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Old 04-26-2016, 10:42 AM   #1
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Mojave Sand JK-EXT

Part 1

If you keep up with our blog, you may have read about our earlier Mojave Sand JKU build. For this thread, we're gonna cover something a little more unique. The first ever Mojave Sand EXT! Mojave Sand is one of our favorite colors, and we're excited to say that this build will feature 35" tires and a 3.5" AEV lift kit, so stay tuned! Here's what we've got so far:

Pictured above is the stock JK Unlimited Sport with non-matched hardtop and fenders, along with the OEM wheel and tire package. In total, this EXT conversion took about five days, with work beginning Monday morning. First, the hardtop, rear seat, carpet, and everything rearward of the driver's seat was removed. Afterwards, the stock roll bar and J-rails (where the soft-top clips in) were also cut and removed.

Rick Robey, lead on this JK-EXT project, is shown below removing the factory rear corners. All areas where the frame and OEM body panels meet the EXT kit are also prepped, to ensure a clean and proper surface for welding. This prep work includes hammering certain areas of the sheetmetal flat, as well as sanding down some of the OEM Mojave Sand paint. It is very important during this step to remove the factory insulation found behind the rear corners, as this material is flammable. The welds for the EXT kit are close enough to this area to cause a fire, and this would be very hard to put out, as the fire would actually be inside the body of the Jeep! The frame extension is then welded to the OEM frame, with inner plates like the ones seen in our Brute conversion to strengthen the connections.

Once the frame is extended (above), the bed kit can be placed on the new rear crossmember and fit around the original body panels. The lower support of the JK-EXT extension fits inside the existing OEM quarter panel. Once everything is in place and lined up, the kit is welded to the body. Rick is shown below during the welding process, and you can also see the seam sealer used afterwards. This sealant is used to protect against corrosion, as per OEM standards.

End Part 1

Old 04-26-2016, 10:50 AM   #2
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Part 2

Next, the outbound body panels are temporarily fitted and aligned. Once everything is lined up and marked, Rick is shown making adjustments to the fuel door cutout, OEM sheetmetal, and the body panels themselves. While the foam in the rear quarter panels has been removed, there is still a substantial amount housed in the body cavity by the rear door sills. We removed the rubber plug next to the door latch, and throughout the welding process, sprayed water into this area to prevent a potential fire.

Seam sealer is applied to the OE quarter panels to guard against rust, and to help hold the JK-EXT panels in place. Once the body panels are clamped in and everything is double checked, Rick is shown below making the final welds for the new outer quarter panels. Once the welding is completed, the welds and any rough areas are ground smooth in preparation for the body shop. The OEM subwoofer cavity is also plated over at this point.

Now, onto the new truck bed. As most JK/U owners know, the factory sheetmetal is rather thin. As a result, there is both a sub-floor and main floor in the EXT kit, in addition to the Line-X protective coating on the completed build. This lets the EXT carry heavier loads without fear of denting the sheetmetal. First, both surfaces are cleaned and prepped for welding. The sub-floor is added over the OEM subwoofer enclosure, and as corrosion resistance is a must, seam sealer is used for this application as well. Once the sub-floor is welded in, the main floor is added. This floor features ridges, like the ones found in pickup trucks, while the sub-floor is smooth. Below, Rick welds these pieces into place; you may notice that we set a tire and a few brake rotors on the bed during this process. This is to help everything set and dry correctly. Next up, the cab closeout, roll-bar, and hard-top!

Below, the JK-EXT roll-bar is set in place and test fitted to what remains of the OEM roll-bar. The edges of the aftermarket extension may need the primer/e-coating removed to fit inside the OEM roll-bar. This will be a tight fit. Once the roll-bar is in place, the holes for the mounting plate are marked and drilled out. The completed EXT roll-bar will bolt through the floor to another plate on the underside of the vehicle. The cab closeout and hardtop are placed on the EXT. First, the hard-top is bolted down, and the cab closeout is then lined up. Afterwards, the cab closeout is bolted to the body and seam sealer is used to close any gaps.

Once everything is bolted in place, the rear doors, accompanying latches and tailgate are all reattached to the JK-EXT, and the truck is pulled outside the garage, now ready for paint and body work! Stay tuned for the next update with the lift kit and tires, this is going to be one unique Jeep!

End Part 2


Old 04-26-2016, 12:32 PM   #3
Join Date: Apr 2016
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This is interesting
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Old 04-26-2016, 09:15 PM   #4
Join Date: Feb 2016
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New in the Jeep world, but hittin the ground running.
Blacked out Mojave w/ Teraflex Lift, Bumpers & Tire carrier, 35 KO2, Halo Lead Headlights, 20LED bar, Windshield Cubes and more..

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Old 05-04-2016, 08:16 AM   #5
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Looking forward to the next round of updates!

2015 White JKU
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Old 05-04-2016, 09:14 AM   #6
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Beyond cool! Subscribed! Looking forward to the next updates!


2012 Jeep Wrangler Sport 4.88
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Old 06-03-2016, 09:46 AM   #7
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Moving slowly along. Customer builds took precedence over this one but it looks like it will be moving to paint and body here very soon


jeep , jk-ext , mojave sand , unlimited , wrangler

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