Triple-purpose JK Build

[jsmoriss]

From black to green.

I've been working on painting the new grille, among other things. I'm also planning a firewall bulkhead for battery cables, an in-cab winch switch, an electronic throttle control, etc., etc. Anyway, here are a few pictures on my painting project. This is the first time I attempt to 'paint something properly', and I now understand why paint shops charge so much. :-D

After sanding...

Putting on a special adhesive spray...

After several coats of plastic primer and sanding...

Laying down some color...

Wet sanding etc.

I came back inside for the clear coat...

Now it's gotta dry overnight, and tomorrow I can give it a nice shine with some rubbing compound....

I expect to finish the front bumper and grille this week-end. I'm going to take this occasion to drill a hole in the winch and run a few wires for an in-cab control. Warn has been a real ***** about giving me some technical specs. My (always handy) father-in-law has been giving me a hand deciphering the remote. It doesn't look too bad, but we'll know for sure when we pop the top on the winch tomorrow. BTW, this is a 9.5si with a 6-wire plug, which -- according to Warn -- is reeeeeeally complicated. We'll just see about that.

js.

 

[stjjames]

I love everything about this build - Awesome !!

 

[bmh]

are you painting in your house?

 

[jsmoriss]

are you painting in your house?

Of course! I may not do that again though. The smell lasted a long time. Luckily I met my wife after work and we took a long walk with the dog. By the time we got back, the smell wasn't so bad.

js.

 

[jsmoriss]

Almost there...

Woohoo! So the new bumper and grille are on!

The clear-coat didn't turn out _quite_ as I would have liked. It's a little 'pitted' and some of the rubbing compound stayed in those pits. Maybe if I find some kind of cleaning agent that won't harm the paint, the grille might look a little more shiny... Still, for a first time painter working on a balcony, it ain't _too_ bad...

js.

 

[jsmoriss]

Working on an in-cab winch controller for my Warn 9.5si...

http://expeditionportal.com/forum/showthread.php?t=17941

js.

 

[SeaRubi]

Painting in your living room ... that's dedication! If I were to try that ...

wife: :gunt:

me:! :rappel:

 

[jsmoriss]

Painting in your living room ... that's dedication! If I were to try that ...

:-D

I took the afternoon off while my wife was still at work. I met her later with the dog and we took a long walk. By the time we got back home, the smell wasn't _too_ bad. Still, I'm not likely to try that again -- without the painter's mask, the smell was overpowering.

js.

 

[SeaRubi]

I'm stuck on the 13th floor down by Wall St. in Manhattan, so I can understand the challenge My JK is gathering dust a couple blocks away ;-( and waiting for registration / insurance to get all processed.

 

[Dave Bennett]

Great thread and awesome build! :REOutArchery02:

 

[jsmoriss]

'Cause I don't have enough switches already! :-D

My current setup (photo from this spring, so not all switches are labeled yet):

The third switch panel -- an in-cab winch controller and backup battery controller -- will be going here:

There's a lot of plastic, both on and behind the console, that needs to be 'massaged' to fit the new switches and LEDs. I also ground down the OEM switch mounts to push out those square switches a little bit (making up for the thickness of the aluminum panel).

Getting a coat of primer before the flat black paint:

On the left will be a 3-position DPDT switch for the winch, and the right will be a 3-position SPDT switch for the backup battery BIC (battery isolator concentrator). There will be 4 LEDs -- from left to right: Green winch on/off, Red winch error (low voltage / overheat), Green backup battery connected, Green trailer batteries connected. When I turn on the winch (high amp solenoid controlled by a switch on another panel), it'll also trigger a relay that will ground the trailer BIC (so that right-most LED will turn off). This way, there's no chance of heating the battery wire going to the trailer when I use the winch.

The switch panels, from top to bottom, are setup as:

1- Bumper mounted driving lights (also needs High Beams to turn on).
2- Roof rack center mounted driving lights (also needs High Beams to turn on).
3- Roof rack corner mounted cornering lights.
4- Roof rack mounted backup / work lights.
5- Winch on (225A continuous duty solenoid).
6- York air compressor on.

1- Winch controller.
2- Backup battery BIC controller (on/auto/off).

1- Front locker on.
2- Rear locker on.
3- ABS/ESP off.
4- FAN off.
5- Electronic idle controller on.

I'm also continuing work on the laptop mount...

I glued it using come Loctite SUMO glue -- a low foaming polyurethane glue.

js.

 

[Starscream]

It's been a while since I have visited this thread. Your JK is coming along quite well. Nice attention to detail!

 

[jsmoriss]

Alright, so you guys have seen me siping tires and clear-coating a grille just off the dining room, so here's cutting up the hood ON the dining room table.

So the Jeep is now completely fixed, although the grille is still a little dull looking. I may just paint it flat black one of these days. I gotta get some pictures of it later today. I'm working on some air tanks at the moment.

Melanie and I drove up to La Verendrye Park in Quebec to try some of our gear. She really liked the fridge, table, stove, and chairs. Now I gotta do something about our tent -- we used our canoe-camping tent, which is fine, but I can do better. I've been working with Susan from Park City 4x4 on a Campa USA trailer.

js.

 

[Gear]

Awesome!! I am enjoying your build. Keep the photo's coming.

 

[jsmoriss]

Awesome!! I am enjoying your build. Keep the photo's coming.

Thanks! It's a little slow going because I don't have a garage -- everything has to be done parked on the curb. There are many advantages to living in the 'trendy' part of town, but parking isn't one of them.

js.