Rusty762's Project "Led Sled" - Page 2 - JeepForum.com

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post #16 of 630 Old 12-03-2012, 11:26 AM Thread Starter
rusty762
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2005 LJ Wrangler 
 
Join Date: Feb 2012
Location: Monterey
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Installed my Savvy modular under armor last weekend, was pretty straightforward I had to make a couple of modifications to some of the brackets. Threw a couple coats of Krylon Satin black on everything first.





First step was to support the Tranny/transfer case and remove the old shovel. I had already installed my Savvy BL and MML couple of months ago, loosened the body bolts up and jacked each side up so I could slip the C channel around the frame, then slid the crossmember in to check fit. I also dropped the front driveshaft to install my Novak kit I have had sitting here, If your doing a TT this is the perfect time to install a Novak. Everything went in pretty easy, I ended up bending my bracket to fit the tub. Novak is now welding the nuts to the bracket and my bracket was slightly off, It was simple to bend the tabs so that everything lay flat on the tub and all of the bolts went in straight.

Next step was to install the crossmember which slid right into place, my tranny mount when bolted up was skewed to the passenger side so I ran both of the holes over about half an inch so I could install the main crossmember bolts.







After the crossmember was bolted in, I ran some fuel line around the brake/fuel lines on the drivers side C Channel to protect them from the exposed threads there and any chance of rubbing. Took it for a test drive and no vibrations but there was a rattle at idle, turned out to be the exhaust rubbing the front passenger side CA mount so readjusted the exhaust and bolted up the skid plates. The front exhaust on the drivers side was also close to rubbing so while I had the engine skid out I made an additional cut to make sure there was no rubbing.



After staring at the skids and all the clearance I had just gained I took it out for another test drive, as soon as I started it there was a loud rattling reverberating through the cab. It sounded like a cage of monkeys had Britney Spears under there and were giving her hell. There was one place on the drivers side of my 241 case that was very close to rubbing the tub, well it is contacting the tub and once the Skids were bolted up everything became so rigid that the sound from the case was being transmitted through the cab.



I dropped the skids took some pictures where it was contacting the tub, going to try lowering the case this weekend and hammering the area up a 1/4-1/2 inch then I should be good to go!






Rusty

If I had eight hours to chop down a tree, Id spend six sharpening my axe.- Abraham Lincoln


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post #17 of 630 Old 12-05-2012, 03:19 PM
AngryTJ
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That looks real nice

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post #18 of 630 Old 12-05-2012, 11:31 PM Thread Starter
rusty762
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Originally Posted by AngryTJ View Post
That looks real nice
Thanks man it is coming along, think I am going to ditch the half cab and go to a soft top. Love the half cab for sound and security but do not think its going to work out with the way this jeep is going to get used.

Rusty

If I had eight hours to chop down a tree, Id spend six sharpening my axe.- Abraham Lincoln


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post #19 of 630 Old 12-10-2012, 03:48 PM
Kodiak17
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Very cool build, glad I caught it before it began to get longer. Any plans for a cage?

Maintain, wheel, upgrade, repeat.

My build: http://www.jeepforum.com/forum/f22/thor-dd-weekend-warrior-1348534/
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post #20 of 630 Old 12-10-2012, 04:42 PM Thread Starter
rusty762
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Quote:
Originally Posted by Kodiak17 View Post
Very cool build, glad I caught it before it began to get longer. Any plans for a cage?
Thanks!

I was going to build a custom cage for the bed that would butt right up against the half cab and tie into the rear of the frame by the tailgate and then a PSC cage for inside. After talking to some members here on the forum and the issues they have had with flexing of the tub and the half cabs and not being able to close doors I think I am going to go to a soft top and full cage.

Rusty

If I had eight hours to chop down a tree, Id spend six sharpening my axe.- Abraham Lincoln


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post #21 of 630 Old 12-10-2012, 05:40 PM
Kodiak17
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Quote:
Originally Posted by rusty762 View Post
Thanks!

I was going to build a custom cage for the bed that would butt right up against the half cab and tie into the rear of the frame by the tailgate and then a PSC cage for inside. After talking to some members here on the forum and the issues they have had with flexing of the tub and the half cabs and not being able to close doors I think I am going to go to a soft top and full cage.
I've read about that too. i think its one of the biggest disadvantages to that kind of conversion.

Maintain, wheel, upgrade, repeat.

My build: http://www.jeepforum.com/forum/f22/thor-dd-weekend-warrior-1348534/
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post #22 of 630 Old 12-13-2012, 11:53 AM
slmason72
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Subscribed! Ought to be a fun build...
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post #23 of 630 Old 12-29-2012, 06:19 PM
CrankyGypsy
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hey, this is a really neat build. too bad about reverting back to a cage.

i'm assuming you already "hammered" the underside of the tub for t-case clearance a few weeks back. if not, you could do what the AEV kit does: take a 2" long piece of 3/32"+ walled steel tubing (OD of 1.250-1.375") and cut it down the center. place one of the halves "over" the t-case nub where the bolt is and jack the case up into the tub - it will make a clean, perfectly-placed dimple.

2004 Rubicon
2005 Grand Cherokee Limited HEMI (fully optioned)
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post #24 of 630 Old 12-31-2012, 10:44 AM Thread Starter
rusty762
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Quote:
Originally Posted by CrankyGypsy View Post
hey, this is a really neat build. too bad about reverting back to a cage.

i'm assuming you already "hammered" the underside of the tub for t-case clearance a few weeks back. if not, you could do what the AEV kit does: take a 2" long piece of 3/32"+ walled steel tubing (OD of 1.250-1.375") and cut it down the center. place one of the halves "over" the t-case nub where the bolt is and jack the case up into the tub - it will make a clean, perfectly-placed dimple.
Thanks Gypsy, I did something very similar to what you described and it worked great. No more vibrations or noise, I am not sold yet on ditching the half cab. I have some ideas for a cage that might help keep the bulkhead from separating from the tub. Going to wheel it hard this summer and see what happens.

Saving up for my new rear axle, 75% there and then I can install my lift finally!

Rusty

If I had eight hours to chop down a tree, Id spend six sharpening my axe.- Abraham Lincoln


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post #25 of 630 Old 12-31-2012, 01:06 PM
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Sub'd. Looking good! I considered doing the halfcab thing by running one of Jeff's roll bar pass thru designs. I admit, it looks and works a lot better on a LJ than it does on a TJ.

Bob's boring build:


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post #26 of 630 Old 01-08-2013, 04:35 PM Thread Starter
rusty762
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Not much new on the build, got the tub clearanced with the 241 so no more monkeys banging the blonde. Decided to install a new Sony stereo that runs off an internal iPod or iPhone, no more skipping cd's and I have 40gb of music on board. There is a tray that opens out, you plug your iPod/iPhone in and it keeps it charged you also have access to Pandora radio which is kick *** and the stereo was only $130. Also installed some of the Nalin speaker adaptors to run some 5 1/4's in the dash, Nalin also has some kick *** Tweeter mounts that mount down by your feet. I ended up installing Marine grade Polks all around and threw a set of 6x9's behind the seats with 6ft of 12 gauge wire so I can throw them on the tailgate at camp for tunes.

With the half cab the sound inside or lack of was excellent, Now I am really looking forward to those long drives to Moab!
Attached Thumbnails
Sony.jpg   iPod.jpg   Polk5.25.jpg   PolkTweet.jpg   Tweet.jpg  


Rusty

If I had eight hours to chop down a tree, Id spend six sharpening my axe.- Abraham Lincoln


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post #27 of 630 Old 01-08-2013, 04:41 PM
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Nice looking audio setup.
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post #28 of 630 Old 01-29-2013, 11:34 AM
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Can't wait to see your finished product-

Subscribed... Looking forward to the build-
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post #29 of 630 Old 02-11-2013, 01:01 AM
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Quote:
Originally Posted by rusty762 View Post
Thanks man it is coming along, think I am going to ditch the half cab and go to a soft top. Love the half cab for sound and security but do not think its going to work out with the way this jeep is going to get used.
a half cab is my dream build.


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post #30 of 630 Old 02-11-2013, 10:41 AM Thread Starter
rusty762
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Parts continue to pile in the garage, Need to order coil overs, Gen Right tank and my rear axle!

Rusty

If I had eight hours to chop down a tree, Id spend six sharpening my axe.- Abraham Lincoln


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