The evolution of "Alpine" Tundra

[RoundOut]

Short term mods: "To do list"

I've been swamped with work and helping start a new Scout unit. Finally today, we came up for air and I finished the modification of the laptop mount foundation. My son and I wrapped it up after dark under our halogen work lights.

After removing the entire mount, I re-drilled the holes in the floor and the new ones for the third anchoring leg. We put 1/4 x 20 machine screws and nylock nuts on each hole in the floor flanges, replacing the sheet metal screws that allowed too much wiggle. It is MUCH stronger now.

:wings:

So, getting back after it, I am excited to start working on the rest of the new mods...

1. Complete the sliders by reinforcing the mounting plates on the inside of the c-channel frame and finishing the rearmost support and mount on each side. When this is done, have them bead blasted then paint them with POR-15. Herculine the top surface when complete.
2. Install my Icom 208h faceplate and the display unit for my new backup sensors (both will need a partial pull-down of the headliner and drivers pillar for the cleanest install, so we'll tackle them at the same time) DONE 11/5/07 - See Pics in post 48.
3. Mount the Icom head unit under front seat. Done 11/5/07 - Pics to follow the next time I have to pull out my front seat for something, LOL. Installed antenna cable and run under driver's side scuff plates to the corner by the back seat. I am using a magnetic mount antenna and will mount it when using Ham and dismount when not, to remain invisible to envious eyes. Installed the power cable & run under driver's door scuff plate to area behind kick plate, through the firewall, along with two other future cable pairs, and on to a battery terminal setup I purchased at West Marine.
   • Still deciding whether to power directly from battery or include a relay and interupt the direct power with a switch. Decided to go directly to battery and utilize in-line fuses from the manufacturer. DONE 11/26/07
   • Still need to locate a remote microphone jack inside the console, visible only when the seat is removed. I am hoping to find a cat-6 wall-jack with a 90 degree socket so I can plug in from above, between the seat and console. (that may sound as clear as mud, but it's my best effort at describing it - pics will follow, for sure). CHANGED Design... Used a 24" Cat 6 cable and a female-female adapter. Icom wants about $80 for their microphone extension wire. I have $7 in this one and it works perfectly. DONE 11/26/07
4. Do a head unit swap with a buddy (his 1-DIN for my 2-DIN to make room for a switch panel in the lower DIN slot) 11/29/07 Pulled my head unit to check the mating of the connectors I bought at Wallyworld. They didn't match. took some pics and will try again later.
5. Get the class III hitch receiver and Tough Country Economy Rear bumper off. I have already sold them to a TSer from Dallas who should come down in a couple weeks to pick them up. He's scheduled to pick it up on Nov. 19th. DONE 11/19/07
6. Replace it with a new custom bumper with swing-out tire carrier... see first draft of plans in next post DONE - finished all accessory wiring today 11/29/07.
7. Relocate primary and backup batteries to new location behind rear differential after bumper build is complete. Done, see later posts
   • OUCH. I bought two runs of 2# Red and one run of 2/0# black. This was almost $300 just in cables. Changed to single red and single black by sealing and relocating my solenoid to the rear inside the battery box. Saved $100.
   • I purchased two battery lockout switches capable of sustained 300 amp current from West Marine today 11/29/07...Another $50. The lockout is installed, and the auxiliary lockout still needs to be.
   • Picked up some heat protective cover for the cables where they run near the exhaust manifolds, plus some exhaust wrap. I'll put it in the former, then wrap all three with the latter. Used the silicone sleeves, but not the exhaust wrap. Not only is the exhaust wrap overkill, it's $50.
   • We're supposed to get to work on the battery compartment next Tuesday or Wednesday, Dec 4 or 5. ( <--- This was written on 11/30/07) Today is 1/5/08 and we still have not finished [maybe read: started :-( I don't know?? ] It's in!
8. Finish the wiring of the backup sensors in the new bumper Done 11/29/07 - See pics & write-up on post #39
9. Add a compressor system with appropriate supply lines, valves & fittings to fill the air tank integral in my bumper. CHANGED to use a proper air tank instead of the bumper. Too many things to go wrong with as many welds as we have in my bumper. My buddy at CE Offroad let me have an old air tank from a truck. I need to pressure test it and sandblast it right away. I went with a Viair 400C compressor and remote mounting kit. I got all the stuff already just before and after Christmas 2007. Cheesy (I thought it would work the first time) compressor mount is in (1/23/08), and will be replaced ASAP, before I do anything but test the system.

Now, if I can only get my welder buddy's attention away from all his bread-and-butter race car work, I'll be able to avoid driving my buggy bumperless. Changed direction on this and hired CE Offroad to build it. See other posts for more info on this.

 

[RoundOut]

Rear bumper build

Here's my rear bumper design. It is the final written attempt before my welder buddy and I tackle it. He will undoubtedly have much wisdom and refinement to strengthen it and make it more functional.

 

[jim65wagon]

Wow! I don't have any mad skills, or anything constructive to add, but it looks to me like you're gonna have one fine lookin rearend when you're done with this exercise!
:shakin:

 

[Haggis]

Wow! it looks to me like you're gonna have one fine lookin rearend when you're done with this exercise!
:shakin:

Not sure where you're going with this Jim, I'll let RoundOut and you work it out.:smileeek:

 

[jim65wagon]

Well, I was going for an interesting way to express a positive opinion on a well designed bumper for a nice looking truck...It's really not my fault your mind reads way more into a compliment than is necessary.

Is simpler better? Nice bumper, Gary.

 

[devinsixtyseven]

Well, I was going for an interesting way to express a positive opinion on a well designed bumper for a nice looking truck...It's really not my fault your mind reads way more into a compliment than is necessary.

Is simpler better? Nice bumper, Gary.

I must admit, I lost it reading your post as well ...paraphrased, it went "Nice ass, Gary!" :shakin:

That rear bumper design is awesome!

I've been looking at the rear mounted battery thing as well...you figure you'll keep the existing crossbrace or just make a new one? It could go either way, but I was thinking there's that X-brace behind the rear axle, the one that normally supports the spare...I was thinking it'd be a great place to sink a pair of batteries instead, with a redesigned cross brace. I like your idea of mounting them aft of the rear axle better than sticking them in front to the right of the driveshaft.

 

[Haggis]

Well, I was going for an interesting way to express a positive opinion on a well designed bumper for a nice looking truck...It's really not my fault your mind reads way more into a compliment than is necessary.

Is simpler better? Nice bumper, Gary.

Sorry Jim, I tried to resist giving in to my baser urges to razz my brother inlaw, but I was in a merry mood. I'll await the eventual retribution at a later date.:sport_box

 

[RoundOut]

Thanks for all the love, guys! LOL

... it looks to me like you're gonna have one fine lookin rearend when you're done with this exercise!

You mean because of all the weight I am going to lose...
(in my wallet)? :shakin:

That rear bumper design is awesome!

Much thanks! I have made one significant design change since posting the plans... moving the hitch receiver from top to bottom.

I've been looking at the rear mounted battery thing as well...you figure you'll keep the existing crossbrace or just make a new one? It could go either way, but I was thinking there's that X-brace behind the rear axle, the one that normally supports the spare...I was thinking it'd be a great place to sink a pair of batteries instead, with a redesigned cross brace. I like your idea of mounting them aft of the rear axle better than sticking them in front to the right of the driveshaft.

What a great lead-in to a (minor) change of plans... (I'm now going to have some extra 3/16" plate to play with)...

Being the patient guy that I am (NOT), I got tired of waiting on Joey, as my bumper build has been getting delayed in favor of his high-priority, bread-and-butter, time-sensitive, dirt track race car repair/fabrication business. If I was him, I'd do the same thing, so no hard feelings, but it sucks not getting his attention.

I found a new fabricator after being referred to him by two different guys in opposite ends of Houston. Check out www.ceoffroad.com, located just northeat of a retail location I have in The Woodlands. After the second guy referred me to Creative Engineering Offroad, I called Mark Klause. He has some down time between some large jobs, so he starts my build Monday morning. He has a CNC plasma cutter and he's going to use a single sheet of 3/16" plate and give me the left-over. As such, I figured I'd get busy designing something for my dual batteries and he can cut that at the same time.

Also, we are eliminating the integrated air-tank idea for a couple reasons...

• The number of interior welds with possible leaks is pretty extreme, and without being able to test them for air-tightness, it could get real frustrating.
• With the humidity around here, condensation inside the air tank/bumper would create significant interior rust. No matter how often I drain it, there is just almost no way to avoid this, short of lining the interior with a coal tar epoxy, which would be expensive and difficult at best.
• We can fit an air tank along with the battery box behind the rear axle where the spare was, and they are not that heavy, anyway.

In answer to your question Sean, I was contemplating making use of an aluminum USMC mortar case that I have. It could fit both Optimas and still have room for a third. It is water tight, until I cut holes for battery cables, that is. I'll then use some spare 3/16" plate to make a skid plate for the rear, protecting my battery box underbelly. If I put some brakes in it, it could be pretty strong, and since the rear isn't near as heavy as the front, 3/16" plate should do the trick. It would also serve as an additional cross-member of sorts.

I will be removing my existing Tough Country rear bumper on Sunday afternoon. The buyer is coming Monday morning to pick it up. That will give me Sunday afternoon to get it all cleaned up and shiny for him.

:wings: :wings: :wings: It is getting close and I'm so excited!!! :wings: :wings: :wings:

One last thing, I still need to finish my slider support in the back, just forward of the rear wheels. Mark had a great idea, welding a tab to the spring hanger and running the rear-most support bracket off of the sliders to the tab. Schwing!!! That is a great idea, and it is a perfect horizontal run of just a few inches of 2x2 tube. So, that is the plan.

After getting the rear bumper, swing-out, & sliders wrapped up, I'll have everything blasted and coated. Mark uses a guy that does blasting very reasonably, so off we'll go.

This phase of the project should be done before we go camping next weekend!!! Maybe, I'll even get the batteries relocated!

:jumping: :jumping: :jumping:

.

 

[RoundOut]

Bumper in progress!

:wings: :wings: :wings:

The new rear bumper project is under way!!!

Here's a teaser pic of the 3/16" plate on the plasma cutter. I know, the quality sucks, but it was taken by my phone. [NOTE: pic lost until ExPo can find it - I lost some pics, too.]

 

[RoundOut]

Fender Trimming - EEEEEEK

The point of no return! LOL. :Wow1: I'll be trimming my fenders today so my rear bumper can offer wrap around rear fender protection. :yikes:

I should have the whole thing bolted up, actually in the bed ready to take to the Rhino Liner guy.

I got a new phone with a 1.3 mp camera, so maybe the pics will be better than before.

EDIT

Didn't do the trimming yet. I just noticed this post and figured I would clear that up. Still planning on it, though, just not until after the battery relocation is finished.


.

 

[RoundOut]

Bumper is on, Rhino today!

Wow, things never seem to go as easy as you expect. What turned out as a 12 hour job, became an all day yesterday (Tuesday) and today (Wednesday), with today until almost 1 a.m. Thursday. Yikes.

It was well worth it though, I am so pleased with the product. I have an appointment at the Rhino place for in the morning. That means that I should be ready to install the backup sensors and rear-facing lights tomorrow night. I can't wait.

One bonus, was that the long-tube hitch that I had fit without modification in the new bumper. This may seem trivial, but it saved me an expected replacement expense.

Here are some progress photos...

1) Left side view before test fit to mark mounting plate holes
2) Right side view before test fit...
3) Pin for spare tire carrier on right side of bumper
4) Mark taking a breather in front of the work-in-progress
5) Mark working on spare tire carrier
6) Vertical for spare
7) Almost done, ready for the final mounting and last few welding steps.

 

[RoundOut]

Bumper pics!

I wish I could have some better quality pics and ones not from my driveway, but I forgot to take some while camping this weekend. Speaking of camping, we weathered the worst storm I have ever camped in. Probably close to 2 hours of red-on-the-radar thunderstorms. Took most of the afternoon to clean and dry out my gear.

Here they are.

1) from PS rear
2) from DS rear
3) clamp holding spare tire rack
4) axis pin of spare tire rack
5) lower view from PS rear
6) right end view high
7) right end view low

Note in pics 4 & 5 the flush mounted backup sensors. The auxiliary backup lights are also highly visible in pics 1, 2, 3, & 5. I have yet to wire the sensors to the controller & display. I also still need to wire the aux backup lights and install the trailer wire harness and socket.

Note also the unique design of the clamp in pics 2, 3, 5, & 7. Mark installed it this way, because it pulls the crossbar down, in, and onto the striker plate from the bottom and front.

Mark also warned me to rattle can the bumper until I was sure I had all the bells & whistles I wanted. I should have taken his advice on that, because we didn't weld a stop post to keep the rack from swinging all the way around and striking the RR fender. I doubt this would ever happen, but Murphy's law says it will, and at the worst possible time.

Pic 4 also shows the radio antenna tab.

 

[jim65wagon]

Wow! I can only refer to aprevious post I made in reference to this subject which raised an eyebrow or two. Now everyone can see I was correct in my prediction!

But I'll restrain myself: Nice Bumper Gary!

 

[p1michaud]

Cool bumper!

Very nice bumper. That came together rather quickly.

On a previous post, you mentionned trimming your fenders for wrap around protection. Have you chaned your mind?

Cheers,
P

The point of no return! LOL. :Wow1: I'll be trimming my fenders today so my rear bumper can offer wrap around rear fender protection. :yikes:

 

[RoundOut]

Thanks guys! I am very pleased with how it came out. Now if I can just get the lights and backup sensors wired before Tuesday afternoon's road trip.

On a previous post, you mentionned trimming your fenders for wrap around protection. Have you chaned your mind?

Nope. We just ran out of time. We'll have to defer additional "evolution" until after Thanksgiving.


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