JeepForum.com

JeepForum.com (http://www.jeepforum.com/forum/)
-   JK Wrangler Technical Forum (http://www.jeepforum.com/forum/f96/)
-   -   Building Rock Rails (http://www.jeepforum.com/forum/f96/building-rock-rails-1131444/)

paul84043 11-21-2010 08:06 PM

Building Rock Rails
 
So, at the promptings of my brother in law who is a total badass at fabbing pretty much anything, we decided to build our own rock rails/steps.
Most rails seem horribly overpriced and I don't like the angles they use...so one big benefit to making your own, you can make them how you want...

The initial parts list:
Full stick each of:
2x3x1/4" square tube stock
2" angle
1 1/2"x.120 OD Round Tubestock.
Scrap of 1/8 Diamond plate.

Total cost $187.00

I used 1/4" tube stock because after the Nuclear holocost, there are going to be three things left intact.....****roaches, twinkies, and my rock rails.

I haven't welded since shop class in High school, so this was the perfect project to relearn on....

Started by ripping 1" off the angle lengthwise to get the angle that I want on the extended rail/step.

Tack together and let monkeyboy (me) try to hurt himself with the welder.

http://i1045.photobucket.com/albums/...2-35-45_33.jpg

After tacked together, we welded Diamond plate to box in the ends..

http://i1045.photobucket.com/albums/...-36-35_527.jpg

Finish welding, cleanup, and start the process of grinding to the profile that makes you happy...

http://i1045.photobucket.com/albums/...4-07-39_17.jpg

Clean rough rail, quick mockup to check some final measurements and send a pic to the wife....

http://i1045.photobucket.com/albums/...1-55_938-1.jpg

Cut tubing and bend on their homemede tubing bender that's freaking awesome...

http://i1045.photobucket.com/albums/...5-47_742-1.jpg

Cut supports, tack in place, finish welds.

http://i1045.photobucket.com/albums/...-50-42_409.jpg

http://i1045.photobucket.com/albums/...-50-36_453.jpg

One badass rail roughly done. Approx weight 55 lbs.

http://i1045.photobucket.com/albums/...-58-32_634.jpg

http://i1045.photobucket.com/albums/...-05-24_961.jpg

http://i1045.photobucket.com/albums/...-06-15_200.jpg

That's as far as we made it this weekend. Probably be finished by the end of the week. We have decided on the mounting brackets that we want to make and I'm still up in the air on whether or not to Powerdcoat, or Bedline. I'm leaning towards bedliner because I can do it, and maintain it myself...

I'll post more as the project proceeds this week....

No_Return 11-21-2010 08:22 PM

Very Nice... I love DIY Fabricated stuff.

Don't make them too long, I think .50 - .75" short of the end of the pinch weld at the rear.

paul84043 11-21-2010 08:23 PM

Sorry if you were one of the first to look at it and see ALL the same picture...Photobucket is having issues.

Any input on this as we go would be GREATLY appreciated....

These badboys are going to be BULLETPROOF.

Thanks..

Paul.

paul84043 11-21-2010 08:32 PM

Quote:

Originally Posted by No_Return (Post 10491463)
Very Nice... I love DIY Fabricated stuff.

Don't make them too long, I think .50 - .75" short of the end of the pinch weld at the rear.

Oh, and I agree...you're right on, I plan on cutting the pinch seam as part of this project, so made the length and angle to all line up when done....

Thanks...

joe002 11-21-2010 08:47 PM

Looks really good! Like No_Return said make sure you leave enough room in the back.

Stock Rubicon slider with 35”:
http://i142.photobucket.com/albums/r...s/IMG_8067.jpg

Not a lot of space. You’ll get rubbing on the trails:
http://i142.photobucket.com/albums/r...s/IMG_8068.jpg

Hacked them back to give plenty of clearance:
http://i142.photobucket.com/albums/r...s/IMG_8083.jpg

Bent the pinch seam back - doesn’t rub with 35s:
http://i142.photobucket.com/albums/r...s/IMG_8098.jpg

paul84043 11-21-2010 08:52 PM

Here's the side shot of the rails, we cut them at a 60 degree angle to match the fenders....

http://i1045.photobucket.com/albums/...-42-06_628.jpg

when we cut the pinch seam, it should all line up nicely...

Love the pics of what others have done!!!!

Thanks.

joe002 11-21-2010 09:00 PM

Quote:

Originally Posted by paul84043 (Post 10491684)
Here's the side shot of the rails, we cut them at a 60 degree angle to match the fenders....

http://i1045.photobucket.com/albums/...-42-06_628.jpg

when we cut the pinch seam, it should all line up nicely...

Love the pics of what others have done!!!!

Thanks.

You have plenty of clearance with your rails :thumbsup: It will be perfect when you adjust the pinch seam.

paul84043 11-21-2010 09:02 PM

It's nice to have someone that is confident and competent to give you the confidence to do a project like this...I love the feeling of building something myself....

McKBrew 11-21-2010 10:31 PM

Very nice rails.

1222 11-21-2010 10:53 PM

Nice project and love the DIY approach. Are you going to show any details concerning how they are mounted? Great work so far.
:cheers2:

paul84043 11-22-2010 05:33 AM

Quote:

Originally Posted by 1222 (Post 10492418)
Nice project and love the DIY approach. Are you going to show any details concerning how they are mounted? Great work so far.
:cheers2:

Yes, absolutely, We saw a mounting system on another retail set that looks super tough. We're going to use the 3 Cab Mounts and make a U-Channel/box bracket that will also mount to the frame, should be very secure and not too terribly hard to make, but MUCH stronger than a simple tab.
It looks like I've got my work cut out for me for at least two more evenings getting the other rail cleaned up. It's a little tedious, but not hard at all. Just need to try not to light the garage on fire.

Any thoughts/input on bedlining these? I think I have the process in my head, but haven't done it before, I'm wondering about the best prep method...

So far the project has been pretty simple, there are a few tools/jigs that were invaluable, the rest is just good old fashioned garage ingenuity.
We used a bench mounted clamp that holds a holesaw to cut the rounded mating portion of the three supports, this was 30$ at harbor freight.
The other special item is the tubing bender. My brother in law and his father made a couple of them out of plans on the internet, the company posts the plans for free and you purchase the dies from them, so they still make their money. It's powered by a manual hydraulic jack and is pretty simple in design, pure genius if you ask me, I'll get a better picture of it.

More pics when I get them...

Warlord2 11-22-2010 05:56 AM

I really like rustoleum bedliner, the liquid type. I used it on my rear bumper and it went on very easy and uniformed with a small roller. After my rock guards get banged up a little more I plan on coating them with it as well. This stuff will go on anything, actually smells just like fiberglass resin and is paintable. I would just use a basic primer if you want some added protection, I think it seals well though without anything. I was in a car crush event and this stuff didnt even get scratched.

GJ on the rails, the mounting was the hardest part when I made mine. Getting everything lined up and stuff was a pain in the butt, just take your time is my best advice.

paul84043 11-22-2010 06:22 AM

Thanks for the input! I'll look into the Rustoleum.. I had planned on priming, but hadn't really formulated that process in my head yet... The Mounting looks a little technical, I've been thinking about making a template out of plywood, should be easy enough to put under the cab and make some indents with a soft hammer to get the spacing perfect.....don't know yet, we'll figure it out....

Warlord2 11-22-2010 06:29 AM

here is my thread on the project if you want to see how I mounted mine
http://www.jeepforum.com/forum/f96/h...tures-1095555/

I have added some more bolts on the sides of those bracket sense I took the pictures. Basically just threaded my own holes into the frame for some added support.

paul84043 11-22-2010 06:42 AM

Wow, very nice setup, I like your mounting system, I'll have to keep that in mind... Those babys look very strong!!


The time now is 09:52 AM.

Powered by vBulletin Version 3.8.4
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.