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Introducing MONSTALINER™ UV Permanent DIY Roll On Bed LineOfficial Chassis Saver Rust Preventive Truck & Auto UnFS: 2007-2013 Jeep Wrangler "HALO" Angel Eye Kit

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Unread 02-21-2012, 02:22 PM   #61
tdij
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I might have to drop in and lend a hand!

I'm not sure I know what all is involved in this... but would a plasma come in handy? If so, let me know and it's yours!

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Unread 02-21-2012, 02:47 PM   #62
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^^
I vote yes! It comes with a welder too...right?
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Unread 02-21-2012, 03:11 PM   #63
tdij
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That it does... I've yet to use it as one due to the easy mig available to me... but it's definitely capable if you want it!
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Unread 02-23-2012, 10:32 AM   #64
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Thanks to both of you again.
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Unread 02-25-2012, 06:33 PM   #65
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Prep

So today I started out to extend my rear hard line. I bought an 8" section of some 3/16 line with 3/8 fittings. I thought I would be good to go based on reading JF.

My bad. I should have checked the fittings on my own, but I was busy this week.

After getting under the heep I checked the fittings prior to breaking the line. I am glad I did. The union between the hardline and the soft line is 7/16.

I hope NAPA has that.

Anyway, I moved on to cutting notches in the tub for the rear Antirock.



With tube in place.





It seems to all fit on mock up.
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Unread 02-26-2012, 06:17 PM   #66
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Added 8" to the hardline today. I will add the finishing touches later.

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Unread 02-27-2012, 12:03 PM   #67
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Prep for rear corners.

Today I cut out the rear corners. Hopefully, the strectch will go off without a hitch this week.









I will clean up the cuts after the axle is located.
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Unread 03-02-2012, 07:13 PM   #68
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Clayton 5" Stretch - Getting to a Roller

Special thanks to hoovail, tdij, xjinvail, and sleenky for the wrecnhing, welding, and garage space. Hoovail worked hard on this one

I started with the OEM wheel base and blew this thing out to 98" with the Clayton kit. This kit takes work. It is not for the faint of heart. I estimate that we put in nearly 18 hours in two days to get to a roller. The finishing touches still have to come (drive shaft, cleaning up lines, shocks, etc...)

I am in an awkward phase, but this will pass. The rig looks good. Hoovail's welds turned out great.

We used up about 11 cut off wheels. Used several sets of stands. And a lot of hard work.

Where we started.







Rear Axle Dropped







Cutting Off the Old Buckets





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Unread 03-02-2012, 07:21 PM   #69
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Clayton 5" Stretch - Getting to a Roller 2

The hardest part (most labor intensive) was making the frame notches for the coil retainers. We had to polish off the old coil retainer brackets and notch out the crossmember. We had to remove about three inches toward the rear of the Jeep and about one half inch toward the center of the Jeep. This took a lot of grinder time.

A tip to others: Make sure you print the Clayton templates in FULL SIZE. They don't default to the right size when you print them.

We measured several times and drew on the shape with a paint pen. Then set to work.





The notch that took forever





Make sure you grind everything smooth (including the inside of the frame). We used flapper wheels for that. If you do not the coil retainers will not seat properly.

Welding the new frame support, bucket brace, and coil retainer





The product

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Unread 03-02-2012, 07:35 PM   #70
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Clayton 5" Stretch - Getting to a Roller 3

The notch for the coil retainer was the hardest cut. After that we moved on to notching the frame to outboard the shocks.

The frame cut out is supplied by Clayton. We seated is so that about a 1/4" sticks out all the way around. I was able to drill holes through the cut out for the gas tank mounts.





If you needed another reason to stay away from Rubicon Express products...we discovered my coils were cracked and had left shards in the old buckets. We repaired what we could. I will have to visit this again later.



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Unread 03-02-2012, 07:36 PM   #71
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Nice work dude.
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Unread 03-02-2012, 07:39 PM   #72
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Clayton 5" Stretch - Getting to a Roller 4



It took us a long time to get the measurements. We did them twice, several ways. I can say that the first time I drove the rig it was tracking straight.







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Unread 03-02-2012, 07:44 PM   #73
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Clayton 5" Stretch - Getting to a Roller 5

The look. Notice the shock tower and bolt for the gas tank.









There is a lot of work left to be done . New drive shaft, clean up the brake lines, shocks, rear corners, AntiRock, etc... But she drives
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Unread 03-02-2012, 07:49 PM   #74
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Quote:
Originally Posted by DaFuzz View Post
Nice work dude.
It was a ton of work, but it was worth it. I couldn't have done it without some fellow Jeepers. I have a bunch left to do, but in the grand scheme, it is fininshing touches.
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Unread 03-02-2012, 07:53 PM   #75
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I ordered my new Billsteins the other day... Those should be here any day now. I also ordered some TnT Customs corners...The build continues
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