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Fabricating the Crew Cab Comanche (full build pictures)
https://cimg5.ibsrv.net/gimg/www.che...5e5a7f111.jpeg
https://cimg6.ibsrv.net/gimg/www.che...31bf674a7.jpeg The building blocks used are a near mint condition base model 4.0L AX15 93’ Cherokee and a drivetrainsless 89’ Comanche that had been sitting in a field since 2003 |
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https://cimg6.ibsrv.net/gimg/www.che...0de7f290d.jpeg https://cimg7.ibsrv.net/gimg/www.che...9f7fa04f8.jpeg First step remove the bed, and clean up the frame, once the bed is removed, begin to remove all unnecessary components from the frame |
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Tack Weld in Brace’s in the interior of the Comanche to help support the integrity of the unibody before removing the bed and splitting the cab |
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https://cimg4.ibsrv.net/gimg/www.che...5f771f5c1.jpeg https://cimg7.ibsrv.net/gimg/www.che...2428e52ad.jpeg For my purpose I chose to shorten my bed, that creates a few more obstacles further down the build, but for my application the shorter wheelbase is preferred https://cimg9.ibsrv.net/gimg/www.che...12dd89dfb.jpeg https://cimg4.ibsrv.net/gimg/www.che...8af3950f2.jpeg https://cimg5.ibsrv.net/gimg/www.che...84714d6c0.jpeg |
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https://cimg3.ibsrv.net/gimg/www.che...0e3efe7d1.jpeg https://cimg4.ibsrv.net/gimg/www.che...18522cd92.jpeg Braced the long bed with square tube before cutting out the section, once the secretion was removed, paying attention to preserving the gas fill for later splicing further down the build time line. I only tacked the front of the bed back on because for final fitment and alignment with the cab it may need to shift a degree or two to keep spacing even. |
https://cimg9.ibsrv.net/gimg/www.che...7db8ef2fb.jpeg
https://cimg0.ibsrv.net/gimg/www.che...d1f398b58.jpeg https://cimg3.ibsrv.net/gimg/www.che...255a74447.jpeg https://cimg4.ibsrv.net/gimg/www.che...978a125ac.jpeg In order to compensate for separating the bed from the cab, I hand cut a 1/8” steel sheet to creat a stronger bond when the bed is welded back on. Later on in the build slots would be cut to accommodate the sub frame stifferner tie in’s as well as 20 plug weld locations |
https://cimg9.ibsrv.net/gimg/www.che...98ba89440.jpeg
https://cimg0.ibsrv.net/gimg/www.che...80fb58e8b.jpeg https://cimg1.ibsrv.net/gimg/www.che...cddb6c95f.jpeg A mistake to be avoided here, I should have taken a larger bit out of the floor. I added extra fab work trying to link up the Cherokee and Comanche unibody frame work, if I had cut in another 8” this would of been avoided and it wouldn’t of been necessary to splice in my own frame work |
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https://cimg3.ibsrv.net/gimg/www.che...98cf4d2aa.jpeg https://cimg5.ibsrv.net/gimg/www.che...021f8cad9.jpeg https://cimg6.ibsrv.net/gimg/www.che...694a7505e.jpeg Next you will want to start prep work on the Cherokee, dropping the driveline, axles, and fuel tank. You will want to add supports on the cab to keep the unibody structurally sound while you remove the rear section of cab |
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https://cimg0.ibsrv.net/gimg/www.che...af26122e5.jpeg https://cimg1.ibsrv.net/gimg/www.che...550623c0c.jpeg https://cimg2.ibsrv.net/gimg/www.che...bbd2652d5.jpeg https://cimg5.ibsrv.net/gimg/www.che...84f40b5b4.jpeg https://cimg7.ibsrv.net/gimg/www.che...064bbee1f.jpeg https://cimg8.ibsrv.net/gimg/www.che...95d1ebc76.jpeg After measuring many times you cut the cab, once the cab is separated, bring in the Comanche cab section and begin rudimentary fitment, this may take several iterations before you get the cab the size you want. Make sure to take as many measurements as you can until you can’t take anymore, then begin tack welding the newly formed cab together |
https://cimg2.ibsrv.net/gimg/www.che...442b0fd22.jpeg
https://cimg3.ibsrv.net/gimg/www.che...ecf675477.jpeg https://cimg4.ibsrv.net/gimg/www.che...0d406dfa2.jpeg https://cimg8.ibsrv.net/gimg/www.che...b48d7d4a5.jpeg https://cimg6.ibsrv.net/gimg/www.che...79eac881f.jpeg https://cimg7.ibsrv.net/gimg/www.che...36fb736d8.jpeg I decided to retain the Cherokee door handle and door internals, opting to relocate the locking pin on the Comanche body to line up with the Cherokee locking mechanism, this proved to be more work than anticipated and I think removing the door internals and keeping the Comanche door handle and locking pin, might have been the easier route |
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https://cimg4.ibsrv.net/gimg/www.che...a8fb4f47f.jpeg https://cimg8.ibsrv.net/gimg/www.che...ec3577b74.jpeg https://cimg6.ibsrv.net/gimg/www.che...197821838.jpeg Grind down the welds, do some basic body work and address any other dents while the bondo is out. |
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https://cimg3.ibsrv.net/gimg/www.che...5d76c05a5.jpeg https://cimg6.ibsrv.net/gimg/www.che...6cc85da40.jpeg I reshaped the Comanche driveline well to meet up with the Cherokee driveline well, in hindsight cleaning up the floor pan and reshaping the drive line well might not have been the easiest rout, just replacing that section of floor and using an English wheel to create a new driveline well would of been the more elegant solution |
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Here you can see the updated cab to bed frame plate with plug weld holes and slots for sub frame tie in’s |
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I used a laser level in combination with constant measurements in order to assure bed to cab alignment when welding the frame onto the unibody. |
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