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Old 01-03-2012, 07:57 PM   #31
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Another couple of days of progress...

First off, we have a progression of my shock tower fix:



From left to right:
1. After banging everything flat again, I made gap cuts along the lengths of the cracks to allow for weld penetration.
2. I welded the cuts with my stick welder
3. Ground all the crack repair welds down
4. Here is my fabricated collar plate I made from 3/16" plate. The slotted hole allows me to fillet weld the interior.
5. Interior welds and then hammered the collar plate to contour along the top of the shock tower.
6. Fillet weld all around.

It is pretty obvious that I suck at stick welding. Oh well, it will hold well enough.

Here is the final fix after cleaning the weld and applying POR-15.



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Old 01-03-2012, 08:02 PM   #32
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Moving on to what I really care about in the first place... the Highline install!!

This is the completed battery tray support bracket:



And now the right fender is up:



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Old 01-03-2012, 08:29 PM   #33
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Cool

And finally, the hood...



I still have not tightened anything down, but things look pretty centered already.

The hood will need some shim plates. It looks a little tight in the corners:





I have some 3/16" scrap plate, I will have to fab some shims out of that.

Also, I will need to drill a couple of new mounting holes for the windshield wiper fluid bottle; apparently, the holes are set up for 2003 and up Wranglers.


Unfortunately, my Christmas/New Years vacation is over and it may be a while before I get some more time to continue this. But I did get quite a bit done these last few days. Not bad for a garage hobbyist...


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Old 01-04-2012, 04:30 AM   #34
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great job on this! looks great so far.
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Old 01-04-2012, 08:11 PM   #35
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Thanks, Beaver!
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Check out my build threads:

AEV-highline-hood-install

My stretched body TJ-6 build
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Old 02-24-2012, 09:21 PM   #36
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Well???
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Old 02-24-2012, 09:42 PM   #37
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Looks good!
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Old 02-26-2012, 11:17 AM   #38
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Nice work! These are the first close up pictures of the AEV kit that I've seen. They look surprising similar to my diy lift, even with the sharp bend on the top by the headlight (but mine is a little sharper)


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my 06 LJ rubicon
2.5" SL, 1" BL, DIY highline, 35s with double beadlocks.
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Old 04-18-2012, 06:08 PM   #39
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Quote:
Originally Posted by jgorm View Post
Nice work! These are the first close up pictures of the AEV kit that I've seen. They look surprising similar to my diy lift, even with the sharp bend on the top by the headlight (but mine is a little sharper)


Nice work!!! How did it turn out?

I just finished my higline last weekend. I will have some new pics up soon. It took longer than I expected because I decided to repaint my grill, install a Brown Dog motor mount lift, and paint my flares (Body matching flares?!! Come on, it's still a Sahara after all. ).
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Old 04-18-2012, 09:39 PM   #40
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Loving your work. I wouldnt be ashamed of the welds. Lord knows I am guilty of some bubblegum myself, but any weld that gets full penetration is a good one, even if it aint pretty. As long as we get a little better and learn a little something each time. As a fellow shadetree type, I salute you.
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Old 04-18-2012, 11:24 PM   #41
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Quote:
Originally Posted by Rusty Knutt View Post
Loving your work. I wouldnt be ashamed of the welds. Lord knows I am guilty of some bubblegum myself, but any weld that gets full penetration is a good one, even if it aint pretty. As long as we get a little better and learn a little something each time. As a fellow shadetree type, I salute you.
Thanks, Rusty! Stick welder sure got the job done; it just takes a steady hand. I recently invested on a Hobart 187 MIG welder. Man, that thing makes so much cleaner welds.
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Old 04-18-2012, 11:27 PM   #42
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Well... after looking at the rusted rock dings on my grille next to the newly painted hood and fenders, I just couldn't let it go...



I have gotten pretty good at clearcoating. Paying attention to the flash time and a dehumidifier in the garage help.
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Old 04-18-2012, 11:34 PM   #43
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I had some exterior grille inserts that I did not want to put back in. But at the same time, I did not want a rock hit to damage the fins on my condenser (This caused an AC leak several years ago... During a 100 deg Texas summer). I decided on this...

I cut a sheet of perforated aluminum to fit inside the grille:



Primed and painted it...



Finished product was bolted at the two tabs on the bottom and the back tabs wrap around the "V" support in front of the condenser.



I am going to fit some door trim around the latch hole to make it nice and pretty.
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Old 04-18-2012, 11:41 PM   #44
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And then it was on to the front flares. Personally, I really like the look of the body colored flares of the Saharas and I wanted to keep that style.

After washing the the flares, scuffing, and wiping them with plastic cleaner, I sprayed them with adhesion promoter:





Within 30 minutes, I then sprayed them with 2K high build primer.





Getting kind of late now... I will have pictures of the finished Jeep tomorrow.
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Old 04-19-2012, 06:52 AM   #45
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Awesome! Thanks for the update!
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Old 04-19-2012, 10:37 AM   #46
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looking good.
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Old 04-21-2012, 11:47 PM   #47
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Update:

It definitely looks like something now. I still need to take care of some miscellaneous things. In particular, to put the battery back in after six months of not running. Here's to hoping it turns over. Anyway, here are some pictures as promised:









The gap in the wheel well is telling me I need to go to 35's. Of course, that was the plan all along.

What about the back flares, Joe? Well, that was done on purpose... (More on that later)
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Old 04-22-2012, 10:29 PM   #48
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I am happy to report that she runs... only needed a jumpstart! I am pretty much done with all the major work. Just a few odds and ends left: wheel well skirts, hood prop, and other small details. Thank you all for all for your encouragement and I hope you enjoyed this as much as I enjoyed installing this awesome product.

I am now looking into starting a new build thread in the coming weeks. It is something that I have seen a few other people do with their rigs and I am chomping at the bit to take it on myself. I will leave you with the following daylight shot and a hint as toward the direction this build will be taking...





Now you know why I am holding off on the rear flares?

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Old 04-23-2012, 01:14 PM   #49
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nice...can't wait to see that one. good luck.
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Old 04-23-2012, 02:32 PM   #50
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nice...can't wait to see that one. good luck.
Thanks, 98tj!
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Old 05-06-2012, 09:54 PM   #51
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looks great!

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