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Building a Bumper?Ruffstuff Axle Simple Swap Kit!~Artec JK 1 TON SWAP~

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Unread 07-14-2012, 01:23 PM   #61
acgcoug
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It's been a little bit since I last posted some progress pics, so here we go:

Moved on to the other side of the rear of the tub.

Just like the other side, this section needs cutout and replaced with new metal.



Backside:





Patch welded in (needs grinding still):



Constructing new body mount/box section:





Finished up. I will weld this piece on later after I clean up/sandblast some some areas on the rear of the tub.





Wheel housing brace removed and cleaned up. I will cut out and replace the bad sections later.



Backside of rusted/rotted section where the brace was mounted.



Topside:



Topside patch welded in:



Backside (still need to weld the folded section that meets the inner side of the tub, plus the spot weld hole that I drilled).



Topside mostly ground down:



Filling in holes from where the diamond plating was installed.



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Unread 07-14-2012, 01:50 PM   #62
Skerr
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WOW!! That's outstanding work!! You are all over it. I so hope my tub doesn't have the same symptoms when I get into it. Great detail.
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Clay's Build Thread
http://www.jeepforum.com/forum/f8/cl...hread-1061897/
Scott's Build Thread
http://www.jeepforum.com/forum/f8/sc...5-cj7-1147913/
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http://www.jeepforum.com/forum/f11/f...-okee-1445206/
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Unread 01-08-2013, 10:13 AM   #63
acgcoug
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Still around guys. Life has been pulling me in other directions, but I'm itching and planning on getting back to the jeep soon...I hope.
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Unread 01-08-2013, 10:16 AM   #64
WNC-84CJ7
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Quote:
Originally Posted by acgcoug View Post
Still around guys. Life has been pulling me in other directions, but I'm itching and planning on getting back to the jeep soon...I hope.
I know what you mean! During the semester, I am off for 4 or 5 months at a time! I can't stop thinking about it though. Now, get back on that Jeep.
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Unread 01-10-2013, 03:43 PM   #65
acgcoug
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Had a little bit of time on my hands, still trying to finish up the valence and rear body mount sections. Getting close to welding the newly made nut/bolt cages, and then I will Por15 the inside of the valence section, and then weld the repaired valence back on.








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Unread 01-10-2013, 06:34 PM   #66
Griffen24
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AMAZING metal work! only wish i has some of your skills...
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Unread 01-10-2013, 07:41 PM   #67
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Dude... awesome body work... looks great!
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Unread 01-10-2013, 09:51 PM   #68
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^^^ What they said, Adam. Heck of a good job.
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"Contemplate the mangled bodies of your countrymen, and then say 'what should be the reward of such sacrifices?' ... If ye love wealth better than liberty, the tranquility of servitude than the animated contest of freedom, go from us in peace. We ask not your counsels or arms. Crouch down and lick the hands which feed you. May your chains sit lightly upon you, and may posterity forget that you were our countrymen!" —Samuel Adams

Clay's Build Thread
http://www.jeepforum.com/forum/f8/cl...hread-1061897/
Scott's Build Thread
http://www.jeepforum.com/forum/f8/sc...5-cj7-1147913/
Fallon (and Dad) Build Thread
http://www.jeepforum.com/forum/f11/f...-okee-1445206/
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Unread 01-11-2013, 10:53 AM   #69
acgcoug
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^^^Thanks Guys!

I've been contemplating making my own threaded square nuts for my body mount nut cages, but decided to stop by Fastenal to see what they had. None of the other hardware stores in town had anything that would work. This is what they had:





As you can see in the pic they are a tiny bit thicker than the original one, but they should work perfect because I made my nut cages slightly taller than the originals. I have 6 total of these darn things to remove, make, and weld on. Anway, so if anyone needs these little guys, check with Fastenal ($2.80 each).
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Unread 01-11-2013, 11:24 PM   #70
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My hat's off to you! You are putting forth a Herculean effort to do a thorough tub repair! Nice metalwork!

Rich
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Unread 01-18-2013, 03:08 PM   #71
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I didn't realize they carried those. I had made mine from 1/4"x1 1/2" flat stock, then drilled and tapped them. Those would have saved me some time for sure. Nice job.
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Unread 01-18-2013, 04:39 PM   #72
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Quote:
Originally Posted by acgcoug View Post
^^^Thanks Guys!

I've been contemplating making my own threaded square nuts for my body mount nut cages, but decided to stop by Fastenal to see what they had. None of the other hardware stores in town had anything that would work. This is what they had:

As you can see in the pic they are a tiny bit thicker than the original one, but they should work perfect because I made my nut cages slightly taller than the originals. I have 6 total of these darn things to remove, make, and weld on. Anway, so if anyone needs these little guys, check with Fastenal ($2.80 each).
Do you have part number or a exact name they go by?
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Unread 01-18-2013, 05:31 PM   #73
acgcoug
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Quote:
Originally Posted by waterdowg View Post
Do you have part number or a exact name they go by?

3/8"-16 Zinc Plated Square Attachment Nut for Concrete Spot Inserts

Fastenal Part No. (SKU): 49464

http://www.fastenal.com/web/products...l.ex?sku=49464

FYI, they had 2 slightly different looking ones in the same tub, the one stamped 3/8 (see pics) was slightly thicker and threaded much better (the ones I bought). If you visit the Fastenal store, make sure you take a body mount bolt to double check that they will thread correctly.
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Unread 01-27-2013, 10:47 PM   #74
acgcoug
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Installed the newly made body mount nut cages and was finally able to seal up the rear valence section.

Degreased, phosphoric acid etched (same as metal ready step), and applied 2 coats of Por 15 to the back of the repaired valence and the boxed section.



Spot welded



Ground down the welds





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Unread 01-27-2013, 10:55 PM   #75
Matt1981CJ7
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Adam,

I think it may have been easier for you to weld up a new tub from scratch.

I'm enjoying watching your excellent work.

Matt
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