My Surgical TJ-6 Build - Page 12 - JeepForum.com
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post #166 of 541 Old 03-24-2017, 12:50 PM
Remko
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I've had the 1452 version sitting in my cart on Amazon for a while now, and keep humming and hawing about it, guess I should hit order.


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post #167 of 541 Old 03-25-2017, 07:51 PM Thread Starter
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Originally Posted by NashvilleTJ
Great workT-Jay. Congrats on the new tool. I recently bought the nutzert tool and I've been amazed how often I've used the thing.
Thanks! Yea this is one of my favorite tools now.

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Originally Posted by Remko
I've had the 1452 version sitting in my cart on Amazon for a while now, and keep humming and hawing about it, guess I should hit order.
Do it!

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post #168 of 541 Old 03-25-2017, 07:56 PM Thread Starter
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Update. Passenger side wall is in. :-)

image-2959303774.jpgimage-3010767827.jpgimage-2196495947.jpg

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post #169 of 541 Old 03-26-2017, 08:52 AM
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I love those clips - I have not seen those before.

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post #170 of 541 Old 03-26-2017, 02:03 PM
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I really like the floor pan. The new found space will be wonderful. As my boys are gone, I can store all sorts of things behind the front seats for weekend trips. Are you looking to finish the sheet metal and paint it, or will you cover it in body armor? If you are gong by way of armor, contact Savvy, ask for Martin (or Gerald) and tell them what you are aiming for and they can cut your corners. And once again, very nice work.

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post #171 of 541 Old 03-26-2017, 04:58 PM Thread Starter
T-Jay
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Quote:
Originally Posted by NashvilleTJ
I love those clips - I have not seen those before.
Sheet metal butt welding clamps. eBay's got um ;-)
Quote:
Originally Posted by a48jeep
I really like the floor pan. The new found space will be wonderful. As my boys are gone, I can store all sorts of things behind the front seats for weekend trips. Are you looking to finish the sheet metal and paint it, or will you cover it in body armor? If you are gong by way of armor, contact Savvy, ask for Martin (or Gerald) and tell them what you are aiming for and they can cut your corners. And once again, very nice work.
Already done. Check out the first post of the thread. And page 10 and 11.

Here's an updated video walk around. Although I've progressed a bit further at this point. I'm in the process of mocking up the drivers side wall now.

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post #172 of 541 Old 03-27-2017, 08:53 AM
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Duh, I totally saw those pictures already. Brain fart. Looks excellent! I'll stop now.

Daily driven, stretched TJ with 108" wheel base.
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post #173 of 541 Old 03-27-2017, 07:40 PM Thread Starter
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Duh, I totally saw those pictures already. Brain fart. Looks excellent! I'll stop now.
Ha! No worries. Thanks.

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post #174 of 541 Old 03-27-2017, 07:42 PM Thread Starter
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Back to work! I got started on the drivers side last night.

image-2989145737.jpg

Here's my C7 wall extension panel in the rough. It does still needs a little trimming and some massaging. It, like the passenger side will run from just below the belt rail, down the side to a 90 deg bend at the bottom.
The bend will cut back in to the side of the Jeep with a 2.5" lap resting on the floor pan. The lap will be structurally glued to the floor pans when all is said and done. Should make for a pretty ridged assembly.

image-1258390533.jpgimage-407329233.jpg

image-1709184016.jpgimage-3179082361.jpg
image-2017140340.jpg

I decided it would make for a much cleaner and stronger patch if I bead rolled a recessed flange on the forward edge of the extension panel rather than cut and screw on a strip of sheet metal after the fact, like I did previously at the passenger side.
I'm actually considering going back and redoing the passenger side like this when I'm done to quiet the OCD voices in my head lol. You can see in the last photo how the flange rests on the inside face of the existing body sheet metal.
The lap joint is conveniently hidden inside the B-pillar so it can be as ugly as it wants to be. I plan in using my 3M structural glue to join the surfaces rather than spot welding and stitching down the panel joint.
The joints at the rear of the extension panel and along the top will be visible from inside the Jeep so they will need to be stitched and cleanly finished.

image-1851780136.jpg
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post #175 of 541 Old 03-29-2017, 07:15 PM
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When you panel bond, make sure both surfaces are free of paint and bare metal showing. Brush a seam about 1/2" wide and keep many clamps on it over night and by morning it's good to keep working

My 2.4 turbo TJ-6 stretch build
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post #176 of 541 Old 03-30-2017, 12:51 AM Thread Starter
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Originally Posted by TJRUSSELL
When you panel bond, make sure both surfaces are free of paint and bare metal showing. Brush a seam about 1/2" wide and keep many clamps on it over night and by morning it's good to keep working
Yep... As with everything else here I've researched obsessively on the stuff. Lol

But as far as coverage goes, you actually want to be covering the entire mating surface. Anywhere where clean bare metal exists should be covered in adhesive so moisture can't get between the two flanges and grow rust. I'll be running sheet metal screws through to hold the flanges together during curing. I'll grind them off and flat when it's all done. ;-)

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post #177 of 541 Old 03-30-2017, 02:33 PM
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Yeah and once the 2 panels touch don't pull them apart. Slide them around to get the fit you need. I would recommend 3m heavy bodied seam sealer in the auto mix for all seams under body and inside. Ultra pro seam sealer drys to fast to make it look nice fyi.

My 2.4 turbo TJ-6 stretch build
https://www.jeepforum.com/forum/f22/my-lil-2-4-tj-build-1092494
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post #178 of 541 Old 03-30-2017, 07:33 PM Thread Starter
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Quote:
Originally Posted by TJRUSSELL
Yeah and once the 2 panels touch don't pull them apart. Slide them around to get the fit you need. I would recommend 3m heavy bodied seam sealer in the auto mix for all seams under body and inside. Ultra pro seam sealer drys to fast to make it look nice fyi.
Nice! Thanks for the heads up.

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post #179 of 541 Old 04-05-2017, 10:06 AM Thread Starter
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Update: I finally got my floor pans rolled
image-764097519.jpg

I'm going to reinforce my B pillars with some 18ga where I separated the factory spot welds holding them to the wheel housings.
image-2498239636.jpgimage-749597589.jpg
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post #180 of 541 Old 04-05-2017, 11:34 AM
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Those rolls turned out really well. Nice work.

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