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Bill Baird Motorsports DIY parts - NalinMFG.comFS: 2007-2013 Jeep Wrangler "HALO" Angel Eye KitFS: Wranger BRIGHT License Plate LED! Just $3! Great value

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Unread 07-12-2013, 07:20 AM   #1
Oman Jeep
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AEV BRUTE build in Dubai

So I figure now is a good time to start the build thread on my Brute - the majority of the parts have finally arrived!

First - an intro on what we have got planned - the whole goal is to make the Jeep much more user-friendly for longer trips. That means replacing the 4 jerry cans with an in-built second tank, more accessible cargo that can be better organised, and more comfortable cabin.

The build will take a 2001 Wrangler and do the Brute conversion, with custom long arm suspension using MetalCloak parts. I'm already starting with on board air, air locker in the front, Ected in the rear, SwayLoc etc etc... And the 6-pak shocks will be complimented with King 2" gas bump stops.

The refined part of the build - will be on two levels - firstly the interior is going to see quite a lot of leather and alcantara trimmings and a lot more noise insulation than it's ever had. Recaro seats may also be done too. The other refinements will be the expedition preparedness like the dual tanks with electric transfer pump, dual battery. The roof top tent. Also a swing-out tire carrier on a custom rear bumper. Taking the hard work out of it all.

The HiTech aspect - it's going to have Garmin in-dash GPS integrated to the OBD-II system. Park sensors. Camera systems front / rear / underneath. Power Sunroof. Power drop down rear window. Power normal windows. Add to that radar based blind spot monitoring system. Already has power retracting running boards. Also some of the technology that will be used to make the parts - using scanning equipment and CAD to do the suspension pieces, design the roll cage, and make the rear bumper and cargo rack (and perhaps re-do the front bumper).


And now some pictures!

This is the Jeep as it stands today:



Photoshop goal:




Unboxing some parts!





Should take a while to wear these bushings out





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Unread 07-12-2013, 08:03 AM   #2
Oman Jeep
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Frame is now cut! After the weekend it will be welded up again in its extended length, and then we worry about the tail section. After that, we throw axles and shocks under it and take measurements on where we will be placing the long-arm bracketry.



This is the cutting template - shows you where to section the frame. It's used on both sides, and you cut on the straight edge of the rear-most zig-zag holes.



This is the rear extension sub-frame - which includes the rear winch mount and the trailer hitch connector.





This is the alignment template for when it goes back together. It has the same holes as the cutting template and access holes for you to tack-weld it in place. This ensures the stretched frame is straight and correct.



This is the section of frame rail that will go in the extended part of the frame.



The cutting template clamped in place for the holes to be drilled.





The frame is now cut - and repositioned on the jack stands using the extension templates. They will then come off again while the inner reinforcements are put on. Then the extension pieces are loosley put in place, re-attach the extension templates and begin welding!






Some of you may notice no pictures of the interesting bit - when it gets cut - but there IS video and I'm working on it
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Unread 07-12-2013, 08:48 AM   #3
wwch99tj
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Looking forward to seeing this thing come together!

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Unread 07-12-2013, 09:06 AM   #4
G Beasley
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Awesome start so far , I look forward to watching this build. .
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Unread 07-12-2013, 10:38 AM   #5
sjones26573
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Unread 07-12-2013, 10:41 AM   #6
rusty762
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Nice, looking forward to this build.
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Unread 07-12-2013, 10:53 AM   #7
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Subbed, although none of the pics work for me.
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Unread 07-12-2013, 10:55 AM   #8
sjones26573
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Subbed, although none of the pics work for me.
Pics are the most important part
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Why don't all cars have no doors? When I come to power I'm going to make it a rule because this is just better.
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Unread 07-12-2013, 11:00 AM   #9
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Unread 07-12-2013, 02:48 PM   #10
TanMan99
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This should be awesome!
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Unread 07-12-2013, 03:29 PM   #11
Oman Jeep
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This should be awesome!
I sure hope so!
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Unread 07-12-2013, 03:30 PM   #12
Oman Jeep
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Subbed, although none of the pics work for me.
They're hosted on my Facebook for now - are you on a work connection that blocks facebook?
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Unread 07-12-2013, 03:57 PM   #13
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I thought I'd never see you again, your last post was ages ago
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Unread 07-12-2013, 04:24 PM   #14
rubidriver
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Pics work!!! This is awesome. I never really liked how short your TJ looked with the highline, no offense. This will be epic.
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Unread 07-12-2013, 07:13 PM   #15
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Subscribed! This looks interesting.
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