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  Topic Review (Newest First)
05-25-2020 05:06 PM
TJsRedTJ
Quote:
Originally Posted by daddyjeep87 View Post
There should have been a few more steps to welding that nodular iron center section. What was his pre-heat and cooling procedure? Other than that, it Looks great.
Oh trust me there were more steps. I haven't gotten the full process from him yet but I know for sure he pre-heated and wrapped with welding blankets afterward. As soon as he gets around to it, I will have a full detailed writeup of what he did to it.
04-27-2020 06:26 AM
daddyjeep87 There should have been a few more steps to welding that nodular iron center section. What was his pre-heat and cooling procedure? Other than that, it Looks great.
04-25-2020 08:05 AM
Boojo35 Those are some pretty welds. Nice work on the project.
04-24-2020 09:20 PM
TJsRedTJ This post will just serve as a search marker. I know a lot of people have been wondering about welding the cast on the Sterling axle. Here is what my buddy said...

"Housing section was welded with Ni-99 and everything else was welded with ER70S-6."


Just ignore this part. These are just some keywords and phrases for people to find this information...

Sterling 10.5, Sterling 10.25, sterling cast section material, how to weld sterling cast section, sterling truss, sterling welding.. yada, yada...
04-24-2020 09:16 PM
TJsRedTJ Alright, drumroll please....

Rear axle and control arms are welded! I must say though.. I've heard all of these jokes about "when your friends a welder", but I don't see the punch line? Seems pretty alright to me?.. Enjoy some weld porn.













But seriously, this guy knows his stuff.. He works for a company that is the only company in the country certified to construct portable explosives mixing units for mining. They convert shipping containers into these labs that mix ammonium nitrate* and diesel. (*If I remember correctly). His welds can never be less than perfect or people may die. He can weld any metal at any angle. Soon he'll have his own shop and I can recommend Klunker Kustoms to anyone, but for now, I'm just lucky he's a good friend

Got it all mounted! Rear suspension is under its own weight! (minus ORI's for now)







I did not have him weld the strut mounts so I knew, in the end, They would be exactly where I wanted them to be.

And just as a fun side note, I asked my buddy to write a quick paragraph about his process with welding the truss to this axle. I will put it in when he gets back to me.

"Insert genius welders info here"

That's all the fun for now! Front axle is underway.. I picked up 6 more Summit Machine flex joints and will be making some measurements for more 2 inch DOM to pick up from Midnight 4X4. I am hoping to have this as a soft rolling frame in a month or so. This way I can put it on the alignment rack and see if my thrust angle is close or if I completely botched my bracket placement
04-24-2020 08:59 PM
TJsRedTJ Next up on the list... I found a killer deal on a hard top I couldn't pass up. I have a soft top for it that I am going to get formed properly, but that will be costing a lot of money honestly. I paid 450 for a hardtop without back glass. (In Salt Lake, hardtops go for a minimum of 1K in good condition, no questions asked). This top is an original top and has tinted side glass which I should be able to get some money back for. (If anyone needs some side glass, I know a guy!)



Anyway, This top was a little rough but still structurally sound. I have never been a fan of fiberglass/SMC before and still am not. Hate the stuff. But it is always fun to learn a new skill so here we go. Hardtop project is underway. Cut it down to what I think will fit, and it was a touch long.. Perfect since you can always cut more, right?





And yes, for this project I had to pull it out of the garage to get the top on. Man did this feel good..






Hardtop cut down..




I didn't think anything of it, but at the end of the day when I pushed the jeep back into the garage... It was too tall! I had to let the tires down to 4 psi in order for it to drop enough to fit. Luckily it was enough to still roll ok.



Big things coming...
04-24-2020 08:45 PM
TJsRedTJ Well work is very hit and miss so I am able to get things done randomly. First off to get my motivation building was touching up some of the interior and exterior trim pieces such as seat bases, steering column cover, headlight bezels, transmission tunnel cover, and some bolt heads.. Nothing exciting but everyone loves pictures..





In addition to the painting, I got the HVAC box all apart and cleaned out. Jeeps really need a cabin filter.. Maybe I'll come up with one. But at the same time, it would get clogged every trip out. Hmm..



Also, I know it's not hard in a wrangler but I figured I would put some new components in there since it was out. New heater core and evap core. Less than a hundred bucks so why not?







Once the heater core was cleaned and assembled, it went into the jeep "permanently". Assuming I don't need to remove it again.. Nice.

In addition to this, I started tearing apart the calipers for a full cleaning.



Got them apart and called it a night so I could finish them up the next day, but over that night I did some research. I knew I wanted powerstop slotted brakes, but I noticed they offer a full kit including their top line pads and rotors, and all 4 calipers for SD axles for around 650.. Yeah screw used calipers. I put them back together to get them ready for a core deposit. I will order brakes at a later date but nice to know that 650 will get me an entirely new braking system in regards to the axles. Gotta stop those 40's somehow...
03-31-2020 07:42 AM
NashvilleTJ Now I canít see them...


...just kidding. [emoji6]
03-31-2020 06:20 AM
daddyjeep87 I can see them now
03-30-2020 08:59 PM
TJsRedTJ I reuploaded them at 50% so I don't know if it was a sizing issue, or the change from JPEG to jpg extension. I know it shouldn't matter but some websites are finiky. It worked for me so let me know if they still appear broken.
03-30-2020 11:18 AM
NashvilleTJ FWIW, I can see the pics just fine.
03-30-2020 09:53 AM
TJsRedTJ Dammit I thought it was just me.. I think it may be a sizing issue. Everything used to be fine I didn’t change my upload process.. I’ll try again tonight or tomorrow
03-30-2020 06:44 AM
daddyjeep87 Lots of exciting things... and I can't see the pics. C'mon man fix it. I want to see.
03-27-2020 09:56 PM
TJsRedTJ Lastly, my mind struck another small but needed idea. After doing some gas tank work on my red TJ, I remembered that I had the tank straps from the donor and I needed to find a way to strap the tank down! I came up with what I believed was the best way to do this using the straps I had. I cut the end with the through pin off so I had one end of just strap metal, and one end with the threaded rod. I was able to bend them a little to make the perfect shape and here is what I ended up with... I just welded the strap end to the under tank straps and drilled a hole where the other side bent up. I then found some half-moon spacers so it could properly sit in the bend of the other strap.

Here are the straps



And you can kind of see the hole I drilled..



The half-moon spacers



And there you have it



I may have to cut off those plastic things but that's not a big deal. I also figured that welding them as I did wouldn't be a big deal because how often will I need to remove the tank? I can bend them a little to slip it out if I have to, but as long as I don't punch a hole in it, it will all be serviceable where it sits. If that becomes a problem, I'll figure it out later U guess.

More to come!
03-27-2020 09:46 PM
TJsRedTJ Alright, we are now into month 3 of 2020 and you all know what that means... Quarantine! I am actually lucky enough to be considered essential, so I am still working, but I did find myself having a tad bit more free time lately so I jumped back into the garage and got some ideas brewing...

First up was mounting a bumper. I made the frame the same width as a TJ frame so I would be mounting the rear bumper onto the main big frame rails. This, however, left the side areas before and after the wheel wells up for consideration. Tonight, I decided that the rear box (in red) will be the same 2x3x1/4 tubing because there is a chance of dropping off of a ledge and smashing it. The front ones, I will likely do from 1x3 to save some weight..



Also, because the 2x3 is smaller than factory TJ frame tubing, I had to make a dropdown for the bumper to sit where I wanted. I just cut a small section of 2x3 to proper height and this also allowed me to weld in a nut for the bumper to mount to.



And here is the first of the extensions..





The rest will be cut tomorrow and welded up later this weekend hopefully. Here is the bumper "mounted"



I will likely not burn this in completely for quite a while so I can make sure it'll work in the long run with all the other stuff going on.
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