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Discussion Starter · #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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In for the fab and payoff. Expect to see some interesting things!
 

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Discussion Starter · #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.
 

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Discussion Starter · #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
 

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Discussion Starter · #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
 

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Discussion Starter · #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
 

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Discussion Starter · #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
 

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Discussion Starter · #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
 

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Very Nice Work!
 

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Getting numb at dentist now. They're are giving me pain meds and said no driving once I start em. So I can't come and play with wrenches :(
 

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Discussion Starter · #20 ·
Metal cloak fenders going on
 

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