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Old 04-10-2013, 09:53 PM   #1
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11 day jeep build for magazine photo shoot

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This current build theme is “Off Road Expedition”. It is centered around the 2013 “Rock Lobster” Jeep Wrangler Unlimited. This build is being accomplished for a Photo shoot for the cover of 4WD.coms Catalog. The photo shoot will take place on Saturday April 13th.

Prior to beginning this build on April 2nd the following had already been completed on the build:
ProComp 7032 rims
315/75/16 Good Year Dura Trac Tires
Front Bumper MBRB Off Camber Fabrications stubby bumper with D-ring mounts and Bull Bar
Rear Smitybuilt XRC bumper and Tire Carrier
Factory flat fender trim



For the build project and Photo Shoot we have 11 days to complete the installation of the following items:

1. Garvin JK Wrangler Overhead Expedition Rack with Wind Deflector and Expedition Rack Ladder
2. Smitybilt Rock Crawler Side Armor
3. Truck Lite LED’s
4. Warn Zeon 10,000lb winch with Synthetic cable
5. Factor 5 Pro-link winch end
6. Rugged Ridge Modular XHD Snorkel Kit
7. 50” rigid LED Light bar to Garvin rack
8. 10” rigid LED Light bar to MBRB bumper
9. Dually D2 surface mount diffused rigid Light mounted into the rear tail lights.
10. 4 Rigid SRM’s (2 on each side) mounted to the Garvin rack.
11. 15lb Power Tank on custom fabricated mount.
12. Custom tool mounts for Highlift Jack, Shovel, and Axe.
13. SPod to control the lighting package
14. Metal Cloak JK Overland Fenders (Front and Rear)
15. Metal Cloak 3.5” Dual-Rate lift, ARB Edition

I am still waiting for the last 3 items on the list so I am taking this opportunity to post some build pictures and talk about some of the fabrication that was required to make some of the parts fit where desired.

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Old 04-10-2013, 09:57 PM   #2
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In for the fab and payoff. Expect to see some interesting things!

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Old 04-10-2013, 10:05 PM   #3
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OK lets start with the Warn Zeon winch … first this winch is bigger then most other winches and the Off Camber bumper is designed to mount the winch in the bumper. I removed the cable to make it easier to move around, see and work on.


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As with most bumpers the vacuum pump is in the way! I had already cut it off the frame and remounted it to the bumper, however with the size of the winch ends it hit the vacuum pump again so I had to weld up a new mount farther back and lower down behind the fog lights



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Pump moved



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Now with that out of the way I was able to set the winch into the bumper only to find that it was resting on the in bumper fog lights. I cut and machined 2 - ˝” aluminum spacers for the winch to clear the fog lights.



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With the spacers in the winch fit nice. You can see the spacer and the mount in this picture looking thru the front opening.




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It would not bolt to the most forward mounting holes because the winch was hitting on the “D-ring Mount” bolts so I had to move it back 1 hole. As seen in the underside picture.


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Fairlead mounted

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This is the end piece that holds the rope in


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Another view


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And the rope wound


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Now because I hand to move the winch back 1 hole I could not get the 3 center clips of the front cowl into the frame so I cut the clips off.


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It is a tight fit and the winch pushes the lower cowl in about ˝ inch but it looks fine


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Here is a side view of the push in


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Top view of the same


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And all completed and wrapped up…….
So the end result is YES it can be done on this bumper how ever unless you are good at fabricating I would not chose this combo.
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Old 04-10-2013, 10:06 PM   #4
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In for the fab and payoff. Expect to see some interesting things!
+1

Where's my popcorn?
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Old 04-10-2013, 10:13 PM   #5
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Next to arrive was the Garvin Rack. 3 of the 4 boxes are the Rack. Let me say that it to a considerable amount of time to unpack the boxes. They do a fantastic job of packaging and protecting their products for shipping


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All of the components and hardware are individually packed and labeled for each step. It made assembly easy to follow.


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This is the step pack

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Sorry for the poor quality photo but this the basket assembled


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To install the rear mounts for the rack, you need to remove both tail lights and the license plate holder.


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Next is to tape and measure 3-4 times before drilling

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Then drill


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Then assemble the mounting hardware and repeat for the other side


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After the rack was full attached, the ladder assembly was attached


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I then installed the Smittybilt side rails and this portion is complete.


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The rack is AMAZINGLY strong!!! When you grab the rack and shake it, it does not budge and the whole jeep rocks from sided.


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Front


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Rear
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Old 04-10-2013, 10:16 PM   #6
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Next is the Rugged Ridge Modular XHD Snorkel Kit! This was almost an all day project with all the steps required to install it. The directions are clear and come with the template for the cut out in the fender. Here is the picture with the fender removed


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And here is the snorkel done. Sorry I got so tied up with the instructions and installation I for got to take the step by step install pics.



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Also the Factor 55 Prolink is now installed on the winch end
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Old 04-10-2013, 10:27 PM   #7
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Next the Rigid Industries lighting showed up!!!!! Its so pretty :-)


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First the 10” on the bull bar, I ground off the factory tabs on the bull bar and moved them apart to match the Rigid mounting bracket.

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Next was the placement of the 50” light bar. This rack does not have mounts for a light bar but the bends on each side of the uprights will match up at the right width in order to mount it.


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Once measured 5 times then I drilled out the mount location


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It is at a great height but I did have to shorten the snorkel about 2” so it was not blocking the light


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Here is with 3 covers


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Here is with all the red lenses covers on it


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Next was to remove the factory rear lights so that I could cut and mount the flush mount Diffused D2’s.


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Lights mounted, the complete step by step details are on page 5 of my other build http://www.wranglerforum.com/f33/mat...ld-160398.html



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Tail lights reinstalled


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For the SRM’s I cut the factory plugs off and wired them so that there would be 2 plugs at the front of the rack for left and right side lights. The rack tilts back to remove the top. In this way you just unclip the 2 concetors and the rack will tilt back.



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Here is a SRM rewired and loomed


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The SRM mounts perfect on the rack without drilling and sets nicely between the rails for protection


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They provide a nice amount of light
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Old 04-10-2013, 10:32 PM   #8
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The power tank I wanted to mount on the outside of the jeep attached to the rear of the rack opposite of the ladder.

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Here is the lower mount set for sizing

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Tank in to check clearance before fully welding it up


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Fully welded and painted, matches the other side great!


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Tank bracket fully mounted

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And tank in the bracket

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It came out great and has nice sementry with the ladder


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Here is looking back at it down the side. It has a nice low profile
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Old 04-10-2013, 10:38 PM   #9
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Tools mounted, shovel and flat head axe

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Highlife jack mounted


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Front wind deflector mounted and adjusted on the Garvin rack.



SPOD, Metal Cloak lift and fenders will be in tomorrow! So final completion will be Friday (maybe an all nighter but Friday) those pictures and some preview shots of the shoot I will try to upload this weekend for everyone
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Old 04-11-2013, 06:19 AM   #10
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Looking awesome. Can't wait to see it with the lift on it.
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Old 04-11-2013, 08:25 AM   #11
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Looking awesome. Can't wait to see it with the lift on it.
Me too
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Old 04-11-2013, 10:20 AM   #12
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Another awesome build!
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Old 04-11-2013, 10:35 AM   #13
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Very Nice Work!
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Old 04-11-2013, 07:29 PM   #14
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Nice Build!
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2011 Sahara Tan JKUR. AEV 2.5" lift with 315/70/16 GY Duratracs with level 8 Tracker wheels. 5.13 Gears, C gussets, control arm skids, ACE engineering rockers, Engo 10,000 winch, OR Fab tire/can carrier. Gobi stealth roof rack. Sierra 4x4 trailer with CVT RTT and awning. ARB fridge.
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Old 04-11-2013, 07:43 PM   #15
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BEAUTIFUL. keep up the good work
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Old 04-12-2013, 01:43 PM   #16
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The Santa has been handed off. Santa is a go.
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Old 04-12-2013, 02:12 PM   #17
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The Santa has been handed off. Santa is a go.
Thanks



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Sneak peak, fenders on lift going on now
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Old 04-12-2013, 02:18 PM   #18
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better see the pics with the lift today ! Great job, cheers!
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Old 04-12-2013, 02:33 PM   #19
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Getting numb at dentist now. They're are giving me pain meds and said no driving once I start em. So I can't come and play with wrenches
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Old 04-12-2013, 11:21 PM   #20
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Metal cloak fenders going on
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Old 04-12-2013, 11:23 PM   #21
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And now the Metal Cloak lift
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Old 04-12-2013, 11:44 PM   #22
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That thing is WICKED-FRESH. What did the wifey have to say?


Thanks Fred, I had a blast.
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Old 04-12-2013, 11:53 PM   #23
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Are those flairs the removable ones? I thought that there was an inner fender first? Prettiest pink jeep I have ever seen!
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Old 04-13-2013, 12:58 AM   #24
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Are those flairs the removable ones? I thought that there was an inner fender first? Prettiest pink jeep I have ever seen!
They're pretty easy to remove, I don't know why you would want to though. There is an inner piece on the front but after you unbolt the fender it comes right out.
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Old 04-13-2013, 01:20 AM   #25
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Nevermind. I checked MCs site and I think those are the new ones that don't have the inner part separate from the outer "flair". I think these are one piece. Look at them closely.
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Old 04-13-2013, 01:35 AM   #26
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Nevermind. I checked MCs site and I think those are the new ones that don't have the inner part separate from the outer "flair". I think these are one piece. Look at them closely.
I did look at them closely, check out my avatar then look at my hat.

I helped install them today.
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Old 04-13-2013, 01:44 AM   #27
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Haha! Ok, I "Where's Waldo"ed you! I'll take your word. I thought they were different then the old ones. But I haven't seen either of them in person. I have the MC 2.5" lift without 6 pax and considered their flairs for along time due to eventually wanting to run 37's. I ended up deciding that they were a little out of my budget with everything I wanted.

D2s are starting to look stock in the rear stockers! LOL!
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Old 04-13-2013, 01:48 AM   #28
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Haha! Ok, I "Where's Waldo"ed you! I'll take your word. I thought they were different then the old ones. But I haven't seen either of them in person. I have the MC 2.5" lift without 6 pax and considered their flairs for along time due to eventually wanting to run 37's. I ended up deciding that they were a little out of my budget with everything I wanted.

D2s are starting to look stock in the rear stockers! LOL!
I can tell you this about those fenders, they are worth every penny.

Fit like a glove against the body.
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Old 04-13-2013, 02:42 AM   #29
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Totally loving this thread.. Though quite jealous of the wife!! :-) awesome looking jeep!!
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Old 04-13-2013, 02:49 AM   #30
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Totally loving this thread.. Though quite jealous of the wife!! :-) awesome looking jeep!!
She is a very lucky Lady.

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