96rokee

Ive never really introduced myself on this forum
but i figure with this project its time to

Im Jake. 19 years old and this is my 7th jeep
but i dont plan on switching any time soon
I am a certified welder and auto mechanic.
My main discipline is MIG but i can also lay a mean arc weld. TIG not so much
Learned all my welding from the WELDING GOD himself, Ben Whitaker. ( if your a welder in sonoma county im sure youve heard of him )
I do all my own work on my jeep, even tho i bout it lifted i know its solid because ive removed and re tightened EVERY bolt lol
I love fabricating things and hope to create a business from it in time.

Keep in mind im 19 and work full time
& also have an AW4 tranny im rebuilding on the weekends as well
soo this project may take bout a month or so..


Steps to take

CHECK Remove fenders
CHECK Remove doors
CHECK Modify door hinges to make removable doors
CHECK Remove undercoating
CHECK Prime surfaces
Remove cross member
Remove more under coating
Prime more surfaces
Mock up/trace stiffeners
Prep welding surface
Pull doors
Pull seats ( cuz the herculiner in my floor pan is probly gonna catch fire. )
Prime inside of stiffeners
Weld on stiffeners
Prime and paint
Drill holes in stiffeners
Install cross member and tcase skid
Cut stock rockers
Clean surfaces
Prime surfaces
Prep weld surface
Weld in 1"x1/8" angle iron
Tap hole for air nozzle
Cut 2x6 at 45*
Cap the ends of the 2x6
Weld in 2x6 x 3/16" tubes
Weld in 2" x 1/8" flat brace bar ( may just use 1.5x1/8" angle iron )
Prime and paint
Cut doors to fit
Cut pieces to fit door bottoms
Weld em on
Prime and paint

take a break for a weekend probly cuz heres where im gonna get crazy

find out best places to run tie in
cut thru the floor board so i can tie in from the frame rail to the bottom of the 2x6 at an angle. might be hard to picture
weld in 2x2x1/8" support beams
weld a sheet of 1/16" metal on
bolt on some uhmw probly 1/4"

monstaline?? maybe? ( not the uhmw ill just leave that clean and slippery )

UPLOADING PICS NOW
but my damn phone is so slow at sending them to my comp
maybe a bit before there up

JerrytheJeep

This is the route I want to take when my sliders give up the ghost. They were a pain in the *** because of the table I welded them on... can't wait to see how this turns out.

Lowrange2

How high do you plan to go with these boatsides?

96rokee

Pics of my first day of progress


Heres the rockers, not too bad of shape but still ready for something beefier.




So i started removing the bulk of the undercoating




^^ any tips on pulling that dent out of the frame rail? ^^
or should i just leave it as is and just cover it.

Havent decided how to deal with the stock uca mounts..
maybe just grind em till there gone.. lol





and then i went ahead and removed my fenders.
lemme tell ya you gotta pull off the front clip to get the fenders off.
i wish i woulda looked that up before strugglin for 30 min or so on one bolt. lol






Im sure your thinking "2x6 boatsides.. why take off fenders??"
i need to remove my fenders to cut the stock rocker panels and make removable doors which is kinda my first step to this build.
and should come next weekend.

as for now i probly wont be updating this untill next weekend.
unless i get time between work to fuss around a bit.
sorry theres not much fab yet. but trust me its in the works!!

Barrelmaker

Ill be watching.

Lowrange2

Thanks for answering my question before you go on your hiatus.

96rokee

Lol calm down buddy.
I plan on following fishie and Ericsxj
So ill probly have to trim like 1.5 to 1.75 inches off each door.

hankthetank

boatsides eh? i'm not usually one for semantics...but boatsides aren't the same as regular old sliders.

Here is the difference...either way, i'm diggin it.

96rokee

I know the semantics. For the most part lol
I'm doing boat sides.

Read my first post and ull see I talk about coating it with uhmw for slippery boat sides.

96rokee

got the day off
removable doors coming today
updates tonight.

JerrytheJeep

Damn that UHMW stuff is pretty cheap, I smell a gas tank skid coming...

Lowrange2

That's why I asked. I don't generally consider it boat sides until you have to fight to get in.

You'll enjoy the higher sliders. It makes a huge difference.

96rokee

So doors came off today
and made it back on.
but im not happy with it. so this weekend ima fix it till i am happy with it

anyways start off with list of tools used.
T40 Torx bit ( and youll want a quality one ive heard of them breaking on these bolts )
Ratchet
Angle grinder
Cut off wheel
Flapper disc
Hammer
3/8" socket ( for pressing out stock pins )
21/64" or 11/32" drill bit ( for the body side of the hinge )
5/16" drill bit ( for the door side of the hinge )
Drill
Welder

started the day looking like this



Fenders had to be removed to get the doors off


^^ one door down ^^


^^ haha its like jeep **** slowly strippin her down ^^





off to the hardware store cuz i thought bolts would be a better idea then rod so i could put a nut on.
but the threads make it harder to get in and out and they get chewed up fast lol
luckily i tested it on the first door. unluckily i chose the driver doors to test it on..
i shoulda done the rear passenger door first.. heinsights 20/20


this door will be re-modified to a pin style

before going to the metal supply store ( for cold rolled 5/16 rod ) i got convinced to try and winch start my neighbors westy..
lol instead of push starting it because it has a low tire that doesnt hold air.





my winch wasnt fast enough. i kinda thought so but was still fun to try


at this point i apparently lost track of taking pictures lol oops..
no pics of the pin style hinges
i started running into a severe lack of light..

after the first doors with the threads taking forever to even get on
not coming back off lol ill have to unbolt it again
i had to go down to steel supplier for 2 ft of cold rolled 5/16" rod
got back and cut off the passenger hinges off cut the pins and rounded the tip
went to go weld it and no gas...
god damn it my dumb *** left the gas on.. of course today was the first time i do that.
when im low on time on a project that kinda needs to be done lol

soo hurry down to the welding store now 4pm.
light is gone at 5pm pretty much
and i still have 3 doors off.
and 2 sets of hinges to cut off and prepare the pins for and drill everything out.

got back and got to work lol
i really wish i wouldntve had to rush some of this but ill get a chance to touch everything up this weekend.

620 ish i got the last door on






some point during the day i painted some zinc primer on my frame rails


^^ wonder how hard thatll be to get off the cross member lol ^^




made some good progress. but i shoulda realized my time constraints were pinching down on me around 12 instead of around 3..
hopefully i didnt **** anything up in my rushing..
i dont think i did but ill see

more to come this weekend.

smeltmaster1

and what was the reason that you took the fenders off when you could just cut the bolt heads and take them out with vise grips and have brand mew hex head bolts that won't strip that easy. a lot easier in my eyes.
also how the hell did you get your fenders off with out taking off the front clip?

DirtRoadXJ

half way down post 4 he said he took the clip off.