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ROCKRIDGE4WD Introduces a NEW Jeep Wrangler JK *led* tail Ruffstuff XJ Unirail Channel Reinforcement....Rugged Ridge Modular XHD Snorkel Now for both 3.8L and 3.6

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Unread 09-06-2011, 12:38 PM   #316
hallsofstone
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Simply fantastic. I've really been wondering how you made those and it was exactly how I suspected! I guess this means I might be learning something. For a young man just getting into major vehicle modification and the related metalwork/fabrication, this build has been hugely helpful and informative. Thanks again for taking the time out of your life to educate and entertain the rest of us!

Really looking forward to seeing where you take this project from here. Mind you I'll be on that virtual stool in the corner with my cold PBR, a pen, and my spiral notebook!

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Unread 09-06-2011, 06:46 PM   #317
50wllystrk
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You guys are great, the feedback is great. At my age I've reached a point to where I am happy to teach. My ideas and interests, I'm happy to pass them on and I'm sure you all will take something away from this thread and put it to use.
I'm getting close to finishing most of the metal work, well maybe a couple more weeks anyway, then I'll prep, clean, and begin prime and paint. Alot of the priming and painting is the same as working with a car body that has been stripped to metal. I'll keep the pics coming as I'm moving along.
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Unread 09-06-2011, 10:52 PM   #318
50wllystrk
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Class is back in session..... get out the notepads, wipe your eyes and let's move forward. Ahhh this thread is getting some characters.
Last picture showed the grinding of the outer edges but before I'm finished I have to cut off the extra inch or so I left on both ends of the plate. So many choices, I can use a torch, plasma, hacksaw, 3" inch air grinder or 4 1/2" grinder with a cut off wheel. I'm going with the 4 1/2". Picture here has the cut off wheel attached.

The shapie marks the line to cut. I figured about an 1/8" extra material for grinding and shaping later.

Cutting is done. Be carefull when using the 4 1/2" grinder for cutting thicker materal as with 1/4" plate. The first couple passes are no problem, but the deeper you go you have to concentrate on keeping the cut off wheel straight and true, other wise the sides of the wheel will grab the sides of the plate in the cut zone and the grinder has the torque to jerk the grinder around unexpectantly .
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Unread 09-06-2011, 11:16 PM   #319
Endimar
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Beautiful! Absolutely beautiful work! What are you going to clean it up with? The flap disk did an awesome job with the weld lines. Use that maybe?
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Unread 09-07-2011, 09:50 PM   #320
50wllystrk
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Yes Endimar the flap discs are gonna clean up the grinding marks and smooth and shape the ends. This will be the last pic focused on the top plates. Let's think back a week or so..........they're leaf spring top plates........have you ever thought top plates would be something to wait in anticipation to see how they're made and the finished product? No, I didn't think so. I like to think it's the product made by two hands, something we've lost touch with in a world of quick fixes and mail order products. You all are further ahead than I, you can see what can be done with a little imagination, you've seen indetail just a few tactics on how to manipulate metal. I'm so pleased to read where some have mentioned that you're motivated to buy some welding tools and go at it. The best part of welding and fabrication is that it is an art, it is a skill, and it is practical, when finished you get a rush out of something you built. Here's a before and after pic.

Suspension along with shocks and mounts are pretty well set, they just need some final welding and grinding before primer and paint. I have to get back to finishing some of the areas that the rust ate into. I still have the rust pockets that formed behind the original shock brackets. Here's a close-up reminder of what needs filling yet. I did the same with these as I did with the rusted away spot above the rear spring mount. Start welding to fill and grind flat. What sucks here is the enclosed area to work in. With a top and bottom frame rail so close it's gonna take careful grinding of I'll start grinding somewhere I don't want to.
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Unread 09-07-2011, 10:35 PM   #321
spyder6
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this has to be one of the best, if not the best thread i have ever read through on this forum. seriously, its been a blast following all the pictures. and i have to say, it makes me happy to see you trudging through the 56k to upload all of these pictures.

really interesting to see the steps you're taking to "bend" metal without access to a brake.

keep it up!!
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Unread 09-08-2011, 07:48 AM   #322
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Sorry 50willys. I see new posts and pictures on this thread and I get excited It's jeep porn I swear. My wife says I talk in my sleep about flap discs and 4 1/2" grinders lol.
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Unread 09-08-2011, 07:49 AM   #323
little_Jeep
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Quote:
Originally Posted by Endimar View Post
Sorry 50willys. I see new posts and pictures on this thread and I get excited It's jeep porn I swear. My wife says I talk in my sleep about flap discs and 4 1/2" grinders lol.


You say this as if it weren't a normal thing to do......
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Unread 09-08-2011, 09:46 PM   #324
50wllystrk
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spyder6, yes, now you see what I was lookining for when I was looking for a thread that showed the process to get to where they got. It's a good study to see the multiple ways of accomplishing metal work.

Endimar, oh no, now people are gonna find this thread in the adult section at blockbuster. Now try to maintain control, someday I'm gonna strip the paint off the body and I may use a flap disc during the process.

little_Jeep, good one....

I had to do some work on the lawn mower, no time for truck work, hang in there, I'll get more pics loaded. I've got more free time next week so hopefully I'll get more progress and more pics posted.
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Unread 09-08-2011, 10:45 PM   #325
Hurley91
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I'm soooooo glad I stumbled upon this thread. Great looking Jeep and amazing fab work.
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Unread 09-09-2011, 01:19 AM   #326
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I'm soooooo glad I stumbled upon this thread. Great looking Jeep and amazing fab work.
I'm so glad i stumbled upon ur profile pic.... haha
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Unread 09-09-2011, 10:16 PM   #327
Cowboyup94
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God bless Canada "Ay"?
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Unread 09-09-2011, 10:28 PM   #328
Endimar
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LoL adult section. It's a jeep thing. On a side note I used my flap disk to clean some rust, i went to turn the grinder off and took a minor chunk of flesh out. Maybe 2mm deep. Im not sure how but that was unpleasant. Cant wait to see and learn more.
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Unread 09-09-2011, 10:37 PM   #329
spyder6
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LoL adult section. It's a jeep thing. On a side note I used my flap disk to clean some rust, i went to turn the grinder off and took a minor chunk of flesh out. Maybe 2mm deep. Im not sure how but that was unpleasant. Cant wait to see and learn more.
once, i was using my grinder on my brothers cherokee and throughout the day the grinder got a light coating of cutting oil all over it. long story short it slipped out of my right hand and went straight into my left hand. through the kevlar glove, into my index finger. by the time gravity caught up with it and made it fall to the floor it had already cut all the way down to the bone.

and the irony of it? i didn't know i had done it till about an hour later when i was washing my hands. never hurt or anything. the disk cauterized the wound as it cut it.
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Unread 09-10-2011, 04:48 PM   #330
Jeff88
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Originally Posted by spyder6 View Post
once, i was using my grinder on my brothers cherokee and throughout the day the grinder got a light coating of cutting oil all over it. long story short it slipped out of my right hand and went straight into my left hand. through the kevlar glove, into my index finger. by the time gravity caught up with it and made it fall to the floor it had already cut all the way down to the bone.

and the irony of it? i didn't know i had done it till about an hour later when i was washing my hands. never hurt or anything. the disk cauterized the wound as it cut it.
Yikes!

I once slipped with a rotary wire brush that burned through my jeans and left a very nice deep gouge in my leg.

If it had been up a little higher, I'd have gone from a rooster to a hen.

I don't know the safety answer on this, but maybe leather chaps should be worn at all times?

Wouldn't look so cool.
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