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post #316 of 394 Old 12-03-2019, 04:39 PM Thread Starter
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Originally Posted by NashvilleTJ View Post
Just make that Jeep a two wheel drive sand rail...
I dig it, that would be way fun. Probably outta finish up one build before I dive into others.

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post #317 of 394 Old 12-04-2019, 07:53 AM
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Quote:
Originally Posted by tbunch View Post
I dig it, that would be way fun. Probably outta finish up one build before I dive into others.
Just stop it with those logical ideas. I wouldn't know what to do with only one project going on. Lets see... the Jeep, the square body Chevy, the camper, the kids' Jeep, the CJ2A that I am dying to get started on.

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post #318 of 394 Old 12-16-2019, 09:18 AM Thread Starter
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Welp, still here, haven’t given up on this thing yet. Though, motivation goes in and out. Haven’t been as good at updating, but not much has gone on, mostly planning.

That said, I have done some stuff. Main thing is finishing the frame extension. I full welded the splices and fish plates, then added tube gussets to add to the strength.
603f18b9-d4ab-40a5-afde-7680a96cc75a_1576512028433.jpg

Painted it up.
6ef7ff8a-26e4-4eac-8a99-235215adff5d_1576512041941.jpg

Then it was on to the tub extension. I measured it 100 times, clamped it with a bunch of sheet metal clamps and spent the better part of an afternoon stitching it together.
697218f1-edba-487c-b688-3cffb4bf3eb7_1576512057375.jpg

All seemed well, but I have run into a snag. Although I lined it all up, the driver side is not right. I don’t know if the tub warped, or if I just screwed something else up, or just wasn’t paying attention, but it’s bowed.
be4e5fa7-49e2-4049-9ad1-24de8323c4e2_1576512070501.jpg
Still not sure exactly what happened, but I’ve got some ideas to fix it and it should be fairly simple, though I will have to re-do some of the stitch welds. My fault though.

Beyond that, I sold my old tires and wheels, 1 of the axles, still pushing to sell the rest. Also tore down the 14 bolt.

In a nutshell, the plan is this now: the front is getting the Dana60. Its a weird one, basically it’s a 96 dodge 60, nobody likes them because they are CAD, have 30 spline shafts and are hubless unit bearings. However, the guy I got them from spent way too much money and retubed it for passenger drop, eliminated the CAD, got 35 spline inner shafts and 33 spline outers. Still hubless unit bearings, but since this is trailered I don’t care and can swap the outers later if I hate it. Because of the truss, and because I wanted too, the front is ditching the leaf springs and getting a 3 link with air shocks.

The rear is a 14bolt with disc brake conversion, both are 67” WMS and 8 on 6.5 lug pattern. Got the 14 bolt with a ruffstuff diff cover, disc brake conversion with the calipers, rotors and pads (still in the boxes) and an anti wrap bar kit (also in the box) and diff gasket for 300! The guy also gave me a d44 gearset for free, just to have it gone. I sold the wrap bar and gearset for $130! So I’m in the 14bolt $170. I also sold my leaf spring stuff which will cover an artec truss to match the front.

The rear is still getting 4 linked, but I’m gonna run coils back there for now until I can afford more air shocks. I have a few sets to play with so we’ll see what works.
Oh, and I’m planning either 5.13’s or 5.38’s for both axles. And drilling my steering. Gear for Hydro assist.

Engine is staying the same, getting an E350 master cylinder for the brakes.. that’s only $22.

There’s a ton of other details I have in the works, but these things are all but set in stone. The leafs are gone and some brackets cut off so I can’t bail now.

Hoping to fix the tub and start the cage next week!
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post #319 of 394 Old 12-16-2019, 07:41 PM
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Woh.

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post #320 of 394 Old 12-17-2019, 04:08 AM
87TPIYJ
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Go ahead and do 5.38. I did 5.13's two years ago because I was only going to run 37's... Well last night I just mounted up two of the four 43's. So yeah go deep!

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post #321 of 394 Old 12-17-2019, 07:31 AM Thread Starter
tbunch
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Quote:
Originally Posted by NashvilleTJ View Post
Woh.
haha, I can only guess you mean "woh, how did you weld the tub so crooked!?"

As for gearing, I'm partial to the benefits of the 5.38's, the only reason I would consider 5.13's is that my buddy, who I trust more than anyone I know when it comes to wheeling machines, has seen 5.38 pinions break as they are smaller when you get that deep. Now, I doubt that will happen with just 40's, but I also thought my D44 would be invincible with just 35's so...

Either way, I'll be doing the gear setup, so if I choose poorly, while it would mean buying new gears, at least I could sell them and not be out the whole setup cost twice. ultimately id like to eventually put a selectable locker in the front so I may end up doing the gears again anyways. For now, its either getting a lunchbox or just welded depending how much money I have. Id rather drive it all season with a welded front, than lose a whole season just waiting for parts. Same thing goes for the rear, though that's probably getting welded and will be that way for a while.
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post #322 of 394 Old 12-20-2019, 07:20 AM Thread Starter
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Just a quick little plug here since I fixed the crooked tub.
f4543727-a015-4643-b1a4-3a02eb27480e_1576851375209.jpg
It was even easier than I expected, cut a little notch, clamped it together and welded it up. Good to go now. Also finish welded it and started grinding the weld down, but got sick of that about halfway through so I’ll hit it another day.

Also got the bender set-up for the cage work!
544ada38-1a3e-4347-9657-d59a856ba6ce_1576851390696.jpg
It’s just got the manual handle for now, which is a workout, but it does the job.
9b46377d-d60b-4269-8683-7abd339e009c_1576851402709.jpg
Pretty excited about this, wanted one forever, just haven’t justified it, now I’m just mapping the cage out and I’ll start knocking it together next week.
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post #323 of 394 Old 12-29-2019, 08:38 PM Thread Starter
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Well, been pretty busy with Christmas and holidays and everything, but did make some headway.
First, I made a ghetto modification to my bender. Since hydro is just an unnecessary expense right now, I tried something I’ve only seen a few people do. I basically used a trailer jack, built a mounting from scrap metal and hooked it up to the bender, almost like you would a air/hyd ram. Then I took the handle off and tried running it with the cordless drill. It worked, but was a huge strain on the drill, so I threw the handle back on and have been just turning that, rather than pulling the long manual lever. It’s still a workout, but it’s easy to control and there’s no spring back and less strain on the bender and mounting.
f14cbbcc-ed21-4132-881e-15118cd3d7ca_1577676225094.jpg

Started by bending up a grill guard and stinger. Had to tweak them a bit after this pic, but you get the idea.
3c9184e1-7407-4d5e-9d1a-f4c050bbebd6_1577676245267.jpg

Then I jumped into the cage and just went to work. It’s slow going, but for my first tube work I’m pleased. I haven’t ruined any tube yet and have almost no waste. Laying out the bends makes a lot of sense in my head for some reason, so that’s good. This is as far as I’ve gotten.
591b8951-ba71-46f6-a3d5-a188d780c659_1577676283201.jpg
e3f5ac9e-c35c-415c-b1cf-83b10f6fa38c_1577676295718.jpg
It may not look like much, but it is all squared up, tacked and I had to drill 2 foot plates for every mounting location, and drill holes in the tub.

I still have to do the rear kickers off that little half-halo loop, then do roof bars, then front seat tie ins, harness bar, then finish weld and paint the whole thing. I have a cage tie-in kit I got from a buddy so I’ll be playing part of the frame and building frame connections. It will mount to the frame in 8 places. This should stand up to some major abuse.

I also checked off another item and got new beadlocks. Just picked them up today, so no pics, but they are simple black allied beadlocks. Good price so I’m happy to have that off the list.

Moving slow but really my motivation is low and it’s cold outside so...
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post #324 of 394 Old 12-30-2019, 06:46 PM
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Looks great. Keep it up.

its a rusty one

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post #325 of 394 Old 01-02-2020, 04:43 AM
87TPIYJ
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You are moving way faster than I am on my cage. Good work.

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post #326 of 394 Old 01-02-2020, 07:43 AM Thread Starter
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Thanks guys, its definitely moving along, but in reality its more time consuming than I anticipated. The bending is quite easy, its the notching, and getting a tight fit at funny angles that is quite tedious. This is especially true when I have things that need to be symmetrical and centered. Seems I can get about 2 bars done at a time then I have to take a break and do something else. I'm also almost through all of my tube, which is nuts since I bought tons and have hardly scrapped more than a foot or 2 in total. I have an extra stick of DOM that I am holding for a buddy, I may end up cutting into that since he wont need it for a while, then replace it later. That way I don't have to stop production so to speak.

On a side-note, I picked up a set of gears for the 14bolt for really cheap. They are 5.13's. I was on the fence between 5.13 and 5.38, but I kept getting feedback from people experiencing breakage on the 5.38's. The guy I bought the 5.13's from said his buddy has gone through 3 sets of 5.38's, granted that's on 43 stickies, a huge motor, heavy foot and poor judgement, but still. For the price I can give them a whirl. I calculated my overall crawl speed will still be slower with 40's and 5.13's then it was on 35's with 4.10's.

Gotta finish the cage, then I can setup the rear suspension, then the front, then finish the axles. Hanfull of little tasks involved in that, but it'll get there.
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post #327 of 394 Old 01-02-2020, 08:00 AM
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The cage is coming out great.

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post #328 of 394 Old 01-03-2020, 07:53 AM Thread Starter
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Thanks!

Here’s a few more pics of the progress. Once again, notching nodes kinda sucks.. or I kinda suck at notching nodes? Either way, it’s slow going.ec8b31e7-d59c-4d87-bfb3-3a95aa812b8c_1578063129665.jpg
20f12153-9fd2-4463-841e-d7c32a5ee0de_1578063144570.jpg
38c8317f-9a0c-440c-9d48-82ef443578f7_1578063159960.jpg
23dfd654-32a5-4a85-83a5-5117eae35eb1_1578063173735.jpg
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post #329 of 394 Old 01-09-2020, 03:40 AM
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Hard to tell in your pics, but is your rear halo in the same plane as the rest of the cage? I should be starting my rear halo either today or tomorrow. Was planning on putting it in the same plane. Do you have a good profile pic of it? Thanks!

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post #330 of 394 Old 01-09-2020, 09:32 PM Thread Starter
tbunch
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Originally Posted by 87TPIYJ View Post
Hard to tell in your pics, but is your rear halo in the same plane as the rest of the cage? I should be starting my rear halo either today or tomorrow. Was planning on putting it in the same plane. Do you have a good profile pic of it? Thanks!
Don’t have a better side pic of it, but it is intentionally out of plane with the main hoops, it kicks down at about 8 degrees. I like the look, takes away some of the boxy-ness of it and gives it more of a rounded feel, not enough to limit room in the back seat, just really for looks.
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