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Unread 05-17-2012, 11:38 AM   #76
Molonlabemike
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1997 TJ Wrangler 
 
Join Date: Oct 2011
Location: Rancho Chuchamonga, CA
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Ok it looks like I'm gonna need more DOM! Question for the cage gods, would I be safe in using 1.50 .120 wall DOM for my seat mounts? Im thinking I need to keep the weight down and think it will be ok. Your thoughts?

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Unread 05-20-2012, 09:23 PM   #77
Molonlabemike
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Ok a little update...I am pretty dang beat, it's been a non stop over the last few days and it's taking it's toll on my body. Still pretty happy with my progress! Looks like my harness bar will be on Tuesday and my seats and harness will hopefully ship soon.

Finally got around to installing my bump stops, install went pretty easy and I can't wait to them them out!

All layout, pretty nice kit and I am looking forward to seeing how they bump out...I forgot to remove my springs and ensure that everything went well, gonna have to wait till I can flex it out!
This is what I am starting with....

So that's not going to work so let's start installing the bumps!

Getting them installed, went pretty smooth
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Unread 05-20-2012, 09:32 PM   #78
Molonlabemike
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Next was to finish up the cage and and install it , got everything I needed done today minus the C pillar mounts. I should be able to knock that out along with the dash tomorrow.


Cage was primed and painted, came out pretty nice and the install was pretty easy.

Since i will be installing my new seats I left some of the cage unprinted, this will allow quick work when welding them in! Replaced those dam n B pillars with some grade 8 hex head bolts, made the install way simpler!

Finally drilled out the A pillar mounts, goal was to get them tied into the frame.

Made some frame reinforcements out of some 4x6x1/4 strap, should hold up nice. Also had to fab up the bushing tabs which are also out of 1/4 steel, shouldnt have any issues with them in the event I have to use them.

Now from what I read that it's a pretty good idea to to sandwich a piece of DOM between the floorplates. In theory this should eliminate the false floor from collapsing In the event that I got rubber side up.

Had to drill out the hole, used a 2in hole saw so I count account for the welds.

Got them all burned in!


Also got the front bumper paint and mounted the lights...not sure how I feel out the lights.


View from the front, gotta figure out the hole rear view morrow thing.

Also spent some time getting my door molds fitted, nothing a little dermal can't get fit!


And here she sits now, hopefully I'm not soar to get the C pillars and dash nocked out.
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Unread 05-20-2012, 10:48 PM   #79
dongalonga
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Wow man great job. That looks like it was a ton of work.
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Unread 05-20-2012, 10:56 PM   #80
Molonlabemike
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Quote:
Originally Posted by dongalonga View Post
Wow man great job. That looks like it was a ton of work.
Thanks man it's been a long week or sanding and fabben! Cant wait to throw the dash back in and get it mop being under its own power
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Unread 05-21-2012, 08:40 AM   #81
G Beasley
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The tie ins look nice , and the false floor reinforcement is a great idea .
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Unread 05-21-2012, 09:05 AM   #82
Xtremegameroom
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Wow man it looks great! You do some nice work
I had a pair of hellas on my Taco and I wasn't happy with them at all. They were more like spot lights and had no light spread so they really didn't do anything.
I got my roof rack leds hooked up this weekend and they practically light up the whole neighborhood.
If you don't mind spending the money they are a great light and they only pull about half the amperage as the hellas. Plus they're pretty small so they won't stick out like a sore thumb

http://www.4wd.com/Jeep-Lighting-Jee...&t_pn=RIG20211
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Unread 05-21-2012, 09:10 AM   #83
Xtremegameroom
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The other thing you can do if you want to keep them if you don't like the rock covers you can paint them black. I did that to mine and it came out pretty good
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Unread 05-21-2012, 10:59 AM   #84
Molonlabemike
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Quote:
Originally Posted by G Beasley View Post
The tie ins look nice , and the false floor reinforcement is a great idea .
Kinda thought so myself, from what I read people who flopped pushed there mounts through the floor I know we must make compromises when building a cage on a TJ and trying to retain the stock elements.
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Unread 05-21-2012, 11:02 AM   #85
Molonlabemike
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Quote:
Originally Posted by Xtremegameroom View Post
Wow man it looks great! You do some nice work
I had a pair of hellas on my Taco and I wasn't happy with them at all. They were more like spot lights and had no light spread so they really didn't do anything.
I got my roof rack leds hooked up this weekend and they practically light up the whole neighborhood.
If you don't mind spending the money they are a great light and they only pull about half the amperage as the hellas. Plus they're pretty small so they won't stick out like a sore thumb

http://www.4wd.com/Jeep-Lighting-Jee...&t_pn=RIG20211
I was planning on throwing a HID setup in them and calling it good. I do plan to get some new LED lights, I was kinda putting them on my want list till the prices come down.
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Unread 05-21-2012, 11:06 AM   #86
Molonlabemike
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Quote:
Originally Posted by G Beasley View Post
The tie ins look nice , and the false floor reinforcement is a great idea .
Also, pick up some 9/16 bushing (metal not poly) and cut down to fit on the bolts furthest from the door on the A pillar. You will notice you will have about an inch gap on those 2 bolts and the bushing prevents any collapsing with the plate. Hopefully that makes sense!
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Unread 05-21-2012, 10:42 PM   #87
Molonlabemike
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Well it's been a long long 3 day weekend for me, but got a lot done and she's driving again!

I have some small projects to get completed, need to finish the driver side C pillar tie-in. Passenger side took up much more time then I though and waking up late didn't help!

Drilled out the factory C pillar mounts and added some nice 9/16 hardware, I don't see this going anywhere....I just hope I never have to find out! (I see I didn't have the washers I place, I promise I have some 9/16 grade 8 washers)

Now I was going to just leave the bushing mounts square but I figured I might as well male it look nicer...not 100% sure these came out that nice lol

For the frame side mount I use a piece of 2x4x1/4 strap ontop of the frame then welded the DOM to that. Driver side is going to suck since I have the fuel lines to work around.
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Unread 05-21-2012, 10:52 PM   #88
Molonlabemike
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Since day light was running low I started to throw in the dash. I am crossing my fingers I don't need to remove it again to mount seats.

In the process of uninstalling and installing the dash I managed to scuff the steering bezel pretty good. Tried to paint it but that looked worse so I need to either strip it and start fresh or buy a new one.

While out driving I went to my local Jeep Gym and flexed the Jeep out to see how everything went. Looks like my rear bumps might be a tad short....I mean a tad! Also my from swap was still connected so no pointing fingers!

Little side shot! Over all pretty happy with it, just need to get my seats and locker in and I'm ready! Well now I think about it, I need to finish the wiring and Monsterline the tub....
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Unread 05-23-2012, 01:03 AM   #89
Molonlabemike
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Another late night innthe garage tonight, can't really say it was 100% productive....on the other hand I let my creative juices flow! First was to paint the inside my fender wells in the rear, the faded blue was not really working so I sprayed them down in black. Also pushed my rear axle out 1/4 on the driver side since it was a tad off after installing my coil buckets. Now the fun started, I know I am not the first to pull this mod off but that didn't matter. I installed my Easy button!!!!! After debating the location I think I selected the best and simplistic location....Enjoy!

First you need to pop the button apart, ai,ply pop off the black screw covers and remove the screws. After that pull it apart and remove the weights that make it heavier then it need to be, that's where I put the u bolts. Next simply drill the holes and install the u bolts, I added some loctight to ensure a nice strong hold.

As you can see its pretty tight so small nuts are a plus!
Start putting it back together, I put the zip tie in and wrenched the u bolts so it wouldn't wobble.

Once you put it all together you should end up with this!

Now put it where ever you decided would be best, in my case I put it out of the way attached to the cage.


Like I said it was a rather productive night in the garage! Also got a chance to add abottle opener, slapped it to the inside of my tire gate. Nice simple and refreshing mod I might say
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Unread 05-23-2012, 10:07 AM   #90
AngryTJ
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The build is coming out great man!

How much of a pain was it to remove the torx bolts that hold the cage in?

Also Ive been tryin to get tips from a few guys, how did you cut the welds on the inside of the frame for the upper spring perch?
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