GCJEEPING's Build/Mod thread-It's a green thing - Page 5 - JeepForum.com

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post #61 of 92 Old 11-14-2013, 12:51 PM Thread Starter
gcjeeping
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2001 WJ 
 
Join Date: Feb 2007
Location: -----Sacramento-----
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Let the fun begin....

The only thing is I dont have a good measurement from the front of the metal part of the bumper you cut out to the plastic bumper where the front of the winch plate touches the back of the bumper. Looks about 5".

Also I think the Limited and Laredo will be slightly different in as far as how much the winch plate will stick out to the bumper. The Laredo's bumpers are indented between the bumperets and Limited's have no indents.

Mine design doesn't curve on the front like the original one. My winch is a 12.5k and the warn one is like 8k so mine is bigger. That wouldn't be a problem reproducing it with the sides 1/2-3/4 curved in.

So the original...







Ok I went out and took a few measurements and cut the center section.









Then the mock up. It fit perfect.









Wont get to work on it again until Thur.


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post #62 of 92 Old 11-14-2013, 12:52 PM Thread Starter
gcjeeping
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Location: -----Sacramento-----
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Got some plate cut and tack welded. Adjusted the one I'm making so the front curves like the Went out and did a quick test fit and seems to be good. Would have done more to it but the wind and rain is blowing and expecting snow tomorrow.

If I get a break in the storm I'll go out and mark the mount holes, drill them out and make the backing plates.

Then I'll make the sides for the winch plate. Also this one is made to fit a Warn XD9000. I found the dimensions online, made a template for the test fit.

Mine will have to be bigger since its a 12.5k. But here are the picks so far.



















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post #63 of 92 Old 11-14-2013, 12:53 PM Thread Starter
gcjeeping
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Went trail riding in the snow.







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post #64 of 92 Old 11-14-2013, 12:54 PM Thread Starter
gcjeeping
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Bought the wife an embroidery machine for her birthday. She couldnt figure how to convert pictures the right format for the machine. So I told her I would figure it out. Looks like it might be a new toy for me too now.



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post #65 of 92 Old 11-14-2013, 12:54 PM Thread Starter
gcjeeping
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Started making light covers for the LED bars using my wife's embroidery machine.



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post #66 of 92 Old 11-14-2013, 12:58 PM Thread Starter
gcjeeping
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Finished embroidering the front of my lightbar cover.














Some others I have made templates for.











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post #67 of 92 Old 11-14-2013, 12:59 PM Thread Starter
gcjeeping
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Finished making my LED light bar cover. It has 1/4" foam on the inside and is made of heavy vinyl. 5 velcro straps across the back and 2 on the sides to hold it on.



















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post #68 of 92 Old 11-14-2013, 01:00 PM Thread Starter
gcjeeping
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Took it out out in the snow for a run. Took some pics of lights too.









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post #69 of 92 Old 11-14-2013, 01:00 PM Thread Starter
gcjeeping
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Was a good day...

Put the half doors on since I haven't seen rain in 10 days here in Cali. Unlike Ohio where its been raining almost every day.



Took it to get smogged and passed with with flying colors. after two hours of the guy looking at every single thing under the hood and asking questions about everything that was moved. LOL



Drove it all over Sacramento and the highway in 100F + temps and the guage stayed around 210. WHOOHOO!



Got the 6" + Jeep to fit into the garage by adjusting the up stop on the door a few inches higher. Yippee!





.
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post #70 of 92 Old 11-14-2013, 01:01 PM Thread Starter
gcjeeping
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Drove it around this weekend and the temp stayed a little above 210 most of the day. It usually stays below 210. So I swapped the thermostat out (Original) and got around to installing the the aux fans I got from the JY a couple years ago.

They are of a 4L Land rover. They push a lot of air and turn the stock fan when they are on.

Wired them up to come onto with the stock fan and or by themselves with the switch on my Whelen controller.

Drove it around today in 100+ temps and didnt go over 210.





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post #71 of 92 Old 11-14-2013, 01:03 PM Thread Starter
gcjeeping
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Went with a small group on here for a Nor Cal coastal beach run this weekend. Ran a few logging roads and mountain trails along the way to visit beaches. Also ran some roads through the Giant Redwoods.



































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post #72 of 92 Old 11-14-2013, 01:07 PM Thread Starter
gcjeeping
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So after a few dent's in the rear QTR's and fenders as well as some broken taillight I finally got around to making some rear QTR protection with nudge bars and recessed LED tail lights.

I also built in a lockable compartment on the pass side. I made it as a remote power station and switches to turn the LED bars, side lights and BU lights. Also put in a cigaret lighter plug and the remote box for my power inverter. It has 2 110v and 2 USB receptacles. It has a switch to turn the inverter on and off from the remote box.

Started with remnant 10 gauge diamond plate, 24 riv-nuts, stainless hex cap screws and two harbor freight LED tail lights. Picked up a mailbox lock from Lowe's. I already had the toggle switches and pipe for the nudge bars.




Made some paper templates.





Cut the plate with the plasma and test fitted and adjusted as needed. I used a bottle jack, scrap metal 2x4 to put the bends in the plate.






Next was drilling holes and installing riv-nuts. I made my own riv-nut tool. I taped the plate to the jeep and drilled through the plate and fender at once.

























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post #73 of 92 Old 11-14-2013, 01:08 PM Thread Starter
gcjeeping
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Cut the metal for the recessed LED tail lights and tack welded them in.

























Cut and tack welded the fender pieces. The plate that is flat and facing out is scrap I had and is thicker than the 10 gauge. I had to cut reliefs in the curved bent part to get the bend right. Will fill them in when I weld them up.







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post #74 of 92 Old 11-14-2013, 01:08 PM Thread Starter
gcjeeping
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All welded up and a coat of primmer.















Also hole was cut for door to access power outlets.



Made a box out of scrap sheet metal for the power outlets and switches. Spot welded it in and sealed around it with RTV.









Waiting to install.



Fitted on and LED's wired up. I tapped into the trailer harness after the relays to get the LED to work like trailer lights. That way I didn't need to make any new wiring for them. Also added red reflectors to help keep it legal. Might have to add a side marker light too.













Access door. Put the cigarette lighter plug in. Will do switches and power outlets later.



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post #75 of 92 Old 11-14-2013, 01:09 PM Thread Starter
gcjeeping
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Location: -----Sacramento-----
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Cut and bent the tube then welded it on. Primed the tube and put the panels on the Jeep.























Here is the little power panel. The 3 switches are to turn on the LED bars, side roof rack lights and back up lights. Any or all can be turned on without starting or getting into the Jeep. The Cig lighter is always hot and the 120v/USB box is turned on/off by the switch on the box. Also added a mailbox lock to keep it secure.







A view from the back. LED's off, park, brake and vid of hazards.







Below is a video.

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