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-   -   TJ Mini Boat side rockers (http://www.jeepforum.com/forum/f37/tj-mini-boat-side-rockers-894976/)

cgmrdc 11-05-2009 05:22 PM

TJ Mini Boat side rockers
 
Figured id do a write up of this for anyone who wants to build a set...

I REALLY like the look of the Poison Spyder richochet rockers and the functionality of Genrights mini boatsides and since i cant afford either and love fabing my own stuff I thought id combine the two and make my own!

The rockers are made of 3/16 steel and the tubes are 1.25, .120 wall HREW

Started by cutting out the rockers
58 x 14.25
http://i189.photobucket.com/albums/z...sliders_04.jpg

then cut where the bends go... leaving 6 1" gaps to hold it together
1st bend is 4.75
2nd bend is 3.5 from that
http://i189.photobucket.com/albums/z...sliders_07.jpg

Next set up on a heavy table and clamp it down as much as possible. I used 2 large pipe wrenches to bend them
http://i189.photobucket.com/albums/z...sliders_09.jpg
http://i189.photobucket.com/albums/z...sliders_12.jpg

Top bend is 120* and the second bend is 150*
http://i189.photobucket.com/albums/z...sliders_17.jpg

next you need to bend the pich seam under to gain the extra clearance of the boat side... this is the hard part if youre like me and had perfect rockers:(
http://i189.photobucket.com/albums/z...sliders_01.jpg

you need to cut where the fender meets the tub so it can fold there... its just 1 inch up at a 45 deg angle... ill take a pic

cgmrdc 11-05-2009 05:27 PM

once that is done you need to cut out the bottom to clear the body mounts... Ill get dems tom too

http://i189.photobucket.com/albums/z...sliders_30.jpg
http://i189.photobucket.com/albums/z...sliders_23.jpg

mount it up to see if the rockers needs to be messaged anymore...
http://i189.photobucket.com/albums/z...sliders_20.jpg
http://i189.photobucket.com/albums/z...sliders_20.jpg

repeat for the other side
http://i189.photobucket.com/albums/z...sliders_31.jpg
http://i189.photobucket.com/albums/z...sliders_32.jpg
http://i189.photobucket.com/albums/z...sliders_35.jpg

cgmrdc 11-05-2009 05:29 PM

Here is the shape of the tubes... ill get the autocad sketch and ad dems or you can bend whatever tube shape you want... or none...
http://i3.photobucket.com/albums/y71...n/IMG_2448.jpg
http://i3.photobucket.com/albums/y71...n/IMG_2450.jpg

cgmrdc 11-05-2009 05:32 PM

Next is welding it together... alternating rockers and ends of the rockers with time too cool... i doubt theyll warp but better safe then sorry
http://i189.photobucket.com/albums/z...sliders_38.jpg

after everything is welded up and you test to make sure they didnt warp or pull out grind the welds smooth. with the welder turned up you should be getting 100%+ penetration
http://i189.photobucket.com/albums/z...sliders_39.jpg
http://i189.photobucket.com/albums/z...sliders_40.jpg

cgmrdc 11-05-2009 05:33 PM

Thats where im at as of today, ill keep updating and get the dems as I progress!

JeSimmers 11-05-2009 05:33 PM

WOW! These are absolutely incredible...Good Job!

cgmrdc 11-06-2009 03:22 PM

Wow, thanks for the compliment. Thats the responce every fabricator strives for:cheers2:

karlo 11-08-2009 07:15 AM

Looking good! I'm excited to see the final outcome.

funshootin1 11-11-2009 05:36 PM

looks great !

Dogman 11-12-2009 10:47 AM

Nice job!!!

Mike1084 11-12-2009 10:56 AM

If I may ask, cost of materials?

cgmrdc 11-12-2009 01:41 PM

$120 4'x8' 3/16 steel plate... which will also make my front bumber and steering box skid
$20 20' 1-1/4 HREW
$25 stainless steel nuts and bolts

i used half the stick of tubing and between half and a third of the sheet... so def a lot less the $499...

Mike1084 11-13-2009 08:26 AM

Nice! Definately worth it. I like some of the Poison stuff also but outta my price range. love to see the finished product, keep up the posts.

cgmrdc 11-15-2009 08:03 PM

got the sliders on for a test run to flat nasty this weekend. The clearance difference between these and my old tube steps is unreal! i actually had to purposefully drive over a rock to get them to hit just so i could see how they held up, and that was the only time i touched them all weekend... but now the lowest point is the body mounts so im gonna fab up some skids for those too
http://i189.photobucket.com/albums/z...sliders_41.jpg
http://i189.photobucket.com/albums/z...sliders_43.jpg
http://i189.photobucket.com/albums/z...sliders_44.jpg
backing plates on the sides are 2x1/4 stainless strips, floor is 2x1/4 mild...
http://i189.photobucket.com/albums/z...sliders_42.jpg
10 stainless counter sunk bolts per side for a nice smooth surface.
now that wheelin season is over....... im gonna pull these off, stripem back down, weld the tubes on, clean up some of the grinder marks and ill paint it gunmetal to be the same color as the TJ

NalinMFG 11-16-2009 10:51 PM

awesome job, this will save alot of people some serious dough! i have been wondering how genright got theirs to fit without trimming the tub...yours made sense of it. Any more pics? How's it mount underneath?


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