Full Metal Fabworks Shop Rig “Build” thread - Jeep Wrangler Forum
Jeep Wrangler Forum

Go Back   Jeep Wrangler Forum > JK Jeep Wrangler Forum > JK Build Forum

Join Wrangler Forum Today


Reply
 
Thread Tools

Please support our sponsors and let them know you heard about them on WranglerForum.com
Old 04-22-2014, 09:10 PM   #1
Supporting Vendor
 
FullMetalFabworks's Avatar
 
Join Date: May 2013
Posts: 79
Full Metal Fabworks Shop Rig “Build” thread

We put “Build” in quotes because this won’t be a tech heavy read, but more of a way to document the transformation of the shop rig from the time we picked it up from the dealership into what it is today. This thread will allow us to show some of our parts to those that don’t venture into the Vendor Spotlight area, and also serve as a place to introduce some of the new things we are working on as they are released. We will try to provide insight into why we designed certain things the way we did, but as always let us know if you have any feedback or questions for us and we will do the best we can to answer them.

Now onto the “build”
We started with a pretty basic 2012 Sahara in Flame Red. Now some of you may be thinking already, why not at least go with the Rubicon? Well this rig’s primary function will be as our Display/Show / First Article fitment rig. Our future plan is to build a dedicated wheeler off of a 2-Dr that will serve as a platform for developing a more “hardcore” line of parts that requires more welding and cutting than our current lineup.

Here is where we started:


Now that we had a rig to prototype off of the first order of business was to address a few things aesthetically. So we did all the little things: got the windows tinted, got a decal made for the hood, added retro fit HID projectors, threw on a 3.0” lift with lower Tera-flex arms to make room for the 37” BFG KM2s on 17” KMC XD807 strike wheels.






__________________
Website:www.FullMetalFabworks.com
Follow us on Facebook: here
909-792-9777
Andrew@fullmetalfabworks.com
DEALER INQUIRIES WELCOME
FullMetalFabworks is offline   Quote Quick Reply
Old 04-22-2014, 09:11 PM   #2
Supporting Vendor
 
FullMetalFabworks's Avatar
 
Join Date: May 2013
Posts: 79
Now that we had a decent enough looking rig it was time to start developing our product line. We started with the most logical place in our book, the front bumper. This seems to be the most common upgrade following lift, wheels, and tires, especially with the need for a place to house a winch. Speaking of winches, we teamed up with Bulldog Winch, a manufacturer we were familiar with from some past experience working with a race team sponsored by them. We think they make some of the best affordably priced winches out there and Bob, the owner, has been great to work with. So we ordered up one of their 10,000lb winches with integrated solenoids and synthetic cable, to build around. For the front bumper design we wanted to stay true to our roots and hand fabricate a prototype so that we could see it come together and have a solid feel for the aesthetics of it since this would set the tone for future parts. Our build criteria for the fronts was pretty much as follows:

1.) Aggressive styling
2.) Retain factory fog lights
3.) Winch provision with internal gussets
4.) No laser cut logo “crap trap”
5.) multiple stinger options
6.) 100% bolt on

This is the look we ended up settling on: The original Apex Front Bumper
This is the hand-made prototype:

The bumper was then put into Solidworks for manufacturing purposes and this is the final product:

3 piece badges opposed to tradtional laser cut out logo crap traps

Overall shot with double bend.

Overall single bend:

And one from a wheeling trip in Big Bear:


And lastly we got a lot of requests for shackle tabs/d-ring mounts on these so we added that option to them.


For more information on this particular part check it out on our website at: Full Metal Fabworks or on our other thread on it HERE

__________________
Website:www.FullMetalFabworks.com
Follow us on Facebook: here
909-792-9777
Andrew@fullmetalfabworks.com
DEALER INQUIRIES WELCOME
FullMetalFabworks is offline   Quote Quick Reply
Old 04-22-2014, 09:13 PM   #3
Supporting Vendor
 
FullMetalFabworks's Avatar
 
Join Date: May 2013
Posts: 79
We'll call that good for tonight and let anyone comment that would like to and then pick back up on it tomorrow.
__________________
Website:www.FullMetalFabworks.com
Follow us on Facebook: here
909-792-9777
Andrew@fullmetalfabworks.com
DEALER INQUIRIES WELCOME
FullMetalFabworks is offline   Quote Quick Reply
Old 04-23-2014, 10:12 AM   #4
Jeeper
 
Join Date: Feb 2014
Location: Reston, VA
Posts: 332
Subscribed! Going to be placing an order for the license plate relocation kit you guys have. Love it.

Also, are those custom made projectors?
__________________
2014 JKU||Granite Crystal||Willys Wheeler Edition
willwork4sushi is offline   Quote Quick Reply
Old 04-23-2014, 02:08 PM   #5
Supporting Vendor
 
FullMetalFabworks's Avatar
 
Join Date: May 2013
Posts: 79
Quote:
Originally Posted by willwork4sushi View Post
Subscribed! Going to be placing an order for the license plate relocation kit you guys have. Love it.

Also, are those custom made projectors?
Awesome, just let us know when we can help you out. They are the retro fit projectors from HIDprojectors.com , I don't think they sell the retro fit kit any more though just from so many people having trouble with the install. I believe they just offer them as assembled kits now but will customize them however you want.
__________________
Website:www.FullMetalFabworks.com
Follow us on Facebook: here
909-792-9777
Andrew@fullmetalfabworks.com
DEALER INQUIRIES WELCOME
FullMetalFabworks is offline   Quote Quick Reply
Old 04-23-2014, 02:11 PM   #6
Supporting Vendor
 
FullMetalFabworks's Avatar
 
Join Date: May 2013
Posts: 79
Now that we had the front bumper into production it was time to start working on the rear, we wanted to start by building a solid platform for our rear tire carrier and then once we had the stand alone bumper into production we could work on the tire carrier portion. Now that posed a slight problem as to what to do with the tailgate area in the meantime, enter the Solution Plate. We knew there were already several options on the market to relocate the tag to the center of the tail gate but we wanted to do something different and a little cleaner. Our criteria for the new license plate relocation system was as follows:
1.) Had to be aluminum to save weight, because whats the point of ditching the heavy spare without cutting as many lbs as possible.
2.) Had to be able to retain the factory vent
3.) Needed to be a single streamlined part, no bolting 3 parts together to make one
So we had a custom die made. With this die we stamp out .090” aluminum which provides a space for the vent to sit behind, as well as a “frame” around the license plate .


We had several requests to add a CB mount to the Solution Plate, and we needed a way to light the tag and retain a 3rd brake light. For the CB mount we decided to make a separate bracket so the majority of people that don't run a CB wouldn't have an extra useless appendage sticking off of it, and those that needed a mount could. For lighting we teamed up with ORO (Off Road Only) to use their Platelite tag/3rd brake light. Eventually we added Mopar license plate delete plugs and some sheet metal plugs for the tailgate to the lineup so we could offer a complete one stop shop for relocating the license plate.



For more info on the Solution Plate check them out here: LINK
__________________
Website:www.FullMetalFabworks.com
Follow us on Facebook: here
909-792-9777
Andrew@fullmetalfabworks.com
DEALER INQUIRIES WELCOME
FullMetalFabworks is offline   Quote Quick Reply
Old 04-23-2014, 02:13 PM   #7
Supporting Vendor
 
FullMetalFabworks's Avatar
 
Join Date: May 2013
Posts: 79
Now that we had been sidetracked long enough on coming up with a clean license plate relocation kit for the JK, we could get back to business on the rear bumper. For the rear bumper our build sheet check list included:
1.) High clearance without the need to cut the frame
2.) Protection for the corners right behind the flares
3.) Solid mounting to handle the added stress of the tire carrier to be added, as well as enough room for the large spindle we planned to use
4.) Tire tray big enough to hold a 37” tire on a stock carrier, but also not so huge that it would look out of place with a 33/35 on it.
5.) D-ring/ Shackle mounts that pass through the face of the bumper and tie directly to the frame mounts
6.) Similar styling as the front, and again no logo cutout
7.) Optional built in reverse lighting

And this is what we came up with, The Apex Rear:


For reverse lighting we went with a Rigid Industries SR-M (single row mini) flush mount.This particular model has 2 LEDS and a diffused lens pattern and it over powers the stock reverse lights quite a bit to provide plenty of light for backing up, but if you wanted to get crazy with it they offer the same light with 3 LEDs in a driving and spot pattern.

For more info on the Apex rear check it out here: LINK
__________________
Website:www.FullMetalFabworks.com
Follow us on Facebook: here
909-792-9777
Andrew@fullmetalfabworks.com
DEALER INQUIRIES WELCOME
FullMetalFabworks is offline   Quote Quick Reply
Old 04-23-2014, 04:37 PM   #8
Jeeper
 
Join Date: Feb 2014
Location: Reston, VA
Posts: 332
Quote:
Originally Posted by FullMetalFabworks View Post


We had several requests to add a CB mount to the Solution Plate, and we needed a way to light the tag and retain a 3rd brake light. For the CB mount we decided to make a separate bracket so the majority of people that don't run a CB wouldn't have an extra useless appendage sticking off of it, and those that needed a mount could. For lighting we teamed up with ORO (Off Road Only) to use their Platelite tag/3rd brake light. Eventually we added Mopar license plate delete plugs and some sheet metal plugs for the tailgate to the lineup so we could offer a complete one stop shop for relocating the license plate.



For more info on the Solution Plate check them out here: LINK

Love it! You're not offering any Wranglerforum exclusive discount promos are you?! haha
__________________
2014 JKU||Granite Crystal||Willys Wheeler Edition
willwork4sushi is offline   Quote Quick Reply
Old 04-23-2014, 07:36 PM   #9
Jeeper
 
Join Date: Feb 2014
Location: Manassas, VA
Posts: 469
I like that rear bumper.
mikeJKUR is offline   Quote Quick Reply
Old 05-20-2014, 10:56 PM   #10
Supporting Vendor
 
FullMetalFabworks's Avatar
 
Join Date: May 2013
Posts: 79
Quote:
Originally Posted by mikeJKUR View Post
I like that rear bumper.
Thank you sir.
__________________
Website:www.FullMetalFabworks.com
Follow us on Facebook: here
909-792-9777
Andrew@fullmetalfabworks.com
DEALER INQUIRIES WELCOME
FullMetalFabworks is offline   Quote Quick Reply
Old 05-20-2014, 10:58 PM   #11
Supporting Vendor
 
FullMetalFabworks's Avatar
 
Join Date: May 2013
Posts: 79
Now that we had a solid platform to build our tire carrier off of we could get started on that. For the spindle assembly we teamed up with Summit Machine to use one of their “Bomb Proof” Tire Carrier Hinge Kits, and also had them custom engrave the caps for us with our logo.

The heart and soul of the tire carrier starts with a variation of our Solution Plate, mentioned earlier in the thread.
This feature allows us to accomplish several different tasks and is what ultimately is one of the things that sets our carrier apart from others on the market. The Dimpled area:
1.) Provides the mounting for the tie-rod and UHMW cradle mount for easy, single-hand open and close just like factory.
2.) Allows the cabin vent to remain in place and out of the elements
3.) Adds rigidity to the mount, making it the strongest available mounting system to date
4.) Helps distribute loads to the tailgate as evenly as possible across all 8 mounting bolts, unlike other mounting systems that transfer the load to a single, smaller, area on a flat plate. For the arm we wanted to do something slightly different than the plate style that was currently being offered, and we also wanted to use this area to shave some weight; our thought process was that every lb saved in this area is less stress on the spindle/ hinge area. Your spare wheel and tire already weighs over 100 lbs, there’s no reason for the arm to also. So we had 2x3x0.120 wall tubing laser cut to give us the kick back that we needed for mounting, and then strengthened the joint with 10ga “fish plates” or plate gussets front and rear.
Kick-back in arm:

Fish Plates


The end result is a tire carrier package that adds less than 40 lbs total to rear of the Jeep over our standard rear bumper. The arm assembly and all over the other parts associated with the tire carrier also fit in a 48x16x10 box which allows them to go standard ground shipping, which allows them to ship powder coated and saves shipping over the normal freight shipping typically required for some tire carrier bumpers.




for more info on the tire carrier version check it out at: LINK
__________________
Website:www.FullMetalFabworks.com
Follow us on Facebook: here
909-792-9777
Andrew@fullmetalfabworks.com
DEALER INQUIRIES WELCOME
FullMetalFabworks is offline   Quote Quick Reply
Old 06-06-2014, 06:46 PM   #12
Supporting Vendor
 
FullMetalFabworks's Avatar
 
Join Date: May 2013
Posts: 79
Well I guess it’s time for our bi-monthly build thread update, I’ll try to make it a good one. If you are the observant type, you may have noticed a few different parts not mentioned in some of the pics so far. A few of them are our A-pillar light mounts, aluminum hawse fairleads, and the fairlead mounts.

For the A-pillar mounts there is obviously only so many ways to mount a light in that area of the jeep so we just added our own little touch to it ( and a little more work for ourselves) and put a dimple died hole in them primarily for looks and also strengthening them up a bit for those that want to hang some large KCs off them. We went with 0.090” aluminum here even though it adds a little more work because they have to be TIG’d but we think that with any smaller parts like this it is important to save weight where we can.



Next up we had to have a way to mount the winch fairlead with the Apex bumper so we did some more old school CAD ( cardboard aided drafting) and made a fairlead mount that would allow use of an aluminum hawse fairlead or a standard roller fairlead

And lastly, even though our Bulldog Winch came with a nice aluminum fairlead, we teamed up again with Summit Machine and had them custom machine some fairleads for us with our logo.


Now that we had an actual product line going it was time to make the shop rig actually look like it belonged to the shop, so we used our local graphics designer that we had make our hood decal for us, The Graphic Solution, and came up with a wrap for the Jeep. We got exactly what we were looking for with the wrap and think it came out visually appealing, but just as a heads up for anyone thinking about wrapping their rig in the future and one thing we wished we would have put a little more thought into is that with our design it pretty much relies on the top being on the Jeep at all times to work. We did consider it being a problem but in the end decided that it wouldn’t be that big of an issue and went ahead with it, in hindsight it would have been nice to have made the focal point somewhere on the doors, especially considering we are in Southern California where there’s so little rain and long periods of topless friendly weather.

Now that we had the rig wrapped it was time to work on sliders, and we’ll get into that with our next post, we had a couple different designs before ultimately settling on our Vertex Rocker guards and Step Sliders that we currently offer. Before we could get on with the rockers though we needed something to tie the whole thing together, and that was fenders. We do have plans to develop our own fender line at some point but at the time we just had too many irons in the fire, being a new company , to mess with trying to reinvent the wheel in an already saturated fender market, so we started looking around at those. We wanted to keep them aluminum, again to shave weight. In our research we noticed something that we had never really seen pointed out before; PSC rear fenders seem to have an aggressive overall look while their fronts are a little more smooth and flowy (<- bad with the adjectives) , and on the other hand Genrights fronts are very aggressive and pointed while their rears are more like the PSC fronts. Being that we wanted the aggressive styling we decided on the Genright fronts with, in our opinion, matching PSC rears. We were able to find a good used set of each on Craigslist (again, nice to live in Socal) and we dealt with the crazy looks as we asked about just buying half of the set. But in the end we think they tied things together nicely and completed the overall look we were going for.
(This pic has a few new parts that haven't been mentioned yet on the shop rig but its the best we have to show the styling similarities that we see in the fenders)


Next week we'll get on with the rockers and our newer front bumper offering.
__________________
Website:www.FullMetalFabworks.com
Follow us on Facebook: here
909-792-9777
Andrew@fullmetalfabworks.com
DEALER INQUIRIES WELCOME
FullMetalFabworks is offline   Quote Quick Reply
Old 06-10-2014, 05:22 PM   #13
Supporting Vendor
 
FullMetalFabworks's Avatar
 
Join Date: May 2013
Posts: 79
Onto designing rockers. Initially our build criteria was as follows:
1.) Frame Mounted
2.) Included a step
3.) Higher clearance
4.) Bolt-on
Seems simple enough right? Well, the one problem these JKs pose to parts manufacturers, as we’re sure you’re all well aware of already, is the curved tub. You can’t just throw something straight up high against the tub because when it’s physically touching the tub in the middle, there is a huge gap at either end. Option A, would be to just take the easy route and drop the entire thing below the pinch seam so there isn’t really a reference line to see the gap between the body and the rockers, and at the same time decreasing ground clearance by several inches; there are already several designs that employ this method and not something we thought needed re-doing. So we set about designing using option B, which was to come up with a rocker system that was curved to match the contours of the JK body, which allowed for it to be tucked up much tighter to the body, and still be frame mounted and high clearance. We got a little ahead of ourselves, and fully designed a rocker in CAD that would use an aluminum extrusion which would then be stretch formed to the contour of the JKs tub, and then would mate to a tube that was roll formed to the same contour. These parts would form the step portion of the rocker which would then attach to the frame using stanchions.
Here is the initial rendering of that part:




Well we thought we were onto something with these and started pricing them out and quickly realized that the extrusion portion of the rocker would only be feasible from a cost and labor standpoint if we ordered enough of them to make somewhere in the neighborhood of like 200 sets at a time, haha. So back to the drawing board we went to figure out a way to make these a bit more cost effective. We started by ditching the aluminum extrusion and went to a laser cut piece of aluminum sheet metal with dimple dies that would be cut to match the profile of the tub on one side and the profile of the tube on the other. This is the basic rendering of what that would have looked like:




We played around with this design and ended up not really liking a few different things on it:
1.) In order for the step portion to remain functional it would need a number of dimple dies and substantial gusseting/ mounting on the backside to add rigidity to it (which equals $$ again), another option would be to go thicker on the aluminum and lose the dimples but then it still need mounting on the backside and once you go thick enough that it doesn’t need the dimple dies it starts to become a really heavy piece and defeats the purpose of using aluminum here in the first place.
2.) We really didn’t like how the edge met up with the tubing and gave the whole deal an unfinished look
3.) The way the stanchions were made we thought they could potentially cause hang ups on obstacles, A skid/boatside would solve this problem, but the stanchions themselves were on several different planes to account for the differences in the frame and the curve of the body, so again a more complex skid would need to be made with several brakes in it in order for it to fit properly.

Feeling a little bit defeated after spending so much time on this design without looking at the big picture we went back to the drawing board. What we ultimately settled on is what we call our Vertex Rocker Guards. This platform has several benefits over the previous design:
1.) They are 100% bolt on, no drilling holes in the body for rivnuts/welding/cutting required
2.) There are no stanchions to get hung up on, and therefore no skid/boat side attachment, that would add weight, is required.
3.) They work with any type of lift (body lift, long arm, short arm, custom, doesn’t matter)
4.) Available for 2 or 4 door models with a simple change of the length of the tubing
5.) They are available as either a high clearance model (high clearance Vertex Rocker Guard) or as a slider with a step ( the Vertex Step Sliders)


High Clearance Vertex Rocker Guards


Vertex Step Sliders


__________________
Website:www.FullMetalFabworks.com
Follow us on Facebook: here
909-792-9777
Andrew@fullmetalfabworks.com
DEALER INQUIRIES WELCOME
FullMetalFabworks is offline   Quote Quick Reply
Old 07-22-2014, 07:35 PM   #14
Supporting Vendor
 
FullMetalFabworks's Avatar
 
Join Date: May 2013
Posts: 79
After releasing our initial front bumper offering we had several requests for it with additional features/ changes, some of those were:

1.) A sunken winch mount
2.) Shackle tabs/d-ring mounts as a standard feature
3.) Plate gussets, rather than tube gussets
4.) A skid plate option
5.) Provisions for the stock fogs along with optional light bar mounting
6.) Mid-width version

So we did a slight redesign to accommodate some of these changes, and thus the Apex Pinnacle Series was born.
Unlike the original Apex front that was hand made before going into CAD for production purposes, the Pinnacle series was built from the ground up in SW.


D-ring mounts pass through the face of the bumper and are standard issue on the Pinnacle series

optional 10" LED bar mount and Pinnacle skid:



__________________
Website:www.FullMetalFabworks.com
Follow us on Facebook: here
909-792-9777
Andrew@fullmetalfabworks.com
DEALER INQUIRIES WELCOME
FullMetalFabworks is offline   Quote Quick Reply
Old 07-22-2014, 09:26 PM   #15
MallCrawler

WF Supporting Member
::WF Moderator::
 
kjeeper10's Avatar
 
Join Date: Feb 2011
Location: Connecticut
Posts: 34,186
Those sliders are freaking sexy.
__________________
2007 Rubicon/Rock Krawler TR 2.5 coils/rear TB/Rancho 9000 31/32XL shocks/Teraflex monster TB/Synergy highsteer,tie rod, ball joints/Hankook MT 315-75-16 on Level 8 ZX's/MC front SB links/Rancho geo brackets & shocks/Fox ATS stabilizer/Adams front DS/Artec front armor w/ Currie upper bushings=Frankinjeep from hell.

Lifting your JK? Read this!!



Click HERE to become a WranglerForum Supporting Member!
kjeeper10 is online now   Quote Quick Reply
Old 07-23-2014, 02:33 AM   #16
Newb
 
Christruitt's Avatar
 
Join Date: Jul 2014
Posts: 1
Is there a way to incorporate a hitch in the rear bumper? Not sure if that was covered or asked. Your work looks great.
Christruitt is offline   Quote Quick Reply
Old 07-23-2014, 12:25 PM   #17
Supporting Vendor
 
FullMetalFabworks's Avatar
 
Join Date: May 2013
Posts: 79
Quote:
Originally Posted by kjeeper10 View Post
Those sliders are freaking sexy.
Thank you sir, let us know if you need a set.

Quote:
Originally Posted by Christruitt View Post
Is there a way to incorporate a hitch in the rear bumper? Not sure if that was covered or asked. Your work looks great.
Thank you,
and yes, the rear bumper is designed to work with the factory hitch.

__________________
Website:www.FullMetalFabworks.com
Follow us on Facebook: here
909-792-9777
Andrew@fullmetalfabworks.com
DEALER INQUIRIES WELCOME
FullMetalFabworks is offline   Quote Quick Reply
Reply

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Jeep Wrangler Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
If you do not want to register, fill this field only and the name will be used as user name for your post.
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:

Log-in

Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off



logo carid shop wrangler parts carid fender flares custom wheels store avs deflectors at carid

» Network Links
»Jeep Parts
» Featured Product

All times are GMT -5. The time now is 02:49 AM.



Jeep®, Wrangler, Liberty, Wagoneer, Cherokee, and Grand Cherokee are copyrighted and trademarked to Chrysler Motors LLC.
Wranglerforum.com is not in any way associated with the Chrysler Motors LLC