Project MULE - Expedition build on a 1991 1500 4x4 Suburban

[PMA4x4]

Ok , We are denied access to the heated curing booth with the minieral spirits in the paint (I guess I can kind of understand). My friend Bruce just did it in jamming booth then.

Before anyone asks. the rear side glass and rear window glass was left in as they are the laminated privacy glass and the seal are a bit stiff. He had their glass guy look at it and mentioned we may want to leave them in as the odd of them breaking are pretty high. Since this is a side job the glass would have come right out of my pocket. Bruce is really good at being able to string and tape window seals left in so he can get paint in under the seals.

 

[PMA4x4]

Recovering from a nasty 48hr cold so I figured I'd do some lighter stuff and start cutting the new aluminum lower door panels.

 

[PMA4x4]

Just about done. The weatherstripping for the windows has haulted this assembly. I cant explain how bad they are.

 

[PMA4x4]

We start mounting the roof rack in tonight. After the rack mounts themselves are mounted we will then take the roof rack off and then paint the roof with the elastomeric roof coating. While the rack is off I will be wiring it for lights. mean while the wife will be assembling the front expedition winch bumper.

 

[PMA4x4]

Very unproductive day. This Chest cold is still kickin' the crap out of me!

I was able to get the rack on the roof and already I need to make modifications for a couple fo the mounts as the roof has a slight bow from front to back

 

[PMA4x4]

You don't have to be crazy to drill 32 holes in a perfectly good roof... but it helps.

 

[warwgn]

Hey I like that mounting idea, cant wait to see it all installed. Be sure to get some close ups of the mounting points after install, great work man looking good.

 

[BBslider001]

looks good! What type of sealant did you use on the rack mounts to keep them water tight? I am thinking of putting some sort of rack on mine as well.

 

[PMA4x4]

looks good! What type of sealant did you use on the rack mounts to keep them water tight? I am thinking of putting some sort of rack on mine as well.

100% Silicone (clear). Caulk gun tube type, its cheaper that way. the whole bottom of the plate was covered, the holes had a dab in them and the threads got it too.

 

[PMA4x4]

Cool coat rooftop is done.

 

[PMA4x4]

CHRISTMAS! from Germany! Thanks to "Northman" for showing these on your rig.

Remember I ordered these?




Here they are!

 

[uscg2008]

I always did love them old burbs, Sub'd for this .

 

[onemanarmy]

Hard to beat these rigs for the passenger space, cost, and ease of finding parts (parts being cheaper too)

 

[PMA4x4]

Welding the expedition bumper together. Wife took some shoot while I was busy, didn't even know until she told me. Enjoy

 

[PMA4x4]

Well this one was ready to go and then I found it needs another adjustment. I need to move the front cross bar up and out in order to clear the control box of the ZEON 12,000lb winch!

But here is it primered and ready for paint.