My 2011 JKU Rubicon Build/Project - Page 8 - 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 11-18-2012, 10:50 AM   #211
Jeeper
 
Andy-RoOo's Avatar
 
Join Date: Aug 2012
Location: Toronto, Ontario
Posts: 140
You have way too many toys my friend. No wonder you're out of money xD

Andy-RoOo is offline   Quote Quick Reply
Old 11-18-2012, 12:52 PM   #212
Jeeper
 
zmotorsports's Avatar
 
Join Date: Mar 2012
Location: Northern Utah
Posts: 618
Quote:
Originally Posted by s.champ View Post
great thread and build Mike, love the write ups and advice that is given
Thank you. I appreciate that. There are no "secrets" and if I can help someone overcome a hurdle that I have come up against the that is the whole point of sharing on an open forum. I love learning from others as well and seeing different ways of doing things.

Quote:
Originally Posted by Andy-RoOo View Post
You have way too many toys my friend. No wonder you're out of money xD
That's debatable and you can always work more and earn more money.

Mike.

__________________
2011 JKU Rubicon
BDS Long-Arm System/ 17x9 ATX Crawl wheels/35" BFG KM2's/ Plus much, much more.

Click here to see my 2011 JKU Rubicon Build Thread
zmotorsports is offline   Quote Quick Reply
Old 01-28-2013, 08:45 AM   #213
Jeeper
 
zmotorsports's Avatar
 
Join Date: Mar 2012
Location: Northern Utah
Posts: 618
Well I haven't been on the forum much lately nor have I done much to my Jeep other than drive it and wheel it. I ordered a steering support kit from JKS last fall but have not had time to install it until this past weekend.

Overall, I am very impressed as the kit was very well thought out and put together. The components are very high quality and I have no doubt it will perform as advertised.

The kit can be ordered in various forms depending on the degree of support and completeness. I ordered the complete kit.

Here is the kit removed from the boxes and spread out for viewing.


First order of business is to remove the track bar from the chassis mounting point.


Remove the four bolts going through the frame which hold the steering box onto the inside of the left frame rail.


Bolt the new tracbar/chassis bracket onto the frame. Do not tighten at this time, just snug so you can still move it a little for alignment purposes. Here is a hint, install the bolt for the tracbar for alignment.


Remove the nut and lockwasher from the sector shaft which holds the pitman arm on and install the new one from the kit. Torque to 185 ft./lbs.


Bolt the metal block to the anodized aluminum block with the spherical bearing and test fit it into location. Locate it parallel side to side and snug the bolts. At this point mark the location that the steel block makes contact with the inner frame/tracbar bracket. I just scribed around the outside of the block.


Drop the anodized block/steel block assembly down and remove the paint from the area in which you marked. I found it easiest to use a small emery roll on a long mandrel attached to a pneumatic die grinder and reached up with relative ease.


Place a spot weld on the bracket to frame.


After putting a spot weld to hold the steel block in place, drop the aluminum block and finish welding to the frame. The steel block has a chamfered edge to allow for the weld profile and not interfere with the bearing support but if you are not careful you can mess the threads up in the steel block. If you are not confident in your welding I highly suggest that you hire this part out as it is also very awkward to access with the gun. Also, make certain the weld is not so large as to interfere with the aluminum bearing supports' full contact. The aluminum bearing support is also chamfered to allow for weld clearance but I brushed over mine with a rotary bit just to be certain to have a complete flat mounting surface.

Here is the competed weld on the block and ready for paint.


I went over the area with a red Scotchbrite pad and wiped down the area with PPG DX330 wax and grease remover prior to hitting it with a couple coats of Eastwood's Extreme Chassis Black. I am very impressed with this paint and its' durability.


Block bolted back in place along with the cross shaft/support bolted in place. Make certain to start all of the bolts prior to tightening any of them to allow for some movement as these bolt holes are very precise and need to have a little "wiggle room" to bolt everything up. Once all of the bolts are started and snugged you can tighten them but tighten them all a little at a time to avoid putting undue stress into the assembly.


Put the support bar across to the right frame rail and mark the location of the bracket for welding. I used a measurement from the sway bar so the bar was evenly spaced front to rear the same distance as the left side. I then marked the frame, lowered the cross brace and removed the paint from the frame rail prior to welding the bracket into place. I used a rosette (plug) weld through the bolt holes and then on the lower perimeter of the bracket.


I removed the bolt, dropped the cross bar, painted the right frame rail after roughing the original paint and wiping with wax & grease remover, painted and reinstalled the crossbar. Once in place I adjusted the cross bar for neutral tension and tightened the two jam nuts.

Job complete. All in all a pretty straight forward installation on a well thought out solution. The average guy should have no problem installing this kit except for the welding portion. If you are uncomfortable with your welding you should hire that part out so as to not weaken the integrity of the upgrade.

Mike.
__________________
2011 JKU Rubicon
BDS Long-Arm System/ 17x9 ATX Crawl wheels/35" BFG KM2's/ Plus much, much more.

Click here to see my 2011 JKU Rubicon Build Thread
zmotorsports is offline   Quote Quick Reply
Old 01-29-2013, 02:42 PM   #214
Jeeper
 
cyclone88's Avatar
 
Join Date: Oct 2012
Posts: 227
Just finished reading all these posts...what a build. You do some great work Mike! As a few other people have said already, I'm extremely jealous of your garage! Unfortunately, work has me moving every couple of years, so it's going to be a while before I have the space that's worth investing in. Great build, thanks for all of the information!
__________________
'12 JK | Black Forest Green
cyclone88 is offline   Quote Quick Reply
Old 01-29-2013, 03:02 PM   #215
Jeeper
 
zmotorsports's Avatar
 
Join Date: Mar 2012
Location: Northern Utah
Posts: 618
Quote:
Originally Posted by cyclone88 View Post
Just finished reading all these posts...what a build. You do some great work Mike! As a few other people have said already, I'm extremely jealous of your garage! Unfortunately, work has me moving every couple of years, so it's going to be a while before I have the space that's worth investing in. Great build, thanks for all of the information!
Thank you for the compliments.

What do you do for a living? I am not being nosy, just curious what line of work keeps you moving around.

Mike.
__________________
2011 JKU Rubicon
BDS Long-Arm System/ 17x9 ATX Crawl wheels/35" BFG KM2's/ Plus much, much more.

Click here to see my 2011 JKU Rubicon Build Thread
zmotorsports is offline   Quote Quick Reply
Old 01-29-2013, 03:05 PM   #216
Jeeper
 
cyclone88's Avatar
 
Join Date: Oct 2012
Posts: 227
Quote:
Originally Posted by zmotorsports View Post
Thank you for the compliments.

What do you do for a living? I am not being nosy, just curious what line of work keeps you moving around.

Mike.
No worries - I work for a general contractor, so I move around wherever the jobs are that we get. Fun, but a little restrictive on really customizing and settling into a place.
__________________
'12 JK | Black Forest Green
cyclone88 is offline   Quote Quick Reply
Old 02-13-2013, 11:39 AM   #217
Jeeper
 
Jeeper Jake's Avatar
 
Join Date: Feb 2013
Posts: 34
Sweet build!

Hey Mike, lookin forward to meeting up this weekend. Just wanted to take a sec to say, You have a super Nice Build Thread sir. Very details and extra unique. Keep up the good work.
-Jake
Jeeper Jake is offline   Quote Quick Reply
Old 02-14-2013, 11:51 AM   #218
Jeeper
 
zmotorsports's Avatar
 
Join Date: Mar 2012
Location: Northern Utah
Posts: 618
Quote:
Originally Posted by Jeeper Jake View Post
Hey Mike, lookin forward to meeting up this weekend. Just wanted to take a sec to say, You have a super Nice Build Thread sir. Very details and extra unique. Keep up the good work.
-Jake
Thanks Jake. I too am looking forward to meeting you this weekend.

Mike.
__________________
2011 JKU Rubicon
BDS Long-Arm System/ 17x9 ATX Crawl wheels/35" BFG KM2's/ Plus much, much more.

Click here to see my 2011 JKU Rubicon Build Thread
zmotorsports is offline   Quote Quick Reply
Old 02-14-2013, 11:52 AM   #219
Jeeper
 
zmotorsports's Avatar
 
Join Date: Mar 2012
Location: Northern Utah
Posts: 618
Well last night I had a couple of small details to take care of that were bugging me. My passenger side windshield wiper makes contact with the backside of my Hella Otpitlux HID's mounted on my windshield hinge. More so when it is cold and the wiper blades are not so flexible but it bugs the hell out of me to hear that "ticking" sound when the wiper goes past the light.

I fabricated some spacers to space the HID's up 1/2" higher and increase the distance between the windshield and the back of the light. I started with a piece of .5" 6061T6 aluminum that I had kicking around.

Here I drilled the mounting holes in the aluminum.


Holes drilled and chamfered.


Beadblasted and painted.


Mounted under the lights.


The only problem now is that with the slope of the windshield and the light bracket follows that slope which angled the lights too far. By mounting the light a little higher now it also angles more. The lights have detents on the mounting block and wouldn't you know it, the position I need is right between two detents. If I go to the lower detent the lights illuminate my hood nicely and one detent the other direction I am signaling aircraft. I removed the spacers and ground a taper on both of them. On one side they measure .500" and on the rear side they now measure .410".

This nets me a perfect 90 degree angle to the ground. Should be about right.

Mike.

__________________
2011 JKU Rubicon
BDS Long-Arm System/ 17x9 ATX Crawl wheels/35" BFG KM2's/ Plus much, much more.

Click here to see my 2011 JKU Rubicon Build Thread
zmotorsports is offline   Quote Quick Reply
Old 02-14-2013, 11:54 AM   #220
Jeeper
 
zmotorsports's Avatar
 
Join Date: Mar 2012
Location: Northern Utah
Posts: 618
The next item that has been bugging me is this.




My KC lights have only lasted less than 15k miles on not even made it through two winters before looking like crap. The rivets were also becoming quite loose between the mounting pod and the housing which resulted in a very "shaky" light beam when on. Drove me absolutely nuts. I originally was going to disassemble the lights, tighten the rivets, beadblast and re-paint the lights but I have been so disappointed in these KC lights I decided to go a different route.

I wanted to stay with halogens on my bumper because I actually use them much more than my HID's on my windshield but I wanted something with a composite/ABS body so I wouldn't have to deal with rust again down the road and preferabely not any rivets to deal with. Upon some research I found these new Hella Black Magic 500 halogens that seemed to fit my criteria, plus they are COOOOLLLL looking. They came with plastic covers to protect them for daily driving or when towing behind the coach and they have a new black optics technology that actually give the lights a "black" look when they are not on.


Here you can see the unique blackout appearance they give.


Mounted and adjusted.


Covers removed.


I conteplated going with the Black Magic 1000's for a bit but they were nearly 2" larger in diameter and after mounting the Black Magic 500's being 6.4" I am glad I went with them.

Mike.

__________________
2011 JKU Rubicon
BDS Long-Arm System/ 17x9 ATX Crawl wheels/35" BFG KM2's/ Plus much, much more.

Click here to see my 2011 JKU Rubicon Build Thread
zmotorsports is offline   Quote Quick Reply
Old 02-14-2013, 03:58 PM   #221
Jeeper
 
cozmo2312's Avatar
 
Join Date: Dec 2011
Location: Utah
Posts: 78
nice jeep/build. you know of any local trails that are open this time of year?
__________________
2011 Jeep Rubicon His
2012 jeep sport Hers
cozmo2312 is offline   Quote Quick Reply
Old 02-14-2013, 06:03 PM   #222
Jeeper
 
zmotorsports's Avatar
 
Join Date: Mar 2012
Location: Northern Utah
Posts: 618
Quote:
Originally Posted by cozmo2312 View Post
nice jeep/build. you know of any local trails that are open this time of year?
Thank you.

A group of us are heading down to Little Moab this Saturday (16th) you should come with us. It is not really a trail just a bunch of obstacles but there is something for everyone. As far as trails we have run the snakes out at 5-mile this time of year but one of our other favorite places to go, American Fork Canyon, won't be accessible for a couple of months yet.

There is more information on Saturday's run in the Utah section.

Hope you join us.

Mike.
__________________
2011 JKU Rubicon
BDS Long-Arm System/ 17x9 ATX Crawl wheels/35" BFG KM2's/ Plus much, much more.

Click here to see my 2011 JKU Rubicon Build Thread
zmotorsports is offline   Quote Quick Reply
Old 02-15-2013, 08:32 AM   #223
Jeeper
 
cozmo2312's Avatar
 
Join Date: Dec 2011
Location: Utah
Posts: 78
i'll check out the Utah section, thanks. unfortunately i work weekends, so this one is out, thanks for the offer. maybe i can try and make the next one
__________________
2011 Jeep Rubicon His
2012 jeep sport Hers
cozmo2312 is offline   Quote Quick Reply
Old 02-15-2013, 10:58 AM   #224
Jeeper
 
zmotorsports's Avatar
 
Join Date: Mar 2012
Location: Northern Utah
Posts: 618
Quote:
Originally Posted by cozmo2312 View Post
i'll check out the Utah section, thanks. unfortunately i work weekends, so this one is out, thanks for the offer. maybe i can try and make the next one
Absolutely. We would love to have you join us.

Mike.
__________________
2011 JKU Rubicon
BDS Long-Arm System/ 17x9 ATX Crawl wheels/35" BFG KM2's/ Plus much, much more.

Click here to see my 2011 JKU Rubicon Build Thread
zmotorsports is offline   Quote Quick Reply
Old 04-07-2013, 05:41 AM   #225
Newb
 
Overmanjh's Avatar
 
Join Date: Nov 2011
Posts: 8
Nice Jeep, love to see some one put so much time and love into one.I'll be moving to Colorado this summer and am really looking forward to hitting some trails out there. Plus Moab will be close. I like your sons lightning too, what year is it, about an 06? I had an 09, but one of my toys had to go last year, it was either the Buell, the Jeep, or the guns. The Buell lost.With any luck there will be a Harley in it's place in the next couple years though.
Overmanjh is offline   Quote Quick Reply
Old 04-08-2013, 08:22 AM   #226
Jeeper
 
zmotorsports's Avatar
 
Join Date: Mar 2012
Location: Northern Utah
Posts: 618
Quote:
Originally Posted by Overmanjh View Post
Nice Jeep, love to see some one put so much time and love into one.I'll be moving to Colorado this summer and am really looking forward to hitting some trails out there. Plus Moab will be close. I like your sons lightning too, what year is it, about an 06? I had an 09, but one of my toys had to go last year, it was either the Buell, the Jeep, or the guns. The Buell lost.With any luck there will be a Harley in it's place in the next couple years though.
Thanks for the compliments. You will love the trails in Colorado. We generally stay in Ouray for a week in August and hit many of the trails. We love that area.

My sons Lightning XB9 is a 2008 (25th year anniversary edition). Nice bike, we are getting ready to do a tail chop, move the turn signals inwards a bit and fabricate a new muffler, then some powder coating and polishing of a few parts.

Mike.
__________________
2011 JKU Rubicon
BDS Long-Arm System/ 17x9 ATX Crawl wheels/35" BFG KM2's/ Plus much, much more.

Click here to see my 2011 JKU Rubicon Build Thread
zmotorsports is offline   Quote Quick Reply
Old 04-08-2013, 10:08 AM   #227
Jeeper
 
GulfCoast's Avatar
 
Join Date: Mar 2012
Location: Vancleave MS
Posts: 175
Just finished reading the entire thread and as many others have stated, your extremly talented at wrenching. When the fever sets in to sell the JKU and move on to the next project hit me up, truck, trailer and all 4 pockets stuffed with cash will head your way.
GulfCoast is offline   Quote Quick Reply
Old 04-09-2013, 12:43 PM   #228
Jeeper
 
zmotorsports's Avatar
 
Join Date: Mar 2012
Location: Northern Utah
Posts: 618
Quote:
Originally Posted by GulfCoast View Post
Just finished reading the entire thread and as many others have stated, your extremly talented at wrenching. When the fever sets in to sell the JKU and move on to the next project hit me up, truck, trailer and all 4 pockets stuffed with cash will head your way.
Thanks, I will keep that in mind. I don't see myself selling any time soon though as I am enjoying it way too much.

Mike.
__________________
2011 JKU Rubicon
BDS Long-Arm System/ 17x9 ATX Crawl wheels/35" BFG KM2's/ Plus much, much more.

Click here to see my 2011 JKU Rubicon Build Thread
zmotorsports is offline   Quote Quick Reply
Old 04-09-2013, 01:35 PM   #229
Commercial Member

WF Supporting Member
 
Wranglin4Life's Avatar
 
Join Date: Apr 2013
Location: Maryland
Posts: 2,552
I dont venture in the JK section very much but I love the JK's and had one a couple years ago and now currently own a YJ. I have been eager to get into an Unlimited JK which would be more comfy for the wife (she hates my yj, damn leaf springs). I just wanted to tip my hat to you and say your jeep is probably top 5 best looking I have ever seen. I didnt read the entire thread... A lot of picture looking and all. If it hasnt been already... Your Rubi belongs in a magazine. Nice work!
__________________
Take a look at my handmade custom paracord grab handles & other handmade paracord items!

You Choose the colors!!

http://www.wranglerforum.com/f37/par...es-236090.html
Wranglin4Life is offline   Quote Quick Reply
Old 05-06-2013, 02:11 PM   #230
Jeeper
 
zmotorsports's Avatar
 
Join Date: Mar 2012
Location: Northern Utah
Posts: 618
Quote:
Originally Posted by Wranglin4Life View Post
I dont venture in the JK section very much but I love the JK's and had one a couple years ago and now currently own a YJ. I have been eager to get into an Unlimited JK which would be more comfy for the wife (she hates my yj, damn leaf springs). I just wanted to tip my hat to you and say your jeep is probably top 5 best looking I have ever seen. I didnt read the entire thread... A lot of picture looking and all. If it hasnt been already... Your Rubi belongs in a magazine. Nice work!

Thank you. I appreciate the compliment.

Mike.
__________________
2011 JKU Rubicon
BDS Long-Arm System/ 17x9 ATX Crawl wheels/35" BFG KM2's/ Plus much, much more.

Click here to see my 2011 JKU Rubicon Build Thread
zmotorsports is offline   Quote Quick Reply
Old 05-06-2013, 02:17 PM   #231
Jeeper
 
zmotorsports's Avatar
 
Join Date: Mar 2012
Location: Northern Utah
Posts: 618
I thought I would throw up a couple of pictures from last month's trip to Moab.

Mike.


Here are a couple of "poser" shots taken while we were south of Moab in the southern Canyonlands area.




This one was taken climbing up and out of Ken's Corner, an optional side route.
__________________
2011 JKU Rubicon
BDS Long-Arm System/ 17x9 ATX Crawl wheels/35" BFG KM2's/ Plus much, much more.

Click here to see my 2011 JKU Rubicon Build Thread
zmotorsports is offline   Quote Quick Reply
Old 06-19-2013, 07:54 AM   #232
Jeeper
 
zmotorsports's Avatar
 
Join Date: Mar 2012
Location: Northern Utah
Posts: 618
Well on to the next project. I decided to sell my Powerplant and change to a Warn 9.5xp and sink it into a home made front bumper. The fact that I have a "store bought" front bumper on my Jeep has been killing me. I have finally gotten caught up on some other things around the shop so I decided to tackle the front bumper project.

Commencing removal of the WARN Powerplant HP and the WARN Rockcrawler bumper.


Front end naked.


I will continue posting pics as progress continues.

Mike.
__________________
2011 JKU Rubicon
BDS Long-Arm System/ 17x9 ATX Crawl wheels/35" BFG KM2's/ Plus much, much more.

Click here to see my 2011 JKU Rubicon Build Thread
zmotorsports is offline   Quote Quick Reply
Old 06-19-2013, 08:15 AM   #233
Jeeper
 
zmotorsports's Avatar
 
Join Date: Mar 2012
Location: Northern Utah
Posts: 618
Last night I was able to start mocking up my front mounting plates and building a template for the winch mounting plate. I am trying to sink it down between the frame rails as far as possible.


Winch mounting plate cut and roughly sitting in position.


The winch should be here tomorrow night so I can mock it up and get the mounting holes drilled and continue fabricating.

Mike.
__________________
2011 JKU Rubicon
BDS Long-Arm System/ 17x9 ATX Crawl wheels/35" BFG KM2's/ Plus much, much more.

Click here to see my 2011 JKU Rubicon Build Thread
zmotorsports is offline   Quote Quick Reply
Old 06-21-2013, 09:17 AM   #234
Jeeper
 
zmotorsports's Avatar
 
Join Date: Mar 2012
Location: Northern Utah
Posts: 618
My new WARN 9.5XP showed up yesterday afternoon so now I can make some serious progress on this project.


I fabricated the center section out of 5/16" P&O for the frame mounts (vertical pieces) and 1/4" P&O for the winch mounting plate (horizontal portion between the frame rails). The entire package will be held onto the Jeep using eight (8) 1/2" grade 8 bolts in the frame horns and two 3/8" grade 8 bolts in the back corners supporting from the rear. There is no way this thing is going anywhere.

I removed it from the Jeep to trim the front edge about 1/2" more to keep the bumper and winch in as close to the front and as low as possible.

Here is the center section of the package prior to me trimming the leading edge.


And here is the test fit of the winch on the Jeep. I had to shift the entire winch to the driver's side about 1.625" to keep it centered in the frame rails.


The roller fairlead will end up being offset to the driver's side 1.625". This will not affect the function. Most of the WARN winches have to be installed in this fashion when placed between the frame rails due to their offset motors and the drum centerline not being exactly in the center of the winch.

Here are a couple of gussets to add some more strength between the winch mounting plate and the bumper mounting points.


I added the radius so they would clear the motor and gear assemblies on either end of the winch. This way I can mount the winch in the bumper after the bumper is installed on the Jeep, unlike most where the winch must be installed on the bumper and then the entire winch and bumper installed as a complete assembly.

Hopefully next time pictures are uploaded there is some major progress or even completion.

Mike.
__________________
2011 JKU Rubicon
BDS Long-Arm System/ 17x9 ATX Crawl wheels/35" BFG KM2's/ Plus much, much more.

Click here to see my 2011 JKU Rubicon Build Thread
zmotorsports is offline   Quote Quick Reply
Old 06-24-2013, 09:32 AM   #235
Jeeper
 
zmotorsports's Avatar
 
Join Date: Mar 2012
Location: Northern Utah
Posts: 618
Finished up the bumper build on Saturday. It is off to the powder coater today. Overall I am very happy with the way it turned out. It really cleaned up the front end of my Jeep and it doesn't look as cluttered anymore. I love the winch sunken down in the front bumper rather than sitting on top.

I am sure I probably went overkill, but then again, overkill is underrated.

Anyway, I constructed the attachment points and then tied the "D" ring mounts directly into the attachment plates at the front of the frame horns.


I also went one step further and added a 3/8" bolt to the back lower section of each side of the winch mount plate where it intersects the frame rail. This will give me a total of eight (8) 1/2" grade 8 bolts and two (2) 3/8" bolts securing the winch plate and bumper to the Jeep.

Here is one of the welds holding the mounting tab to the frame.


"D" ring mounts fully welded to the mounting plates, along with tapered wedges to allow my front piece to be slightly angled.



The front bumper piece is made out of 3/16" P&O. I cut out for the roller fairlead as well as for the "D" ring mounts to protrude through.


I then welded to "D" ring mounts to the front of the bumper. This way when I am using the "D" rings with any load on them, it will actually be pulling on both the inner mounts where they attach to the frame as well as the bumper front at the same time. I have seen several bumper manufacturers that use square tubing for bumper, mainly on the older CJ's and TJ's, and just weld the "D" ring mounts to the outer tubing. If they ever had to attach much of a load it would pull the outer tubing wall away from the inner and literally oval the square tubing out.


I then went one step further and welded a small piece on top of the frame mounts to close off the void between the frame mounts and the front bumper section. This is mainly to keep any moisture out of this void and prevent rust from forming.


Test fitting the top piece. I cut the opening for the winch just large enough so I could mount the bumper and then install the winch. I can also still get to the clutch/engagement lever.


Now onto the outer ears of the bumper. I was really torn, I love the looks of a stubby bumper but don't want to hassle with it at time of inspection. I was looking at the new Shrockworks mid-width bumper and thought about copying that size but then again, inspection time. I finally decided on building it the same width as the WARN Rockcrawler full-width bumper that I removed. Utah law states that the bumper must be full trac width to be considered a full-width bumper. Trac width would be hub to hub or about center of the tires. I had not experienced any interference with my WARN bumper so I shouldn't have any issues here.


Making the templates out of cardboard first, CAD (Cardboard Aided Design), really helps to keep the fitment nice and tight to produce good solid welds with harldy any clean-up with the grinder. Nothing worse than having poor fitment and then having to grind like hell to produce that nice tight, rounded corner effect.


Side overview prior to fabricating the lower and outer sections of the ears. I like how low the winch sits and only the top of the winch and the control box sitting above the top plane of the bumper. Well below the radiator/grille.
__________________
2011 JKU Rubicon
BDS Long-Arm System/ 17x9 ATX Crawl wheels/35" BFG KM2's/ Plus much, much more.

Click here to see my 2011 JKU Rubicon Build Thread
zmotorsports is offline   Quote Quick Reply
Old 06-24-2013, 09:33 AM   #236
Jeeper
 
zmotorsports's Avatar
 
Join Date: Mar 2012
Location: Northern Utah
Posts: 618
Final welding completed and the bumper metal-finished. Ready for the powder coater.





Now all mocked up with the winch, control box and roller fairlead attached.



All that it left is to bend up my grille hoop and weld it on then it is ready to go to the powder coater today. My 2" die should be here today.

Mike.
__________________
2011 JKU Rubicon
BDS Long-Arm System/ 17x9 ATX Crawl wheels/35" BFG KM2's/ Plus much, much more.

Click here to see my 2011 JKU Rubicon Build Thread
zmotorsports is offline   Quote Quick Reply
Old 06-26-2013, 10:02 AM   #237
Jeeper
 
RedSectorA's Avatar
 
Join Date: Sep 2012
Location: Alabama
Posts: 201
Mike,

I just wanted to say that I am blown away by your skill and attention to detail. I really appreciate you taking the time to document all of the work you have done and I'm looking forward to your next project.
__________________
2013 JKU Rubicon Billet Metallic
2.5" Rock Krawler Max Travel - 35" BFG KM2's - 17" Fuel Revolvers - Poison Spyder Brawler Lite and Skid - Warn Zeon 10S - JW Speaker Headlights
RedSectorA is offline   Quote Quick Reply
Old 06-26-2013, 11:51 AM   #238
Jeeper
 
zmotorsports's Avatar
 
Join Date: Mar 2012
Location: Northern Utah
Posts: 618
Quote:
Originally Posted by RedSectorA View Post
Mike,

I just wanted to say that I am blown away by your skill and attention to detail. I really appreciate you taking the time to document all of the work you have done and I'm looking forward to your next project.
Thank you very much for the compliment. I enjoy posting pictures and details about my build. Hopefully it will inspire others to tackle more jobs themselves.

My bumper will be back from the powder coater on Monday and then I can install it and set my winch/lights in place. Then the next project will be an onboard air system that I am putting together.

Mike.
__________________
2011 JKU Rubicon
BDS Long-Arm System/ 17x9 ATX Crawl wheels/35" BFG KM2's/ Plus much, much more.

Click here to see my 2011 JKU Rubicon Build Thread
zmotorsports is offline   Quote Quick Reply
Old 07-02-2013, 08:10 AM   #239
Jeeper
 
zmotorsports's Avatar
 
Join Date: Mar 2012
Location: Northern Utah
Posts: 618
Here are a couple of pictures of the bumper after bending up the grille hoop and welding it on just prior to sending it off to the powder coater.



I just picked it up from the powder coater yesterday and this is when I first got it in the shop and unwrapped it.


Bolting it on the Jeep.


Picture of it completed with the winch installed, new roller fairlead and my Hella 500 Black Magic lights bolted on and wired up.




Another project crossed off the to do list. Next and probably last project will be my on-board air system that I am putting together. I should have all of the pieces within the next several weeks.

Oh, by the way I also did the fender turn signal mod. With my 7" Hella driving lights on the bumper if off to the side much it is hard to see my turn signals in the grille, by having the side markers act as turn signal indicators it will allow full visibility of my turning intentions, too bad more people in Utah don't know what turn signals are.

Thanks for looking.

Mike.
__________________
2011 JKU Rubicon
BDS Long-Arm System/ 17x9 ATX Crawl wheels/35" BFG KM2's/ Plus much, much more.

Click here to see my 2011 JKU Rubicon Build Thread
zmotorsports is offline   Quote Quick Reply
Old 07-05-2013, 03:06 PM   #240
Jeeper
 
RedSectorA's Avatar
 
Join Date: Sep 2012
Location: Alabama
Posts: 201
As always, very clean, functional and with extreme attention to detail. I'm curious about your choice of wire rope vs. synthetic. Do you prefer traditional wire or was it simply cost driven?

I take it your Jeep is rarely driven at night given the stock headlights and the removal of the factory driving lights. Are the Hella's designed to be used on the road or off road only?

__________________
2013 JKU Rubicon Billet Metallic
2.5" Rock Krawler Max Travel - 35" BFG KM2's - 17" Fuel Revolvers - Poison Spyder Brawler Lite and Skid - Warn Zeon 10S - JW Speaker Headlights
RedSectorA 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


Similar Threads
Thread Thread Starter Forum Replies Last Post
What I did to my TJ today TJeepman TJ General Discussion Forum 25776 Today 08:11 AM
What I did to my YJ today 1990_YJ YJ General Discussion Forum 10968 Yesterday 09:21 PM
Looks like my roof is leaking - '12 Sahara adg44 JK General Discussion Forum 34 11-02-2013 05:34 PM
CA: 2012 JKU Suspension and Driveshaft suicideking Classifieds Archive 6 09-12-2012 01:21 AM
first real drive in my yj with a clutch issue olbaid_83 YJ Tech Forum 13 03-04-2012 10:36 AM


logo carid shop wrangler parts carid fender flares custom wheels store avs deflectors at carid
» Rates
Get low rates on auto insurance in Canada!

» Network Links
»Jeep Parts
» Featured Product

All times are GMT -5. The time now is 05:04 PM.



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