Should we start with some pictures?

Ok...First the before.
This is day one when I brought it home almost 10 months ago.




This next pic is from about 4 months ago after I had done all the major work. I have a build thread on this if anyone is interested.



Now get ready for what comes next.
I went about doing this because I broke the back window and keeping with my project cheep jeep, I didn't want to spend $300 for a new one.




This has only cost about $60 so far. I have a little bit left to do with some fiberglass, paint, and getting a piece of lexan for the window.

It was done with one piece of 3/4 inch mdf which I sealed and then put 6 coats of od green on. The tailgate was made from the left over mdf and pressure treated 1x2 furring strips.
The rear shoulder belts were replaced with lap belts from the junkyard.
The exhaust doesn't stick out as far as it looks. I took this picture from a weird angle I guess.
I will take another picture of the removable slant back top when I get home.

 

I guess it doesn't quite fit with the theme but if all of that would was replaced by steel . . . that would be insane.

 

It would have been but since I do not have a welder........

I used the absolute heaviest piece of wood known to man (100 lbs per 4x8 sheet), cut it to fit perfectly, and put 3 coats of water sealer then 6 coats of paint on it.

To tie it into the frame on top I used a 2x4 cut a half inch to long that I wedged in between the roof rails. I then screwed the roof into that from the top and the top sides.

On the bottom, I did the same thing but screwed through the metal from underneath.

I left a 3/4 inch lip of metal all the way around the cut for the mdf to fit into. I then screwed the mdf to the 2x4's and screwed through the sheet metal into the mdf all the way around the lip I left.

Then I used acrylic sealer all the way around it. I am about to do some fiberglass work around the perimeter of the cut to smooth it out then paint it one more time.

It is way stiffer than it was stock. I can tell a real difference driving it around. There is no more flex in the body the way there used to be.

So far, everyone who has seen it thinks it is metal until I tell them to bang on it.

 

A couple pics with the top as promised.
It is a US Army Shelter half with a wood frame that clamps on inside and the bungee ties down the back.

 

anyone done this but with a removable top like the old blazers?

 

I think this looks pretty sweet. I've always liked that style top on wranglers.

 

Nice rig.

I like the cheep way too!!!

 

I really like the way this turned out. Great job man! Love the army theme. Woulda been cool to see some army XJs instead of Hummers!

 

Looking good bud!

 

I love the soft cover!!!!!!!!!!!!!!!!

 

Wood?!

 

I subscribed to see how long it would take low range to get here.

Not that long.

I'd keep that soft top on and not tell people its MDF.

 

Any kind of reinforcement to help protect that unibody?

 

At least he didn't spray paint his tail lights black...

I wonder if he realizes that someone keeps laying a shovel on his hood right before he takes a picture?

 

That's what I'm wondering. That's quite a bit of xj cut out. I'd want some more structure in there.

Hey! I resemble that.