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11 day jeep build for magazine photo shoot

38K views 80 replies 32 participants last post by  n3tfury 
#1 ·
Land vehicle Vehicle Car Tire Jeep


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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#3 ·
Technology Electronic device Tool


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.


Automotive exterior Auto part Bumper Vehicle Car


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



Auto part Vehicle Car Fuel line Engine


Pump moved



Electronics Technology Electronic device Auto part


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 - ½” aluminum spacers for the winch to clear the fog lights.



Automotive exterior Bumper Vehicle Car Vehicle door


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




Automotive exterior Bumper


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.


Bumper Automotive exterior Vehicle Auto part Car


Fairlead mounted

Bumper Auto part Automotive exterior


This is the end piece that holds the rope in


Vehicle Car Automotive exterior Bumper Automotive design


Another view


Automotive exterior Bumper Auto part Vehicle Tire



And the rope wound


Automotive exterior Auto part Bumper Vehicle Grille


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.


Land vehicle Vehicle Car Automotive exterior Bumper


It is a tight fit and the winch pushes the lower cowl in about ½ inch but it looks fine


Motor vehicle Vehicle Automotive exterior Red Bumper


Here is a side view of the push in


Bumper Automotive exterior Vehicle Auto part Car

Top view of the same


Land vehicle Tire Vehicle Car Jeep



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.
 
#5 ·
Wood Hardwood Table Lumber Flooring


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


Auto part


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


Automotive exterior Bumper Auto part Plastic bag Plastic


This is the step pack

Iron Metal Automotive exterior Steel Floor


Sorry for the poor quality photo but this the basket assembled


Land vehicle Vehicle Automotive tire Tire Bumper


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


Automotive exterior Fender Vehicle Bumper Car



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

Automotive exterior Motor vehicle Bumper Vehicle Fender


Then drill


Automotive exterior Vehicle Bumper Automotive tire Tire

Then assemble the mounting hardware and repeat for the other side


Vehicle Automotive tire Automotive exterior Tire Car

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


Land vehicle Vehicle Car Automotive tire Tire


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


Land vehicle Vehicle Tire Car Jeep


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


Land vehicle Vehicle Car Jeep Tire


Front


Land vehicle Tire Automotive tire Vehicle Automotive exterior


Rear
 
#6 ·
Land vehicle Vehicle Car Automotive tire Jeep


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


Vehicle Car Automotive exterior Transport Mode of transport


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.



Land vehicle Vehicle Tire Car Automotive tire


Also the Factor 55 Prolink is now installed on the winch end
 
#7 ·
Brickwork Brick Wall Room Bricklayer


Next the Rigid Industries lighting showed up!!!!! Its so pretty :)


Land vehicle Vehicle Tire Car Automotive tire


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.

Land vehicle Vehicle Car Motor vehicle Jeep


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.


Vehicle Auto part Car Automotive exterior Bumper


Once measured 5 times then I drilled out the mount location


Land vehicle Vehicle Car Motor vehicle Off-road vehicle


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


Land vehicle Vehicle Car Jeep Automotive tire


Here is with 3 covers


Land vehicle Vehicle Car Automotive tire Jeep


Here is with all the red lenses covers on it


Land vehicle Vehicle Tire Automotive tire Automotive exterior



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


Light Red Automotive lighting Electronics Electrical wiring


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



Land vehicle Vehicle Tire Car Automotive tire


Tail lights reinstalled


Wire Cable Electronic device Technology Electronics accessory

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.



Auto part

Here is a SRM rewired and loomed


Automotive exterior Bumper Vehicle Roof rack Tire



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


Land vehicle Vehicle Car Automotive exterior Off-road vehicle



They provide a nice amount of light
 
#74 ·
View attachment 234670

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


View attachment 234687

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



View attachment 234688

Tail lights reinstalled

Nice build and of course both your Jeeps are pretty Cool....
I like the the tail light mod... might have to look into doing that one day..

:drinks:
 
#8 ·
Box Auto part Packaging and labeling

The power tank I wanted to mount on the outside of the jeep attached to the rear of the rack opposite of the ladder.

Vehicle Automotive exterior Bumper Car Auto part


Here is the lower mount set for sizing

Vehicle Automotive exterior Automotive tire Tire Car


Tank in to check clearance before fully welding it up


Land vehicle Vehicle Car Automotive tire Tire


Fully welded and painted, matches the other side great!


Vehicle Tire Automotive tire Automotive exterior Car


Tank bracket fully mounted

Land vehicle Tire Vehicle Automotive tire Automotive exterior


And tank in the bracket

Land vehicle Vehicle Tire Automotive tire Car


It came out great and has nice sementry with the ladder


Automotive exterior Vehicle Transport Asphalt Mode of transport



Here is looking back at it down the side. It has a nice low profile
 
#9 ·
Land vehicle Vehicle Automotive tire Tire Automotive exterior


Tools mounted, shovel and flat head axe

Automotive exterior Vehicle Car Roof rack Automotive carrying rack


Highlife jack mounted


Vehicle Car


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
 
#13 ·
Very Nice Work!
 
#20 ·
Metal cloak fenders going on
 

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#21 ·
And now the Metal Cloak lift
 

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#27 ·
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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