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1987-2016 Wrangler Jammock Black 2.0 Jeep Hammock (YJ, TJ Rancho rockGEAR promotion gear from January 1-February 29,Zone Offroad Body and Suspension Lift Kits, Brackets, Disc

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Unread 03-18-2015, 06:26 PM   #1
drnimzelJeepFan
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1969 C101 
 
Join Date: Aug 2008
Location: Dallas
Posts: 106
drnimzel Jeep Fan's 69 Commando Build picture heavy

My other build… nothing quite like building two Jeeps at once!

1969 Jeepster Commando highly modified restoration
- Throttle Down Kustoms reproduction frame
- 4L60E Transmission
- 5.3L 2001 Silverado
- Dana 60 front axle and matching Sterling 10.5 rear From 2004 F250
- 40×17 Tires Originally was going to be on 37x13.5x17 Toyo Open Country Muds
- Method Race Wheels 17x8.5 8x170mm bolt pattern

Unfortunately this build has now eclipsed the one year mark, now well into my 2nd year.

The Jeeps primary purpose is going to be daily driving duties and will see light expedition style trips. For this reason I am going to use Wagoneer and XJ Leaf Springs instead of a link suspension.

To start, I contacted Jeremy Pulse owner of Throttle Down Kustom's in Moore Montana to build me a Jeep frame for the Commando. I sent Jeremy the original frame so that he could expertly reverse engineer a frame for me. If you are not aware of Throttle Down Kustoms you should. JEREMY and his crew are to my knowledge the only American company building reproduction Jeep, Land Cruiser, and Bronco frames.

Commando frames are not known for their strength and the one I had wasn't going to perform up to my standards. As with all of TDK's Frame's they are built using 3/16 rectangular tube and then hand welded on jigs.

Axles: I've been scouring junk yards for years now looking for Snow Fighter 60's and other ideal front axles. Finding none reasonably, I've gotten acquainted largely from Pirate with the Super Duty 60's from the 1999-2004 versions and the 2005 to current. While I've had a slew of axles in my garage over the last couple of months, I settled on the 2004 front 60 and plan to run it at full width. Holding it to the frame will be stock height, but new Wagoneer Leaf Springs. From what I've read this will push the axle 2" more forward than will a YJ spring. The Superduty axle requires me to put the leafs on top of the axle so we will see soon how much lift this yields me. For the Rear end I with a Superduty Sterling 10.5 out of a 2005 F-250. I did so because I didn't want to have to worry about a parking brake or a figuring out a disc brake solution.



I've waffled on choice of transmissions but my choice of engine was easy. The 5.3 Vortec engines are well regarded and seem to be the standard for gas engines. This choice made picking up a 4L60E a rather easy decision. Not wanting to break the budget I opted for NP231 out of Jeep Cherokee for my transfer case. With a slip yoke this case will more than take care of the needs of this Jeeps purposes off road.

In late 2013 I took the Commando to ATX Customs in Amarillo, because my schedule at the time wouldn’t quite allow me to work on the Jeep like I wanted too. I’ve made it to Amarillo to work on the Jeep some, and expect soon that Paint will be done and the build done.

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Unread 03-18-2015, 06:29 PM   #2
drnimzelJeepFan
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1969 C101 
 
Join Date: Aug 2008
Location: Dallas
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this is what I started with back in the fall of 2012....





I got started right away.



Mocking it all up.






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Unread 03-18-2015, 06:31 PM   #3
drnimzelJeepFan
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Join Date: Aug 2008
Location: Dallas
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The body was already without a floor when I got it...



Clean TDK Frame









I sent the original frame to Throttle Down Kustoms to reproduced and modified.

Getting brackets and various parts in the mail is always a good day.


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Unread 03-18-2015, 06:34 PM   #4
drnimzelJeepFan
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Join Date: Aug 2008
Location: Dallas
Posts: 106


These brackets are the best from Ruff Stuff. I've used them many times on many projects.


A good look at the TDK Custom Commando frame.




















It came welded! Someone once asked me.
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Unread 03-18-2015, 06:39 PM   #5
drnimzelJeepFan
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1969 C101 
 
Join Date: Aug 2008
Location: Dallas
Posts: 106
Engine came from a 2001 Silverado, its a 5.3



Fitting the full width spring hangers to the frame.



Organized chaos:


Front axle is a Dana 60 from an 2004 F250...

Burning it together,




Was a hot day.






Front suspension is done!






Excuse the makeshift tie rod!






42's on the left and 37's on the right!


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Unread 03-18-2015, 06:41 PM   #6
drnimzelJeepFan
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Howdy!!!
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Unread 03-18-2015, 06:43 PM   #7
drnimzelJeepFan
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1969 C101 
 
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Location: Dallas
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My custom rockers, 3/16. formed in two pieces, then welded.



Got a rebuilt upgraded 4L60E from Novack


Aint she a beauty




I love the look of a chassis with axles and tires










Going to have to trim those!
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Unread 03-18-2015, 06:48 PM   #8
drnimzelJeepFan
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Location: Dallas
Posts: 106
Due to proximity to the oil field, I moved the jeep from my place in Van Alstyne texas to ATX Customs in Amarillo, TX....




Got those rockers fitted.


Engine is in!








I used 3/16 for the main floor section to tie into the 3/16 rockers, I used 1x3 channel to support the 3/16 floor and tied it all together at the rocker pannels.

I did this for pure strength and longevity. Who knows I might move to the rust belt some day.





Fire wall trim



Got clearance issues with headers, tried more than one type... bummer on this.



It will flex.




Remember this:
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Unread 03-18-2015, 06:52 PM   #9
drnimzelJeepFan
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Location: Dallas
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Rockers are trimmed












A cleaner line





Fit and finish










Transmission X-Member


The tunnel!










More of that tranny x-member.









Not as tucked as I had hoped for, so much for that flat belly pan.
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Unread 03-18-2015, 06:55 PM   #10
drnimzelJeepFan
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1969 C101 
 
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Location: Dallas
Posts: 106
One idea for tail lamps



Working on the interior sheet metal.








CNC Plasma Table... can't fight technology!






Rear corner of tub!
Burned in.





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Unread 03-18-2015, 06:58 PM   #11
drnimzelJeepFan
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1969 C101 
 
Join Date: Aug 2008
Location: Dallas
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Two weeks ago Derek and I of ATX got to work on the cage.

Test fitting the seat.




I have a ton of appreciation for the time and work that goes into building a cage...






Matching one side to the other...


Fire wall, mocked but not tacked.





I am all about building it stout!

Tub...

End of day one building the cage
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Unread 03-18-2015, 07:06 PM   #12
drnimzelJeepFan
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day 2 of cage build.








Seat bracket






MOCKED!













Gussets are 1/4"


Some shape





Rear X-Member



















There she sits!



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Unread 03-18-2015, 07:06 PM   #13
drnimzelJeepFan
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Location: Dallas
Posts: 106
Some custom gussets














What a journey!


This weekend we will be prime-ring, and block sanding fun times!
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Unread 03-23-2015, 07:46 AM   #14
drnimzelJeepFan
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1969 C101 
 
Join Date: Aug 2008
Location: Dallas
Posts: 106
We unfortunately were not ready for block sanding and underestimated the time it takes to build fenders. We spent most of the weekend building the rear and conceptualizing what the front need to look like…
40” up no lifting of any other tires,





The bumper is a work in progress also.



Me finish welding the floor

3/16” plate,



Mocking up a rear fender.

Test fitting,











Creativity was tapped out on Saturday morning and didn’t return for Sunday…. Bummer….
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Unread 06-29-2015, 06:54 PM   #15
drnimzelJeepFan
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1969 C101 
 
Join Date: Aug 2008
Location: Dallas
Posts: 106
As projects will do this one has taken considerably longer than anticipated, mostly due to tight schedules on customers vehicles and time to dedicate a weekend to working on it.
This past weekend we tackled the front fenders which had eluded us on how to construct them.
Here is what we came up with. Traditional tube fenders, followed by a framed flare. What do y'all think?







flat to round




they will be removable





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