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Topic Review (Newest First)
Today 07:55 AM
jscherb
Quote:
Originally Posted by ds1948 View Post
This barn door is awesome. And those hinges. Yes please I'll take a set as well very impressive work sir
I'll have some news on the hinges next Tuesday from SEMA, stay tuned.
Today 07:37 AM
ds1948 This barn door is awesome. And those hinges. Yes please I'll take a set as well very impressive work sir
Today 07:28 AM
Milkman
Quote:
Originally Posted by Espo78 View Post
Looks like it's working great!

I have to say though that the rear window looks really small, relative to all the real estate available. I know a lot of options were discussed but it really seems like the window should be wider, and I'd almost go as far as to say eliminate the wiper altogether so the window is lower. I know a lower window would be wasted due to the spare tire, but it would be more aesthetic. Am I completely off base?
The window could be wider if a manufacturer chose to do so. Since this was a prototype it was more efficient to use the same mold for both barn doors which made the window narrow for use in the 07-11 style rear door. This is also the basis for size for the Safari Cab.

The lower section is also needed to provide a support mechanism for the entire barn door so even if you did remove the wiper that space is needed. Once it is final installed we will take some photos from inside the Jeep to show the view out the back.

I bet when it's painted it will make it look more to scale too.
Today 05:58 AM
Milkman In the above video you can see the ModuluS tailgate system in a configuration to hold the barn door with the large uprights. Since it is modular in design the idea was to have it configurable for several different options.

Here's a pic of the base configuration I used this past week to carry a fire extinguisher and Molle packs holding my first aid kit and extra storage for food. As you can see there is still additional room on the bottom for additional quick fists or other items.

Yesterday 09:53 PM
okstatejk
Quote:
Originally Posted by Milkman View Post
In case you need another reason to change hinges....here's the amount of oxidation on mine and it's only a year old. If only Chrysler wouldn't cheap out and actually prime the surfaces before assembling for final paint.

I have been thinking of pulling all my hinges and clear coating them before this even starts.

The amount of fab work in this post makes me feel woefully inadequate. Keep up the great work guys, even if it is just a hobby and for fun. I would love to have the skill needed to think of ideas like this, let alone build them.
Yesterday 09:43 PM
Espo78 Looks like it's working great!

I have to say though that the rear window looks really small, relative to all the real estate available. I know a lot of options were discussed but it really seems like the window should be wider, and I'd almost go as far as to say eliminate the wiper altogether so the window is lower. I know a lower window would be wasted due to the spare tire, but it would be more aesthetic. Am I completely off base?
Yesterday 08:25 PM
jscherb We got the barn door bolted in place tonight, and had lots of fun opening and closing it, slamming the door, etc. The heavy duty hinges are really smooth, and the barn door slams with a satisfying solid sound (it might not sound that way on this video, the bass response recording may not do it justice). The glass isn't in place right now, nor is the wiper blade or wiper cavity cover on the inside, but anyway here's Tom playing with his new toy...

BarnDoorTest1 - YouTube
Yesterday 08:06 PM
jscherb Tom came over this evening so we could do some more work on his barn door, but before we got into that we checked the fit of the accessory rack on his JK. He's holding it in place in this photo, we didn't take the time to bolt it on because we had lots to do on the barn door and limited time. But anyway, the rack fits very nicely and we'll get around to road testing it very soon.

Yesterday 03:32 PM
jscherb
Quote:
Originally Posted by rjf98 View Post
I know you've said you don't make stuff to necessarily sell it a thousand times on this thread. I really wish someone like you lived close by. It would be very neat to work on stuff and learn from you. Very, well jealous Prob isn't the right word, but jealous of your shop, ingenuity, and talent my friend
My workshop isn't really over the top, it's maybe a slightly above average home woodworking shop, plus a metal-cutting bandsaw and a 180-amp MIG welder. I spend a lot of design and planning time trying to figure out how to achieve what I'm trying to build within the very finite limits of my tools and talent, if you put your mind to it there's a lot that can be done without having lots of special tools and machinery.

Tom's been working with me on the barn door project and he's been a great help - he's a talented engineer and adds a lot of value to the process. I think he's learning some things too, because he's used to having access to all the coolest CAD toys at work, then he comes to my workshop and we have none of that, so we make do with the tools that are here and somehow get the job done.
Yesterday 03:26 PM
jscherb I finished up the Hi-Lift mount today; here are a few photos of the prototype, some primer and paint and it'll be for some road testing.

The Hi-Lift mount consists of two parts, both of which can mount anywhere on the grid. The shovel is mounted with two Quick Fist clamps, which also easily bolt to the grid. Also I've implemented a low-cost way to allow the various accessories to be bolted to the grid without having to remove the grid from the Jeep, which makes it quick and easy to change the configuration of stuff on the grid.

Yesterday 02:46 PM
rjf98 I know you've said you don't make stuff to necessarily sell it a thousand times on this thread. I really wish someone like you lived close by. It would be very neat to work on stuff and learn from you. Very, well jealous Prob isn't the right word, but jealous of your shop, ingenuity, and talent my friend
Yesterday 11:52 AM
jscherb Here are some photos of the work-in-progress on a prototype of the tailgate accessory mounting system I showed concept drawings of yesterday. I haven't done the top bracket for the Hi-Lift yet, probably will get to that this afternoon. This is really just a proof-of-concept prototype to see what dimensions work best; I'll need to do a test install on an actual JK (instead of just the tailgate in my workshop) so I can finalize dimensions and a few other details.



I'd appreciate any thoughts or comments you might have; your input will help me finalize the design.
10-28-2014 07:14 PM
SilverMiner Safari top in Crush orange, with new hinges and Jerry can mount. Where do I send the check?
10-28-2014 01:48 PM
jgk200
Quote:
Originally Posted by skooter View Post
Looking really nice...I, want one of these
Very Cool! I Like It!!!
10-28-2014 08:17 AM
jscherb Here's a rough idea of what Tom and I are thinking about for mounting accessories on the heavy-duty hinges. We've still got some work to do on design details, so consider these just concept images for now.

Here's an example of a Hi-Lift carrier mounted to the hinges:



If you wanted to carry more than one thing back there, we're thinking about a base plate with a grid of mounting holes. The base plate bolts to the hinges, and then the accessory carriers bolt to the base plate. For just the Hi-Lift, it would look like this:



Accessory carriers can be bolted to the grid, in any combination that fits and clears the spare and the tail light. Here are a few examples showing other stuff mounted. On the left, some rubber "Quick Fist" clamps mount a military shovel. In the center, a bracket mounts an ammo can, perhaps containing a recovery strap. And on the right, a jerry can.



Mounting things as wide as a jerry can, or mounting a Hi-Lift plus an ammo can might cause interferance with the tail light when the tailgate is fully open, so for some combinations it might be necessary to install an optional stop in the hinge that limits the tailgate opening to 90-degrees. We made Tom's hinges to overcome that problem, they're designed with a wider swing than the stock hinge geometry so a jerry can will fit just fine on Tom's hinges, but for the heavy-duty hinges with the stock geometry a stop might be necessary for some combinations of accessories.

We're also thinking about a few other accessory carriers that would bolt to the grid system, such as a Rotopax container holder.

We're about to make up a prototype, but before we do, is there anything we've overlooked? And any other items that you think we should allow for mounting to this system?
10-27-2014 02:16 PM
skooter
Quote:
Originally Posted by jscherb View Post
Looking really nice...I, want one of these
10-27-2014 10:53 AM
jscherb Here's a photo of the barn door in a factory hardtop compared to a photo with the Safari Cab rear panel setting against the factory hardtop to sort-of simulate the look of the panel on a hardtop.



BTW, this panel could also be installed as the rear panel of a factory hardtop with a little fiberglass surgery... removing the factory panel and transplanting this one in its place.

Also, based on the look of the actual fiberglass parts, I've updated the concept drawing slightly (changed the radius on the top and bottom of the rear opera windows), and I've also drawn in a second Alpine window on each side of the roof.

10-27-2014 08:12 AM
jscherb Now that actual parts are made, here's a comparison of my concept drawing to the parts.

10-26-2014 09:36 PM
Dr.Ew Looking great! It's cool to see this coming together. Thanks
10-26-2014 01:41 PM
jscherb I've installed clear windows in the barn door and the Safari Cab rear panel. It's just plexiglass for now, I don't want to have real glass in there while I'm still in the prototype phase of the project. Real glass will be installed later, and probably some degree of tint to be decided later.



Up on the workbench to see through the windows...





From the inside...

10-25-2014 03:52 PM
jscherb I drew on the photo to simulate what it might look like with tinted windows in place.

10-25-2014 03:40 PM
jscherb Here's the Safari Cab rear panel after trimming. Since I made the panel to accept the factory liftgate weatherstrip, I put that on after trimming to test the fit (fits just like factory).



Another shot, with the barn door setting in place. The barn door is slightly large, I won't do a final trim on it until the parts are on a Jeep, which will enable me to final trim it get the door gap perfect all around.



I've still got the plywood "window" in this barn door, and I haven't cut the holes in the panel for the opera windows yet. I do have clear windows on hand to install, so over the next few days I'll put clear windows in all 3 openings. In case you're wondering about the opera windows, the openings the opera windows mount in are the same height and vertical position as the side windows, so they'll match the sides nicely. When the opera windows are installed, the viewable area out of them will be roughly 1" less than the size of the mounting surface on all 4 sides due to the window frame/gasket, so if the window opening looks a bit large in these photos that's why.
10-25-2014 09:54 AM
jscherb This week I finished up the work on the mold for the JK Safari Cab rear panel, and yesterday I made the first part in that mold. Here's the resulting part, just popped out of the mold. It hasn't been trimmed yet and the mold release hasn't been washed off, I'll get that done later today.

It's very similar to the factory hardtop rear panel, but it's got recesses for mounting the opera windows on each side of the barn door opening, and it doesn't have hinge recesses above the door opening. It's also got some differences not visible in this photo, such as the bolt flanges for attaching the removable side panels to it.



More photos to come as I get it trimmed and cleaned up.
10-23-2014 09:24 PM
Krashdragon I'll get in line for a set of hinges. Totally sick! aka awesome!
10-23-2014 08:25 PM
Milkman
Quote:
Originally Posted by Espo78 View Post
How did you fix that?
I plan to tape off, sand and prime with self etching primer when I get a decent day with the temperature high enough to paint. I hit it with a quick sand and put a layer of wax on it for now until I can get back to it.

Quote:
Originally Posted by Jeep sauce View Post
I would love a set of these when they are ready for market. Great work jscherb and milkman!
Stay tuned....Jeff deserves all the credit for these. They are his design, I'm just lucky enough to live close enough to him to get to work on making my set.

Here's an action shot of these hinges getting welded up on Jeff's welding bench It is really amazing to watch and work with him to create these designs.

10-23-2014 08:11 PM
Jeep sauce I like the upgraded hinges. The first time I got my tires rotated the tire was dropped so hard on the carrier that a popping-click sound was made every time the door fully opened. I would love a set of these when they are ready for market. Great work jscherb and milkman!
10-23-2014 08:10 PM
Espo78 How did you fix that?
10-23-2014 07:24 PM
Milkman In case you need another reason to change hinges....here's the amount of oxidation on mine and it's only a year old. If only Chrysler wouldn't cheap out and actually prime the surfaces before assembling for final paint.

10-23-2014 03:04 PM
jscherb
Quote:
Originally Posted by JCDriller View Post
... What will these give you that the stock ones don't?
In addition to what Tom said about these hinges being stronger, they have larger hinge pins that run in bronze bushings, and there's a zerk fitting for easy greasing, so they're not going to wear over time like the factory ones do, which can result in the tailgate sagging. And it they ever should happen to wear, they're easily rebuildable - the bushings can be replaced with new ones as can the hinge pin, both can be found at most hardware stores.

Oh and there's no cheezy plastic covers to break like on the factory hinges .

And stay tuned, Tom and I are working on an accessory mounting system for them. We're thinking options to hold:

- a jerry can or NATO can
- a Hi-Lift
- a Rotopax container
- A trail shovel

It wouldn't hold everything at once, for example a jerry/NATO can takes up enough room between the spare and the tail light that not much more would fit, but perhaps a Hi-Lift + shovel or + Rotopax at the same time.

Did we miss anything important?
10-23-2014 02:57 PM
Milkman
Quote:
Originally Posted by JCDriller View Post
They look really nice but do you think the hinges will be enough to secure the tire on rough terrain? What will these give you that the stock ones don't?

I'm just thinking abou the teraflex unit and they have the hinge directly supporting the tire, so the door is no longer supporting its weight.
Personally for me I have no issue with the stock tire carrier. It handles my 33" tires fine, the worry for me was actually tweaking the tailgate via the hinges with the additional load and offset of my spare tire rattling even with the cheap Daystar bumpers.

No issue with this now and it will also give me the capability to carry accessories like a hilift on that hinge.

Is it that large of issue with the stock tire carrier? I did a quick search and most were damaged when the spare tire was hit or backed into something.
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