I got the front end stripped down a bit so I can get the front area plated. I am going to use 1/8 and a bit of 3/16 up at the front. I made three paper templates for cutting the metal.

Last chance to change my mind about the D60 & long arms. Once that mount is cut off there will be no going back.




Front stripped down so I can reinforce the front section

 

I'm pulling off the stock axles this weekend. I only get to work on it about 4 hours a week so it is coming along pretty slow.

If anyone reads these posts I am trying to decide about the rearend and tank. I've seen tanks dropped in from the top and then boxed over. I am kicking around the idea of moving the rear axle back about 4 inches and hanging the rear shackle off of the rear bumper. I'm not sure if I will be happy with the loss of cargo space so I really need to think about this some more.

 

How large of tires are you running? The stock wheelbase is awesome with smaller tires. Say 36" and smaller. Moving it back though is a great idea in my opinion when larger tires are used.

 

Also with the tank keeping it behind the rear axle is bad for crawling. Whether it's in the stock location or in the cargo area. Sometimes what Is easy or common is not always the best.

 

Holycaveman I am not sure what tire size I will land on. Since I am going to use the larger axles I've been pricing 37's and up on 17" steel wheels.

We don't have many rocks here so it will mostly see snow and logging roads. Working on something in the garage is a great stress reliever and I enjoy the planning as well as the work.

A tank that makes room for the 14b by wrapping around it would be ideal.

 

Yea 37's seem to be the magic number where the price really jumps up. LOL. Unfortunately.

 

Yeah I have some PTO set to cash out in May for tires/wheels.

 

Holy Smokes! It nearly doubles from 35 to 37 inch. Crazy

 

High wind and rain here lately but did manage to get one piece of the front frame reinforcement cut out of the 1/8".

I've done a review of where I am with the build and looked at my time and money situation which is no money and little time. The one ton axles are going to go on the back burner or get used in a different project. I purchased them for a pickup build which I gave to my youngest son. And the XJ was purchased with him in mind.

The XJ will only see snow and logging roads as there aren't any real wheeling areas on our island.

So Far:
New track bar (OEM)
Cargo area & both floorboards replaced
Center section frame rails reinforced
Rubicon Express 3.5 leaf springs purchased
Rubicon Express 4.5 front coils purchased
JKS Shackles purchased
Crank position sensor
2x12 to split and use for rocker guards
1/8 inch sheet to reinforce front frame rails ( in progress Oct2014)

Next:
Control Arms
Center skid plate
Adjustable shackle mount DIY
Drop pitman arm
Rust repair passenger fender or replace
D30 cover
Tires
Wheels
Shocks
Bumpers – maybe the JCRO DIY fronts & 4x4 airtank rear
Paint orange & black (already purchased)

Possible
Explorer Axle
RCV Shafts
Gears
Selectable Locker
Cage
Roof rack

 

Slow progress. Both sides are cut out and I need to cut some holes out and weld them in.

 

My TJ had no brakes this morning. So, I am going to buy a double flare tool and redo them all they are super corroded and rusty. Good skill to learn for the XJ I bet.

 

I haven't been in the garage the past few months but now that we have more light I am back on the project.

There is still plenty of welding to do. Plus, I need to come up with rear hanger for the shackles. And I want to put a rollcage in while I am at it.

I'm trying to decide whether I should get a JD2 tube bender and materials or spend less on a pre-bent kit. Kit is about 625 after shipping which is about what a bender is with dies.

Meanwhile, I am welding reinforcement.

 

my JD2 model 32, notchmaster, stand, and 1 die came out to about $1200 after shipping (the 5.5 1.75" 180 die is like $300 by itself). worth every penny. those pre-bent cages are mostly complete garbage. do some research, you'll end up wanting your own bender for other projects anyway. plus you can get good and make your money back building cages for your friends

 

Holy Smokes 12 hundred? I hope that was because it's hydraulic or something.

I'm looking at the Model 3 the 1 1/2 die and maybe the 1" too.

And Atmos thanks for your input. Maybe I should move bender to top of list and then wait on other items (tires/wheels) until I actually have it close to rolling. Mmm, Plasma cutter would be nice...

 

building a jeep Cherokee.. can't say I've gotten much use out of a plasma. I'm pretty quick with the angle grinder. if you're in production or to the point where you're cutting your own tabs, trusses, mounts etc then you'll get your moneys worth. I'd rather just buy the frame plate kit front to back from HDO and call it good

what would you need a 1.5 or 1" die for? cages need to be made of 1.75" 120 wall. so you'll need a die for that.

if you're going to buy a tool for building structural things like cages, spend the extra $100 and get the model 32. you'll be happy to have the die lock and anti springback ratchet. I don't have hydro and don't feel the need yet, I'll probably go with a different machine rather than set the 32 up for hydro. it's a big investment, I paid for the notcher and stand which ate up a few hundred in cost but it's just worth it to me at this point. a good cage is very important for safety as well as uniframe longevity. do it once do it right son!!