Refreshing the TJ - Build Thread

[GP'd]

Seat Brackets:

Built and drilled simple seat brackets out of 1.5" x .250" cold roll. Using the factory brackets we transfered the pattern with a center punch then used the mill to drill through all 4 brackets at one time. These four 18" pieces will span the cage floor bars and secure the factory sliders. This will allow me to use factory seats or any aftermarket seat with a TJ adapter.

My friend checking center on the next hole.

 

[GP'd]

Friday Night I installed Poly Urethane Body mounts (Energy Suspension 2.4107G) so that the cage frame tie ins and body flex at the same rates.

I did not take photos of this process but it was a quick install completed under an hour and a half. The trickiest part of the install were hammering the body mounts straight and putting in the front grill bumpers. If you ever have to do this, grease the rubber bumper posts first!

Bent body mounts were due to a slight misjudgment at the dunes. This incident 6 years ago resulted in a bent fender as well. Fortunately that was all. At least I have a picture of it.

Younger and dumber self behind the wheel. Don't listen to friends with cameras.

Bent Mounts required hammering and filing to get the metal sleeve to pass through and seat correctly.

On Sunday I also started on my boat side rockers and tacked my seat brackets in. The drivers seat still needs a bit of adjustment. No pictures of seat brackets yet.

 

[GP'd]

It looks like my Beams Tri-Lock Seat belts shipped today. Hoping to have them to install next weekend.

 

[Septu]

Bent body mounts were due to a slight misjudgment at the dunes. This incident 6 years ago resulted in a bent fender as well. Fortunately that was all. At least I have a picture of it.

Younger and dumber self behind the wheel. Don't listen to friends with cameras.

And it is a great picture!

 

[swift7777]

Yee - Haa, great & expensive picture.

 

[GP'd]

And it is a great picture!

Yee - Haa, great & expensive picture.

Hah! Thanks. $150 dollar picture. Found a set of used fenders a few years later for cheap. I bent the newer set a few months ago wheeling in Big Bear.

Still waiting on some used AEV fenders or will just bite the bullet and buy new ones.

 

[GP'd]

I was able to get the Lower B Cross bars in. The upper B-C Cross bars were made but not tacked in this image. A couple hours of tweaking left with it in the tub and I can pull it later this week/weekend for final welding and paint. I hope it can be lifted with just 3 guys. I'll know after I calculate the weight later tonight.

 

[GP'd]

PROGRESS! The notching and bending is over! Over 3 dozen different tubes went into this.

Next : Finish seat/seat belt brackets and pull it out of the tub for final welding and gusseting. Frame Tie ins. Boat sides. Truck Bed lining.

 

[GP'd]

Completed all bars and brackets on Sunday and had 3 buddies come help me lift it out of the tub. Unfortunately I had to cut one of the tub brackets to remove the cage, but it can be easily reattached.

Next steps : Finish cutting for the boat sides, sand the interior for heat/sound deadening and roll on liner, finish welding and add the gussets. The stages of this project ended up a lot bigger than I expected... Garage is also a mess right now.

 

[Flashole]

WOW! You sir, have mad fabrication skills.

And, this thread makes me want a mill and a pipe bender

 

[paulsmith]

nice work!!

 

[GP'd]

WOW! You sir, have mad fabrication skills.

And, this thread makes me want a mill and a pipe bender

nice work!!

Thanks guys! Appreciate the feedback. I have never done most of these projects, especially to this scale; so it has been a blast to learn along the way!

 

[GP'd]

Some Updates:

AEV Highlines come tomorrow! Mixed feelings. Really excited to get them, not so excited to get brand new fenders and have to cut them for boat sides and shock towers.

Cage Welding - 90% Done. Only a few more taco gusset and trick tabs for consoles and attachment points before it's ready for paint.

Current To-Do whiteboard list...

 

[GP'd]

Finished mocking up the boatsides on Saturday. Filler panels on the tub sides are next before heat and noise reducer and Al's liner install. Cutting the AEV highlines that just came in is going to be tough!

 

[RugerTrailer]

Looking forward to the finished product. The hood chop is the biggest pain of the highline job...unless you got the AEV hood too?