Project "Bugout" - JeepForum.com

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post #1 of 33 Old 02-25-2013, 11:16 AM Thread Starter
1hand
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1988 YJ Wrangler 
 
Join Date: Feb 2013
Location: Medford
Posts: 154
Project "Bugout"




I broke the news to the better half today, and got the nod to proceed.


Project "Bugout"
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post #2 of 33 Old 02-27-2013, 06:02 PM Thread Starter
1hand
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1988 YJ Wrangler 
 
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Started working on the Bugout frame today.

First on the passengers side rear, I cut off the rusted out stock shock mount to get ready for the M.O.R.E extra travel rear mounts. Under the old mount was a chassis frame rail inspection hole.......



Cleaned it up to see how bad it was. Sounded thin about 2/3's the way down on the inside as I tapped on it. Also notice I removed the upper track bar mount.



I found a piece of 13ga and bent up the new replacement section.



I don't have a Mig, but do have a 185amp Tig/Arc welder. Just takes a bit longer thats all. That is my helper today Chloe Jo "CJ" setting the amps for me.



Notched out the frame for the replacement, and removed last years stash of acorns!!!



Ta Da!



Moving rearward, the gas tank cross member has holes rusted through.



Notched out the bad, and took some measurements.



I picked up this 12" hand shear a couple years ago figuring I would have a use for it someday. Well..............



Mark out some lines on a piece of 16 GA.





The El'ceapo brake



Fits pretty good for the first go at it.



Weld, ground down and relocated and drill holes.



That is it for today. Tomorrow will be a carbon copy of today, just over on the driverside I guess.

Matt

Project "Bugout"
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post #3 of 33 Old 02-27-2013, 08:27 PM
Salt222
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Nice work keep pictures coming
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post #4 of 33 Old 03-06-2013, 11:12 AM
20jeepster10
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Location: Lapeer
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Nice start! was it a whole jeep at one time or just starting with pieces?
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post #5 of 33 Old 03-06-2013, 01:09 PM Thread Starter
1hand
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Quote:
Originally Posted by 20jeepster10 View Post
Nice start! was it a whole jeep at one time or just starting with pieces?
Here it was 3 weeks ago
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Project "Bugout"
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post #6 of 33 Old 03-06-2013, 03:45 PM
Rubicon0311
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2005 TJ Wrangler 
 
Join Date: May 2012
Location: Kalamazoo
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I love frame off restorations, can't wait to watch the progress. Keep up the good work!


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post #7 of 33 Old 03-06-2013, 07:32 PM
20jeepster10
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Wow you Are moving fast on this great job
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post #8 of 33 Old 03-18-2013, 05:07 PM Thread Starter
1hand
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Location: Medford
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Made it home with my new axles. $300 for the pair.










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post #9 of 33 Old 03-18-2013, 08:56 PM
Crazyantix_TJ
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Nice build
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post #10 of 33 Old 03-19-2013, 06:46 PM
Tanimal
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2008 JK Wrangler 
 
Join Date: Jan 2012
Location: Bartlett
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Love it so far and your fabricating skills are impressive. The "XJ Build" in my signature my father and I have been doing our own fabricating and cut all the rusty floors out and are replacing them but our skills are not nearly as good as yours. Trail and error and learning as we go is how we've been doing it! Plus flux core welding isn't very appealing but it does what it needs to for just sheet metal.


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post #11 of 33 Old 03-20-2013, 08:39 PM Thread Starter
1hand
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I started a little bit on tearing down the front axle. I did manage to get one of the locking hubs off. Only had one cap screw that rounded out on that hub. Then I was off to town to get an axle nut socket, and then got the spindle and brakes off. I had then found I need a Ball Joint Spanner Wrench.

I'm using info off of Mr. N's 44 page for the tear down.
http://77cj.littlekeylime.com/Mr.N44.htm#The Tear Down

I had to order from Napa # 278-2030 and will be here tomorrow


You can see the inner ball joint preload nut here


So far about 3 hours to get one side this far






Also, today I did a little horse trading. Traded my Lincoln 185 tig for a Thermal dynamics 180 Tig/Arc and a Hypertherm 30 Plasma cutter and bought a Lincoln 180 HD Mig. They will be coming next week. I should be set-up for the cutting and welding for the project pretty good now.

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post #12 of 33 Old 03-20-2013, 10:13 PM
edshotshotllc
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Looks good You going to plate entire frame or just bad rust spots. Super nice tig i would like to have one just seems like a task vs mig

call 916 539 nine39O
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post #13 of 33 Old 03-20-2013, 10:26 PM Thread Starter
1hand
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Quote:
Originally Posted by edshotshotllc View Post
Looks good You going to plate entire frame or just bad rust spots. Super nice tig i would like to have one just seems like a task vs mig
Just splicing in new metal in the bad spots, mainly in the rear. Going to french in outboard shock mounts, stretching, and linking there anyway. Tig welding everything would take forever and if it isn't perfectly clean new metal it is a real PITA! So hence getting a new Mig for the Project. The New Plasma sure will beat the hell out of burning through cut off wheels llike candy.

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post #14 of 33 Old 03-21-2013, 12:20 AM Thread Starter
1hand
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My little basement furnace-room machine shop has been a "catch all" this winter. So in the the morning I'm holding my breath and "going in" to clean it up. If I don't come out by nightfall, better send someone in after me.












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post #15 of 33 Old 03-21-2013, 12:38 AM
Tanimal
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Wisconsin is very close to IL and I might need to come poke around looks like a great setup !


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