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Old 06-08-2011, 04:05 AM   #1
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Memorial Day Weekend mega-build!

so this probably won't live up to the hype, and contrary to the title was not exclusive to Memorial Day weekend, as everyone knows our builds are never really quite finished. Beginning Friday morning, my dad and I spent over 50 hours from start to finish, and encountered a crap load of hurdles and gremlins along the way. But we got her "done" and I was on the road back to Chicago by Monday night.

To start, I originally planned on the following:

- buy/install new G2 D44s w/ 4.56s
- Raptor line entire interior tub
- Raptor line lower half of exterior tub
- cut and install MCE flatties
- install new headlights w/built in turn signals
- trim factory flares
- install new rear swing out
- fab new front winch plate and install new Warn M8000
- finish wiring in new KC hilights
- install new sony head unit and polk speakers
- Krylon fusion entire dash (take from spice to flat black)
- Eastwood internal frame rust reformer
- nite shade the rear taillights
- finish my cargo carrier for my congo cargomaster rack

so call me ambitious. too ambitious.

first, got married this summer and the wedding/reception budget got waaayyy out of hand, so something had to give. Bye-bye axle and rear swing out purchases. At least until August. Then in middle of build dad's air compressor regulator crapped out Sunday, so that seriously set us back time wise (no one was open Sunday or Memorial Day with right part.) Luckily we had finished triple coating the Raptor. Lastly, there was something wrong with his welder so we were also screwed on the front winch plate. So my M8000 is still sitting in his barn. anyhoo, enough of the bad, for now. Here's what Trudie looked like the day I brought her home last September:
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Old 06-08-2011, 04:10 AM   #2
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and here's what she looked like before the build (after new tires and a new-to-me hard top) :
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Old 06-08-2011, 04:22 AM   #3
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so while dad started installing the new headlights w/built in turn signals, I got started masking and cutting the rear factory flares:
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Old 06-08-2011, 04:29 AM   #4
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more fender cuts
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Old 06-08-2011, 04:34 AM   #5
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As seen in the pic, I just used a heavy-duty razor knife. I used a dremel rotary sanding bit to take off the big burrs and sharp edges, then then I took them off to prep the ext. tub for the Raptor. After taking them off I used a hand foam sanding block to give them a nice smooth finish.
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Old 06-08-2011, 04:39 AM   #6
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In a couple of those pics you can see how that nasty frame rust was starting to rot around the holes. More on that later.

Next up was pulling the interior carpets, center console, and seats. Guess what I found hiding under the carpet?
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Old 06-08-2011, 04:42 AM   #7
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so needless to say that had to be dealt with. I'll post more pics tomorrow after I get home for work, gotta hit the hay for now
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Old 06-08-2011, 06:39 PM   #8
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Keep it going Big E!!! Oh well, I'll see the finished product first hand in 3 days..
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Old 06-09-2011, 01:02 AM   #9
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here's how I got that corrosion out






so here's what it looked like at the point of no return:
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Old 06-15-2011, 02:03 PM   #10
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Lookin good! Gotta love the fact that the Hood can go all the way back!
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Old 06-16-2011, 10:11 AM   #11
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thanks, yeah I have been neglecting this thread and posting all the pics from the Hoosier Off-Road Day last weekend. I'll get back to posting on this probably this weekend.

I will say this; that Raptor is tough stuff! the Badlandz proved that. As a result of the Badlandz, I'm probably going to have to start a follow-up Labor Day Weekend Mega Repair Build thread.

it was worth it tho!
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Old 06-20-2011, 01:12 AM   #12
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sorry for the long delay.
So after we got all the trim pieces off, dad started cutting the fenders for the MCEs and I went at the tub with the wire brush. Got it down to bare metal a couple of places, but just hit that with rustoleum rust reformer spray paint. Sorry no pics of dad in action, I was too busy
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Old 06-20-2011, 01:29 AM   #13
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so I mentioned earlier that my frame had some rust rot going on, especially internally. I bought

Internal Frame Coating w/Spray Nozzle

and spent about a half hour and 4 cans of this stuff on the inside of my frame. I didn't want to miss any spots...




then we got the flatties on and hit it with the u-pol raptor. No pics of that as it dries to fast and we had those air compressor issues to deal with. Here she is, "almost done."
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Old 06-20-2011, 01:33 AM   #14
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a topless after-action shot
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Old 06-20-2011, 02:05 AM   #15
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the Raptor turned out really well, I still have to touch it up some in a couple of hard-to-reach spots. I learned a ton, like Jeep uses 3 standard hex-head bolts and 1 torx bolt to bolt the seats in (WTF!!??) every dang torx bolt on the thing is dipped in red loctite (WTFx10) and how much I despise torx in general. I busted 3 different torx sockets, and I'm talking good brands.

I also painted the entire dash in black krylon fusion, and replaced the head unit and speakers. I've already posted those on a few other relevent threads but here's pics of the sound bar, which I also went over with fusion (that turned out really nice)
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Old 06-21-2011, 03:15 AM   #16
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So i guess you are leaving the lower section in raptor liner, not Cherry Red?
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Old 06-21-2011, 12:19 PM   #17
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that's the idea. awful waste of time and money otherwise.
it looks sharp and it's tough as nails. also covers all the trail damage I was getting.
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Old 06-25-2011, 01:02 AM   #18
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i cant decide if i like the raptor linning on it like that... but to each his own =)
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Old 06-25-2011, 01:59 PM   #19
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Quote:
Originally Posted by Zombiekiller View Post
i cant decide if i like the raptor linning on it like that... but to each his own =)
no offense taken.

it was a little hard to pull the trigger initially, as I love the factory sienna pearl color. I was just getting too many scrapes, gouges, scuffs, and a couple of rust repair spots. It was starting to look a little wore out. I would have had to have it professionally painted to make it look good as new, so I went this route. Much cheaper than a pro paint job (that would have just gotten trashed again) or body armor. Plus it goes well with the MCEs.

it may not be for everyone. It looks much more aggressive, altho I have to admit at this point it's a bit of a poser w/ my weenie axles and gears. After labor day that will change though

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