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Topic Review (Newest First)
07-21-2014 11:03 PM
chop110 With major welding out of the way, I drove the TJ-6 out of the garage to hose off all of the grinding dust that had piled up in there over the last year.



After a thorough wash, it is now time to prep the exterior for bondo, primer, and painting. This next set of steps cannot be rushed.

Here are some shots of the cleaned interior.





The side compartments are not done. I am mulling starting the sheet metal work for these and then welding them on prior to applying monstaliner at a later date. It all depends on how much free time I am going to have over the next three weeks.
07-21-2014 10:54 PM
chop110 I then completed the roll bar connections using the same interior-sleeve method with plug weld holes as before:





07-21-2014 10:48 PM
chop110 After grinding everything flat, it was important to hit the top of the tub edges with some weld through primer. Once the belt rails are in place, any exposed metal in the interior gaps would be exposed to rust.



I bought a new LJ rail on the driver's side which I had no problem welding on.



For the passenger side, I fabricated one extended belt rail from the removed pieces.



07-21-2014 10:35 PM
chop110 I am now under the gun to finish this project in three weeks. I am selling my daily driver and will need the Jeep to drive around until the new daily driver arrives. Needless to say, the pressure is on to avoid being stuck with a rental in the interim.

Continuing with the interior of the side panels...

I fabricated the tops of the storage compartments. In order to attach the lid hinges, I needed to weld some nuts on the insides.



I knew that creating the belt rail supports at the top of the tub gaps would be a challange. Ideally, I would have liked to have found some donor sections from a wrecked TJ tub. However, this proved to be a difficult errand. It was tough finding two unblemished 15" sections and the few that I did find, the sellers wanted me to buy the whole tub. Trying to fabricate some of my own would only result in some ugly bends (I am not that skilled).

In my search, I came across this weld-on TJ repair panel from NOR/AM that just happened to have the sloped bends that I was looking for. The sheet metal was thin (21 gauge) and felt flimsy, but in short sections, it was stiff enough to work. Best of all, it was only $60.



Look how perfectly the bends match the factory tub!





Passenger side welded:

06-25-2014 05:50 AM
solman No trouble at all with the top, Other than it hitting the ceiling in my garage I have to pull it out in the driveway to put it up or down.
06-24-2014 06:36 PM
chop110
Quote:
Originally Posted by solman View Post
It's worth it though, I have about 100 trouble free miles on my stretched tj since the axle swap and it's running great! I'm taking it to an off road park Saturday, I hope it runs good!
I am sure it will run like a champ!

Incidentally, do you have any problems folding back your LJ top? Do the rear TJ style bars get in the way? I have tested it with just the Bestop framing and it seems to clear but I have yet to try it with the actual top inplace.
06-24-2014 11:39 AM
solman It's worth it though, I have about 100 trouble free miles on my stretched tj since the axle swap and it's running great! I'm taking it to an off road park Saturday, I hope it runs good!
06-22-2014 07:39 PM
chop110
Quote:
Originally Posted by solman View Post
Looking good! I love having the storage pockets
Such a great idea you came up with, but daaaahhmn! It sure is a lot of work.
06-22-2014 07:38 PM
chop110 Finished welding in the passenger side panel, cleaned it up, and slapped on a coat of primer to combat rust from the Houston humidity (It really takes a few hours for bare metal to start turning).



I am getting closer, but there is still a lot left. I have to have it painted by the end of July!
06-21-2014 08:28 PM
solman Looking good! I love having the storage pockets
06-21-2014 04:13 PM
chop110 I had some time to work on the TJ-6 this weekend...

I bent some more sheet metal for the driver side storage compartment:



And then installed it...



Now the floor panels are starting to look like something. I still need to grind down all of those spot welds.



I made a few fitting adjustments to the passenger side panel, drilled a couple of holes for the AEV flare connections and proceeded to weld it in place. This will be a slow, careful process; we don't want excessive heat to burn through the sheet metal or warp it.

05-31-2014 02:27 PM
chop110 Then came the actual compartments... with some posterboard mock up work first...



Spot welded it in place...



I was running short of time and the air was feeling kind of damp. I knew it would be a while before I picked this up again so I painted the interior with primer for rust protection:



Just for kicks, I decided to test fit the side panel:



I need to finish this already!!
05-31-2014 02:22 PM
chop110 Time for sheet metal work!! After seeing Solman's build, I could not in good conscience leave the floor completely flat as I originally intended to. So, I kicked some ideas around and decided to make use of the available space for some storage compartments that will continue off from the wheel wells. It will take a lot more work, but... what the heck! It is going to be so sweet!

First, I made my templates out of posterboard material. Then, working with 18 gauge sheet metal and using a homemade press brake, various cutting tools, and a heck of a lot of hammering, I made this support bulkhead. I started out painting everything with weld though primer, later I just stopped doing this because of the time it took to get the stuff to dry and for some reason, I could not get good spot welds that held together.



Welded it in place with one half of the floor panel...



05-31-2014 02:07 PM
chop110 I was able to take advantage of the long Memorial Day weekend to get a lot done...

The support frame for the floor extension (made from channel and L1.5x1.5x1/8" angle):



Installed... Note the welded nuts for the relocated rear seat brackets!



Once I got the tub squared with adjustable scissor jacks at four corners and measured 100 times, I welded on some rail extension supports to hold everything in place.

05-31-2014 01:58 PM
chop110
Quote:
Originally Posted by thebestskibum View Post
Thanks for the detailed info, I have them ordered.

How about an update? With pics please!!! I'm going to tear into mine in the next week or two.

Question: what flaring tool did you use for the brake and fuel lines?
I've got my head wrapped around the welding and cutting and grinding and bracing and crying about my jeep being in two pieces but I can't find very good info on flaring the lines.
I used the Eastwood flaring tool. It is definitely not cheap (Around $200), but I did not feel like messing with the screw flare and it made the job pretty easy.
05-08-2014 10:39 PM
thebestskibum Thanks for the detailed info, I have them ordered.

How about an update? With pics please!!! I'm going to tear into mine in the next week or two.

Question: what flaring tool did you use for the brake and fuel lines?
I've got my head wrapped around the welding and cutting and grinding and bracing and crying about my jeep being in two pieces but I can't find very good info on flaring the lines.
04-21-2014 04:10 PM
chop110
Quote:
Originally Posted by thebestskibum View Post
Chop, where did you get the new E. brake lines?

I assume you got new ones...

I'm thinking of doing this to my TJ after EJS.
I am using Unlimited E-brake lines from the stealership. Part #52013455AB &
#52013457AB for disk brakes
04-21-2014 04:09 PM
chop110
Quote:
Originally Posted by OverkillYJ View Post
I am curious why you went with a CV shaft. I plan on stretching my YJ. Goal is to reduce the driveline angle so I can get away with a 1350 straight shaft and do away with the CV. I have not decided if I will do a complete tub and frame stretch, but after reading every word of this entire thread it is much more likely I will.
I ended up needing the CV drive shaft because of my tummy tuck. The angle was just not going to let me get away with a slip yoke, even with the added 15 inches.

Word of advice, it is very easy to screw up the angles on the frame. If I had to do it over again, I would have put the frame completely on similar jacks and leveled it out before cutting (No wheels touching the ground). Once this is done, you will need to measure the elevation of the rear of frame or better yet, stack some blocks like this guys does to tell him where the end should be once you put it back together. That and I would have done a better job of bracing the frame before cutting. Mine "sprung" after I cut it so now my left corner is 1\2" high.

http://www.virtualjeepclub.com/showt...cook-up-a-TJ-6
04-21-2014 04:06 PM
chop110
Quote:
Originally Posted by Kaoskrewpb View Post
Out of curiosity what welder do you use?

Thanks
Man, I am horrible about updates. I am using a Hobart Handler 190 MIG welder.
04-07-2014 12:26 PM
thebestskibum Chop, where did you get the new E. brake lines?

I assume you got new ones...

I'm thinking of doing this to my TJ after EJS.
03-31-2014 10:05 AM
OverkillYJ I am curious why you went with a CV shaft. I plan on stretching my YJ. Goal is to reduce the driveline angle so I can get away with a 1350 straight shaft and do away with the CV. I have not decided if I will do a complete tub and frame stretch, but after reading every word of this entire thread it is much more likely I will.
03-25-2014 07:41 PM
Kaoskrewpb Out of curiosity what welder do you use?

Thanks
02-18-2014 01:03 PM
chop110
Quote:
Originally Posted by TJK8 View Post
Nice…love to see your progress as yours inspired my build! I drove mine across the parking lot today after 5.5 months…can't imagine waiting 1.5 years!!

Just signed up for Jeep Beach in Daytona…you should attend!
My build may have helped inspire yours, but you and Solman took yours in way cooler directions! Yeah, it was nice to take it out for a doorless spin.
02-17-2014 08:29 PM
TJK8 Nice…love to see your progress as yours inspired my build! I drove mine across the parking lot today after 5.5 months…can't imagine waiting 1.5 years!!

Just signed up for Jeep Beach in Daytona…you should attend!
02-17-2014 08:11 PM
chop110 While the frame is getting fixed, I took the opportunity to cut some sheet metal for the sides of the tub.



I can't wait to ge my Jeep back. There is still quite a lot to do, but it does feel like I am getting closer to completing this. To add to my excitemnet, the Olive Drab Monstaliner arrived today!! Woohoo!! :2thumbsup:
02-17-2014 08:11 PM
chop110 To make it easy on the folks at the frame shop to remove the rear portion of the tub while still having functional brake lights, I used a six pin Deutch connector to tie in the extended electrical rail.



After charging the battery overnight, I placed it back on the Heep and what do you know? It drives! Drove it right out of the garage! There were no exhaust leaks but one of the fuel line connections had a slight leak. I tightened it up some more and it ran like a champ. Huge milestone.



The drive was mostly uneventful, except for the big gap on the floor and the temporary cardboard sides threatened to blow away. Brakes are functional, no wobbles from the track bar, I do need a serious steering alignment after putting in the OME lift... Drove slow the whole way, I am surprised I didn't get pulled over by the fuzz. Yes, I did put the driver's seat and seat belt back in.
02-17-2014 08:08 PM
chop110 More progress:

To attach the rollbar extensions, I used 6 inch long 2" diameter inserts with the same wall thickness as the factory rollbar. I also drilled some plug weld holes for additional hold.



Clamped things down, measured and remeasured to confirm the extension sections are straight and true...



Other side...



Once my extensions are welded in, it becomes pretty obvious that my earlier goof with the frame is messing with the tub alignment.



The cheap option is to shim the body mounts and get on with my life. Unfortunately, this will bug me and knaw away inside of me for many years. If only I hade been a perfectionist back when it really counted; when the frame was being put together.

So I decided to go with the more expensive option and take the Jeep to the frame shop. Luckily the frame shop is only five minutes away from my house and is run by a trusted shop owner. It is the perfect opportunity to test drive the Jeep after one and a half years of sitting idle.
01-21-2014 06:20 PM
chop110
Quote:
Originally Posted by 00tj2 View Post
I'm in the middle of a rear axle swap before I do my stretch and looking back on your pictures I can't believe how clean your frame is!!! I'm so pissed at the snow and salt of the northeast. Keep up the good work!! Can't wait to see the finished product!
Thanks!
01-20-2014 07:49 PM
00tj2 I'm in the middle of a rear axle swap before I do my stretch and looking back on your pictures I can't believe how clean your frame is!!! I'm so pissed at the snow and salt of the northeast. Keep up the good work!! Can't wait to see the finished product!
01-19-2014 09:17 PM
chop110 I pulled my exhaust to complete the welds. I will media blast the joints and paint them for rust protection. Here is a view of the assembled exhaust system after the cat connection:



I also finally got around to putting the tub back on the frame.



The wheel well spaces look huge with the highline and the 33" tires on the OME 2.5 inch lift. I eventually want to go to 35's.

The build is getting pretty exciting now!
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