MY WJ rear QTR protection w/nudge bar and recessed LED tails. - JeepForum.com

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post #1 of 20 Old 11-07-2013, 07:13 PM Thread Starter
gcjeeping
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MY WJ rear QTR protection w/nudge bar and recessed LED tails.

So after a few dent's in the rear QTR's and fenders as well as some broken taillight I finally got around to making some rear QTR protection with nudge bars and recessed LED tail lights.

I also built in a lockable compartment on the pass side. I made it as a remote power station and switches to turn the LED bars, side lights and BU lights. Also put in a cigaret lighter plug and the remote box for my power inverter. It has 2 110v and 2 USB receptacles. It has a switch to turn the inverter on and off from the remote box.

Started with remnant 10 gauge diamond plate, 24 riv-nuts, stainless hex cap screws and two harbor freight LED tail lights. Picked up a mailbox lock from Lowe's. I already had the toggle switches and pipe for the nudge bars.




Made some paper templates.





Cut the plate with the plasma and test fitted and adjusted as needed. I used a bottle jack, scrap metal 2x4 to put the bends in the plate.






Next was drilling holes and installing riv-nuts. I made my own riv-nut tool. I taped the plate to the jeep and drilled through the plate and fender at once.



























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post #2 of 20 Old 11-07-2013, 07:13 PM Thread Starter
gcjeeping
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Cut the metal for the recessed LED tail lights and tack welded them in.

























Cut and tack welded the fender pieces. The plate that is flat and facing out is scrap I had and is thicker than the 10 gauge. I had to cut reliefs in the curved bent part to get the bend right. Will fill them in when I weld them up.







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post #3 of 20 Old 11-07-2013, 07:14 PM Thread Starter
gcjeeping
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All welded up and a coat of primmer.















Also hole was cut for door to access power outlets.



Made a box out of scrap sheet metal for the power outlets and switches. Spot welded it in and sealed around it with RTV.









Waiting to install.



Fitted on and LED's wired up. I tapped into the trailer harness after the relays to get the LED to work like trailer lights. That way I didn't need to make any new wiring for them. Also added red reflectors to help keep it legal. Might have to add a side marker light too.













Access door. Put the cigarette lighter plug in. Will do switches and power outlets later.



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post #4 of 20 Old 11-07-2013, 07:14 PM Thread Starter
gcjeeping
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Cut and bent the tube then welded it on. Primed the tube and put the panels on the Jeep.























Here is the little power panel. The 3 switches are to turn on the LED bars, side roof rack lights and back up lights. Any or all can be turned on without starting or getting into the Jeep. The Cig lighter is always hot and the 120v/USB box is turned on/off by the switch on the box. Also added a mailbox lock to keep it secure.







A view from the back. LED's off, park, brake and vid of hazards.







Below is a video. Click on pick

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post #5 of 20 Old 11-08-2013, 10:03 AM
Merc1973
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Looks great GCJeeping. Very creative and well executed.

2002 WJ Ltd. 4.7 V8, QuadraDrive
1973 Mercury Cougar Xr7 convertible 351CJ, C6, 9" rear
1970 Kaiser-Jeep M35A2 W/OW 6x6 Multifuel D-Turbo.


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post #6 of 20 Old 11-08-2013, 10:18 AM
adavis39
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looks great...never got around to finishing mine before I sold it. Glad someone did it

2002 WJ Limited 4.7: 6" Clayton REALLY long arms....yep, they are longer than yours SOLD : (
1998 Platinum 5.9 DD
2007 WK Overland 5.7 wifes DD
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BUILD: http://www.jeepforum.com/forum/f197/...-crap-1399123/

"In a world that he did not create, but he will go through it as if it is his own creation. Half man, half beast, whatever it is it is weird, it is ticked off and it calls itself Slash"
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post #7 of 20 Old 11-08-2013, 10:32 AM Thread Starter
gcjeeping
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Thanks. It was a fun build. Might paint them OD green to match the rest of the Jeep.



.
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post #8 of 20 Old 11-08-2013, 10:32 AM
skain8
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Nice.

Did you seal the plate to the sheetmetal at all? My concern would be moisture and other gunk trapped between the two panels.

adavis39 - sold? WTF!?

'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
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post #9 of 20 Old 11-08-2013, 10:56 AM Thread Starter
gcjeeping
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Gunna run some RTV around it before I decide if I want to paint it to match the rest of the Jeep.
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post #10 of 20 Old 11-08-2013, 10:59 AM
adavis39
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Quote:
Originally Posted by skain8 View Post
Nice.

Did you seal the plate to the sheetmetal at all? My concern would be moisture and other gunk trapped between the two panels.

adavis39 - sold? WTF!?
yup......few weeks back. she gone

2002 WJ Limited 4.7: 6" Clayton REALLY long arms....yep, they are longer than yours SOLD : (
1998 Platinum 5.9 DD
2007 WK Overland 5.7 wifes DD
TNJEEPS.COM

BUILD: http://www.jeepforum.com/forum/f197/...-crap-1399123/

"In a world that he did not create, but he will go through it as if it is his own creation. Half man, half beast, whatever it is it is weird, it is ticked off and it calls itself Slash"
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post #11 of 20 Old 11-08-2013, 08:03 PM
its-me-B
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Just badass

Do the world a favor, hurt a honda...
Iro 3" lift with pro comp 9000es shocks, adjustable trackbar, led rock lights, all interior lights converted to leds, two 10" kicker comp with Kenwood 600 watt amp
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post #12 of 20 Old 11-08-2013, 11:10 PM
PatriotUSMC
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Yeah that looks great and I love the lock box!

2002 WJ Overland (Upcountry, 4.7 HO, Quadradrive).
1997 XJ Sport 4" Lift, 31's.
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post #13 of 20 Old 11-09-2013, 03:27 AM
alfaitalia
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Looks good and tough and I like it lots...........................you really have got too much free time on you hands! Im still trying to find the time to finish my hidden winch mount.....that I started about the same time you started yours!
50 hour a week job, 4 year old son and a house/garden that constantly needs repairs due to wind damage from living on the beach eats up all my time!
Good job!

If you can't fix it with a hammer, you've got yourself an electrical problem!
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post #14 of 20 Old 11-17-2013, 11:28 PM Thread Starter
gcjeeping
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Thanks. Yeh you you got a lot on your plate. I'm retired after 20+ years in the military. I remember the days of working all the time. Thankfully I'm done with that and still got good health to keep Jeepin. Got the kids out of the nest and living in sunny Ca now so that helps too. I never put the hidden plate on mine. Went a different rout. The finished plate is still in the garage though.
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post #15 of 20 Old 05-06-2014, 12:40 PM
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Wow this looks great!. May need to steal this idea at some point.

David.

2004 WJ Ltd. (steel blue pearlcoat)
4.7, 242 HD swap, 6" Clayton's, 35" BFG KM2s, F/R chromo'd JK Rubi D44s
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