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Unread 09-13-2013, 12:45 AM   #16
Dumpsterfish
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Finally had a day off, and managed to get some work done.

First I made a Template out of cheap-o pine...



image-400246906.jpg

Then I cleaned up all my parts and got them clamped up for welding:



image-1801549537.jpg

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Unread 09-13-2013, 12:48 AM   #17
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Oops, hit send by accident.




image-991160571.jpg



All tacked together...



image-876996515.jpg

And when I fit it to the jeep...the dang mounts AREN'T ALL AT THE SAME HEIGHT!!!



image-2845450392.jpg

Turns out the rear mount sits a full 1" lower w/r/t the tub than the front. Time to break out the calculator and make some miter cuts....at least all the holes line up. I'll take what I can get here.
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Unread 09-13-2013, 03:24 PM   #18
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Used some scrap tubing to move the ends of the sliders apart, tacked them up using miter cut standoffs (it was a 15 deg miter)



image-1130506655.jpg

Don't like the way they line up. Close, probably passable, but not good enough. Headed to the yard to find some scrap plate, gonna make a jig and do this the right way.
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Unread 09-20-2013, 01:23 AM   #19
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Ok, got the stock for a jig, some 1x3x.125 from the rems section. Here's the progress I made today:



image-2208475092.jpg

Also got my DOM in for the rub rails. Hope to have some more pics up soon.
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Unread 09-24-2013, 07:58 PM   #20
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The journey continues. As I noted a few comments up, the body mounts are not vertically equidistant from the tub. I had assumed they ran sequentially farther away from front to back, but before adjusting the mount heights on my jig, I took some measurements using a piece of scrap flat bar and a combo square. Back:



image-175144236.jpg


Middle:



image-211033579.jpg


Front:



image-4199432005.jpg

So the front, at 1/2", is in fact the shortest...but the longest is the middle at 1&1/8". Glad I checked!

Here's a sketch of the planned adjustment to my jig:



image-1231014024.jpg

I know I have some leftover 3/16" stock, and pretty sure I can rustle up some 5/8". Hope to finish this jig on Thursday, maybe have a set of sliders welded up by Friday afternoon.
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Unread 09-25-2013, 04:40 PM   #21
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two 5/16" plates would work in a pinch. I have some 5/8" in AR400 that I can plaz for you if you need it. I'm am in Inland Empire.

WSS

LOOKIN GOOD!
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Unread 09-25-2013, 07:58 PM   #22
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Quote:
Originally Posted by WSS
two 5/16" plates would work in a pinch. I have some 5/8" in AR400 that I can plaz for you if you need it. I'm am in Inland Empire. WSS LOOKIN GOOD!
Thanks!

Our scrap bins runneth over, so I had no trouble digging up some 5/8 structural cutoffs. If only I had the day off....
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Unread 09-26-2013, 08:22 PM   #23
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Only had an hour or so today...finished the jig:



image-1590282452.jpg



image-3274272909.jpg

Have tomorrow off though...will post progress!
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Unread 09-27-2013, 11:57 PM   #24
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Big day today...

First I got all my pieces cleaned up and in the jig:



Attachment 713361

Then time to tack and check the fit:



Attachment 713369

And SWEET JEEBUS THEY ACTUALLY FIT!!! HUZZAH!!



Attachment 713377

So time to weld...

Attachment 713385

And start bending some tube. Gotta say, bending 1.75" .120 wall on my model 3 is a WORKOUT.



Attachment 713473

I use templates...because I was told there would be no math.



Attachment 713481



Attachment 713489

After bending, I struggled to find a good way to accurately miter the bent rails. Settled on a basic jig made of some 4" angle, and some fancy work with the old angle grinder/cutoff wheel.



Attachment 713505



Attachment 713513



Attachment 713521

Then it was time to toss them on the jig, and weld them on. I tried to match the upward angle of the rails to that of the lower portion of my rocker panels (54 degrees from horizontal). They look great, but the miter made for an opening way wider than the 2". Fit was bad, welds suffered. Had to use a little piece of 1/8" to fill the gap.

Pretty happy with the day's work. Should be able to finish next week.



image-3221544662.jpg



image-363378597.jpg
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Unread 09-28-2013, 12:29 AM   #25
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None of my pics uploaded!



image-2239848928.jpg



image-3128462803.jpg
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Unread 09-28-2013, 12:29 AM   #26
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image-2178167691.jpg



image-2004389381.jpg



image-2508123430.jpg
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Unread 10-01-2013, 12:06 AM   #27
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So I finally finished!

Had to weld in some standoffs...the miter/fit issue was solved by adding in some 1/8" flat bar ground to fit.



image-3054234387.jpg




image-3114695045.jpg



image-3873470154.jpg

Finished and painted:



image-1060444354.jpg



image-3228835135.jpg

And mounted up!



image-2663872504.jpg



image-583895312.jpg

All in all, I'm very happy with the fit. They sit just a bit higher than the frame rails, and the rub rails hug the tub nicely. Now to go test them on some rocks...
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Unread 10-01-2013, 01:08 AM   #28
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Duly protected! A strip of anti-skid/slip across the top would make a nice footing to get in and out. I used the stuff that feels like sandpaper, it sticks really good

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Unread 10-01-2013, 11:35 AM   #29
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Quote:
Originally Posted by WSS
Duly protected! A strip of anti-skid/slip across the top would make a nice footing to get in and out. I used the stuff that feels like sandpaper, it sticks really good
Nice. Yeah I'm gonna slap some on. The roll bar paint I used (VHT) says it fully cures in 7 days. Will stick some on then.
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Unread 10-01-2013, 03:42 PM   #30
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Sweeeeeeeet!!!!! Cant wait to get mine!!!!!!
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