspect the top could be hand carved out of foam......or cnc machined if you had the means/cad data. Then that used for a composite mold plug or whatever.
Carbon fiber/kevlar/honeycomb composite anyone?
Metcalf
Expedition Leader
yup, I am heading over to the EJS vendors show Friday. I am going to poke around the idea a bit.
AeroNautiCal
Explorer
Perhaps have a chat about your idea, the door infill panel and roof, with jscherb, who's already on this, and the Jeep forum.
His idea's, prototyping, testing and manufacturing are great, and he may be able to offer help, advice etc.
Just a thought!
His idea's, prototyping, testing and manufacturing are great, and he may be able to offer help, advice etc.
Just a thought!
Clutch
<---Pass
Metcalf
Expedition Leader
I would probably prototype the idea in aluminum at this point, then make a mold if it worked out well. Changing a few things in the aluminum version would be easy compared to in the mold/plug.
Anyone know the weight of the factory hard top? I don't think they are THAT light anymore.
Anyone know the weight of the factory hard top? I don't think they are THAT light anymore.
12husky
Adventurer
JScherb may be able to help you out with panels and a top.
http://www.expeditionportal.com/for...Overland-Camper-quot-Trailer-Build?highlight=
http://www.expeditionportal.com/for...Overland-Camper-quot-Trailer-Build?highlight=
Metcalf
Expedition Leader
I got to look over a JK 4-door last night. A few observations....
-Removing the rear doors and making a fill plate would be pretty dang easy. I think the fill plate would need to retain the factory style door seal to work correctly. Using a factory rear half door could make it REALLY easy if you still wanted the 'door' style access to the lower storage areas. I think a bolt in 'skin' in place of the door would give you the most interior space. I think the door is 4-5" thick overall? That is a lot of space that could be turned into storage volume!
-The rear section of the top would be pretty easy as far as the attachment and sealing. The factory system could be easily continued over the top of the door insert.
-The sealing at the back of the B-pillar would be a little complex. I think the best way to do it would be to have a lip on the front of the top that was the same as the front of the rear door edge. Then just add in a section of factory weatherstrip in that area to seal the new top to the B-pillar.
-Keeping the freedom top system would bring down the cost and complexity of the long wheelbase top, but I think there is value in eliminating those parts to allow a simple and clean looking top. I think all the factory forward top attachment points could be used.
-Having the new top use the factory rear glass would probably be the easiest. I do want to look at the possibility of making the 'kitchen' door in the rear that was a one-piece unit with an integrated window. The factory wiper could be used in either case. The JK glass and rear door 'tailgate' are the same side so I think this could work.
I am still thinking for a fully functional one off prototype that aluminum would be the way to go. There would be a lot of welding and forming, but I still think that is probably the best route to make something you could mold....that was fully functional to test. With an aluminum 'skin' style top I think some reinforcements would need to be added on the inside of the top to help with noise and rigidity. These reinforcements would not really affect the molding process if it went that way.....
Or......just get a REALLY big 3D printer.......
-Removing the rear doors and making a fill plate would be pretty dang easy. I think the fill plate would need to retain the factory style door seal to work correctly. Using a factory rear half door could make it REALLY easy if you still wanted the 'door' style access to the lower storage areas. I think a bolt in 'skin' in place of the door would give you the most interior space. I think the door is 4-5" thick overall? That is a lot of space that could be turned into storage volume!
-The rear section of the top would be pretty easy as far as the attachment and sealing. The factory system could be easily continued over the top of the door insert.
-The sealing at the back of the B-pillar would be a little complex. I think the best way to do it would be to have a lip on the front of the top that was the same as the front of the rear door edge. Then just add in a section of factory weatherstrip in that area to seal the new top to the B-pillar.
-Keeping the freedom top system would bring down the cost and complexity of the long wheelbase top, but I think there is value in eliminating those parts to allow a simple and clean looking top. I think all the factory forward top attachment points could be used.
-Having the new top use the factory rear glass would probably be the easiest. I do want to look at the possibility of making the 'kitchen' door in the rear that was a one-piece unit with an integrated window. The factory wiper could be used in either case. The JK glass and rear door 'tailgate' are the same side so I think this could work.
I am still thinking for a fully functional one off prototype that aluminum would be the way to go. There would be a lot of welding and forming, but I still think that is probably the best route to make something you could mold....that was fully functional to test. With an aluminum 'skin' style top I think some reinforcements would need to be added on the inside of the top to help with noise and rigidity. These reinforcements would not really affect the molding process if it went that way.....
Or......just get a REALLY big 3D printer.......
Metcalf
Expedition Leader
I didn't think you could get a 3d printer that big....but you can.....
http://www.voxeljet.de/en/systems/vx4000/
2x4x1 METER building envelope!
http://www.voxeljet.de/en/systems/vx4000/
2x4x1 METER building envelope!
Clutch
<---Pass
No offense, but that is just silly, so it would be little portal opens to the storage area ....why not just keep it a 4 door, then?
I know everyone has their own needs and desires, I dunno seems a little odd to remove some of the vehicles' already built in utility, just because of some minor issues...especially all the work, time and money that would be involved.
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Metcalf
Expedition Leader
I'm just saying....if you WANTED to do it that way you could. Access to storage and access for people are two different things. The factory door is pretty heavy, bulky, and takes up a decent amount of space on the interior....just sayin'
And, it would be my vehicle so I can do what I want!
And, it would be my vehicle so I can do what I want!
Clutch
<---Pass
I'm just saying....if you WANTED to do it that way you could. Access to storage and access for people are two different things. The factory door is pretty heavy, bulky, and takes up a decent amount of space on the interior....just sayin'
And, it would be my vehicle so I can do what I want!
Yeah yeah it is your vehicle....but really , how much weight are you going to save...is worth all that time and effort?
My buddy has a JK...I don't think the door takes up that much space, I guess you could make a nifty map holder out of the door inserts.
Not really bashing your idea, just being a devil's advocate...perhaps the voice of reason to some
Saw a guy once make his Wagon SUV into a Ute....cut the section off behind the rear doors, roof and all....gets it all finished and what not....then builds a camper shell to go over the Ute bed....ummm....isn't that pretty much what he had before he sawzalled the roof off...all that work and basically rebuilt what he started with...actually it was worse since he blocked off the rest of the interior space with a wall...totally wasted the usefulness of having a SUV...
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Clutch
<---Pass
Remember a friend will listen to your crazy idea, and ask "Are you sure you want to do that...?"
An enemy will love to watch you struggle...
My suggestion would be, go buy a JK 4 door..go out and use it just the way it is...and try not to use the those rear doors...I'll betcha they'll come in handy more often than not...
An enemy will love to watch you struggle...
My suggestion would be, go buy a JK 4 door..go out and use it just the way it is...and try not to use the those rear doors...I'll betcha they'll come in handy more often than not...