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Unread 10-15-2012, 06:47 PM   #46
sailsurf7713
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1999 TJ Wrangler 
 
Join Date: Jun 2008
Location: Rhode Island
Posts: 1,112
Tried to make some progress for you guys this afternoon.

First cut was a tad shaky, but things got better as I went along



Got the rest of the main shape cut out



Then made an amateur mistake and went ahead and did this



I think that jeep in the background good use some paint



...which made the piece arc, but not to worry I had a solution for that.



With a few shims, a tape measure and a square I got everything to my specs and tacked the receiver in to restore the squareness of the piece.

The cuts are a bit rough, but I have to make some adjustments and the big red "glue gun" will make everything look purdy

More to come.

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'99 SE: The "It could be worse..." jeep

Quote:
Originally Posted by 97flexy View Post
...I say don't lift but CUT. :)
My Rusty Revival
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Unread 10-16-2012, 02:44 PM   #47
sailsurf7713
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Join Date: Jun 2008
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Picture of the reciever tacked in.

This is actually just a 2.5" to 2" adapter from advance auto for 10.99 if my memory serves me right. It won't see anything heavier than a few hundred pound boat. Should be perfect.



I'll grind those tacks down and burn it in nice and hot. Didn't have a chance to work on it today. Hopefully tomorrow.

Got a nice tow hitch for sale if anyone wants it. I believe its pictured earlier in the thread, just painted it and I have all brand new grade 8 hardware to go with it.

Also found a cherokee 44 not too far north from me. May go pick it up and start building it up slowly. Or an 8.8 for $75 locally. Hmmmm. Then I'll just need to find a HP30. Otherwise, biggest concerns are still the stock shovel, front arms, front traction, and making the exhaust lower profile for the planned crossmember. Also I would like to upgrade the cage for safety. Thinking the BTF sport cage tied into the frame.

Just need more time and money

Think I'll likely start building for 35s soon. But I'd like the TDi to come first.
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'99 SE: The "It could be worse..." jeep

Quote:
Originally Posted by 97flexy View Post
...I say don't lift but CUT. :)
My Rusty Revival
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Unread 10-16-2012, 03:22 PM   #48
GreenTJ04
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Looks awsome bud keep the pics coming
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Unread 10-16-2012, 06:52 PM   #49
sailsurf7713
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Quote:
Originally Posted by GreenTJ04 View Post
Looks awsome bud keep the pics coming
Thank you! I'll try.
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'99 SE: The "It could be worse..." jeep

Quote:
Originally Posted by 97flexy View Post
...I say don't lift but CUT. :)
My Rusty Revival
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Unread 10-17-2012, 11:06 AM   #50
BAMFpullin719
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2000 TJ Wrangler 
 
Join Date: Apr 2011
Location: Fonda, New York
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i can almost smell the burning metal haha
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"4 low, 2nd gear, skinny peddle on the right"
bought not built, broke, then rebuilt
you thought you had rust? [url]http://www.jeepforum.com/forum/f22/wasnt-me-my-2000-tj-weekend-warrior-1269820/[/url]
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Unread 10-17-2012, 11:11 AM   #51
BAMFpullin719
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Quote:
Originally Posted by sailsurf7713 View Post
But I'd like the TDi to come first.
might as well, you can lift it anytime, not to mention i'd rather build my lift based off the motor. you never know what you might have to hack off or weld on, not to mention motor/tranny weight and your cross member designs could influence the lift or lift parts you wanna use

oh and what r u using to cut metal?
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"4 low, 2nd gear, skinny peddle on the right"
bought not built, broke, then rebuilt
you thought you had rust? [url]http://www.jeepforum.com/forum/f22/wasnt-me-my-2000-tj-weekend-warrior-1269820/[/url]
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Unread 10-17-2012, 05:01 PM   #52
sailsurf7713
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Got some progress done today. Although, not nearly as much as I would have liked.

Got the holes cut for the clevises.




Ground down my tacks and removed mill scale




Straightened out my awful first cut



Got the mill scale off the clevises with a flap disc and got one tacked in





BUT, its nearly 2 degrees off square (bad camera angle) which I can't live with


So, I'll clearance a bit more tomorrow (if time allows), tack them in, grind the tacks, preheat and weld the clevises it.
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'99 SE: The "It could be worse..." jeep

Quote:
Originally Posted by 97flexy View Post
...I say don't lift but CUT. :)
My Rusty Revival
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Unread 10-17-2012, 05:06 PM   #53
sailsurf7713
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Quote:
Originally Posted by BAMFpullin719 View Post
might as well, you can lift it anytime, not to mention i'd rather build my lift based off the motor. you never know what you might have to hack off or weld on, not to mention motor/tranny weight and your cross member designs could influence the lift or lift parts you wanna use

oh and what r u using to cut metal?
This jeep will hopefully only see 2" front/1" rear lift. But, definitely a great point, and one which will be followed. I'm very happy with how the 32s perform and they're brand new. 35s later .

As far as cutting, just a 7 amp 4.5" Dewalt angle grinder and the most expensive chop saw that harbor freight sells. Used a wide variety of discs. Harbor Freight's, and I'm completely shocked by this, were the best.

Others I used were SAIT, some special expensive italian one the welding shop gave me to try, and ACE generic.
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'99 SE: The "It could be worse..." jeep

Quote:
Originally Posted by 97flexy View Post
...I say don't lift but CUT. :)
My Rusty Revival
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Unread 10-18-2012, 02:19 PM   #54
sailsurf7713
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Some more pics for you guys.

Got that damn clevis the way I want it



Mocked up and tacked my bracing/chain points/step



OK, WELDERS. Cause I'm not one. Let me know how I stand here before I keep going. Machine was running good. Bit of a cold start on the second one , but my buddy is off camping and has my propane torch. Little bit of splatter, but I'm using 100% CO2. I just like it better for mild. Call me weird.





Its getting there. Just need to get this welding done, box it, and find some time to lift up the body, drop the tank and get here welded into the frame.
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'99 SE: The "It could be worse..." jeep

Quote:
Originally Posted by 97flexy View Post
...I say don't lift but CUT. :)
My Rusty Revival
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Unread 10-18-2012, 06:36 PM   #55
sailsurf7713
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Started boxing it in while I was waiting for a buddy to show up.

I cut some pieces of 2x3/16" to length and beveled the mating edges. Clamped, ensured squareness with the bumper body and tacked in.









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'99 SE: The "It could be worse..." jeep

Quote:
Originally Posted by 97flexy View Post
...I say don't lift but CUT. :)
My Rusty Revival
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Unread 10-22-2012, 05:24 PM   #56
sailsurf7713
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I wasn't good at taking pictures today. I cleaned up those cut lines, then burned the clevises in front and back and temporarily removed the gussets to burn in the receiver.

Some pictures:















In addition, because I like being different, I'm seriously considering picking up a locked tacoma axle to swap into the jeep, then sell or part out the decent junk in the Dana 35. How many axle ideas have I tossed around now?
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'99 SE: The "It could be worse..." jeep

Quote:
Originally Posted by 97flexy View Post
...I say don't lift but CUT. :)
My Rusty Revival
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Unread 10-22-2012, 05:37 PM   #57
BAMFpullin719
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uber jealous. what welder r you glueing your pieces together with. lookin good
__________________
"4 low, 2nd gear, skinny peddle on the right"
bought not built, broke, then rebuilt
you thought you had rust? [url]http://www.jeepforum.com/forum/f22/wasnt-me-my-2000-tj-weekend-warrior-1269820/[/url]
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Unread 10-22-2012, 05:58 PM   #58
sailsurf7713
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Quote:
Originally Posted by BAMFpullin719 View Post
uber jealous. what welder r you glueing your pieces together with. lookin good
Lincoln 180T. Basic, but I love it.
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'99 SE: The "It could be worse..." jeep

Quote:
Originally Posted by 97flexy View Post
...I say don't lift but CUT. :)
My Rusty Revival
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Unread 10-23-2012, 06:26 AM   #59
GreenTJ04
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Can't wait to see this thing mounted up
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Unread 10-23-2012, 03:48 PM   #60
sailsurf7713
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Thank you, but could be delayed

Well. My inexperience has once again gotten the better of me. The piece isn't quite square and I made the mistake of burning in the hitch tube. So should I grind the side welds down (on the hitch), cut them, square it again and weld again? I think that is ideal, but I could also cut down just outside those welds, square, bevel and weld together again. Ideas? I need to buy a welding table. Working on a vice attached to a warped wooden work bench is far from ideal.



And some pictures of progress while I think of a solution to my newbness

The difference between not enough heat and good settings:


And so forth:





Using, the no weaving technique. I like it.


Started boxing in:













__________________
'99 SE: The "It could be worse..." jeep

Quote:
Originally Posted by 97flexy View Post
...I say don't lift but CUT. :)
My Rusty Revival
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frame repair , Frame rust , mce fenders , no lift , rear crossmember
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