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CJ5 wild stretch and full build (Big Booty Judy)

Drilled some 1" pass throughs for comm antennas.
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Then took some 1" X. 120 wall, cut and machined to fill the holes and bring strength back to the tube.
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Welded gussets into all the corners where I drilled and buffed holes for electrical pass throughs, to prevent tube collapse in the event of a rollover.
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Then welded the tube strengtheners in place.
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Started on the overhead console and got the bolt pattern drilled in.
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Then installed it. Turned out slick so far.
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After getting it in, I hand hammered all the edges with a dead blow, to help keep its shape and integrity. Will finish the edges with the nglish wheel so they're all flush, even and pretty before I start on the switch panels, and overhead radio installation.
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I guess. Just seems not right to slice and dice the crossmember that is right at the links without adding some back. Car hitch receivers are 3/16 or 1/8 and they use 3/4 or larger plate for the exhaust hoops.
 
arse_sidewards said:
I guess. Just seems not right to slice and dice the crossmember that is right at the links without adding some back. Car hitch receivers are 3/16 or 1/8 and they use 3/4 or larger plate for the exhaust hoops.
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All the links are forward of that crossmember and the upper links are tied directly to the cage mounts. A vehicle hitch has to be rated for a full pulling load, the inertia load (emergency braking) plus a safety factor. Most tube buggies don't even run tube behind the links, just cage and upper shock mounts. I figured if anything, this is overkill since the frame really won't see much if any twisting forces the way the cage is tied in.
 
I still don't know what I'm doing with the exhaust. Tempted to be lazy and run side pipes like most of the old school jeeps. But I haven't even started the header build yet, so there's that.
 
Been a minute, so practicing a little aluminum tig so I can start on the fuel cell shortly. 4045 on 6061 .090 plate @ 100amps AC 25cfm Argon 180 pulse rate.
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1Sinner said:
I still don't know what I'm doing with the exhaust. Tempted to be lazy and run side pipes like most of the old school jeeps. But I haven't even started the header build yet, so there's that.
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I still have those Ice Engine Works blocks if you decide you want to give them a try. I'd think for a simple header design they wouldn't be needed, but for a convoluted mess of tube, they are priceless.
 
See. Not all my welds are sweet. Inside corners on aluminum can suck my balls. Arc jumps around too much to get consistent melt. I got it in, I guess that's good enough.
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Outside corners are tits at 100 amps with this material
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Oblique corners are even more fun. Just dabs right in there.
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And one thing i found that helps on an inside fillet, is 10 more amps. Concentrate the heat on the "base" plate, start the bead and then "walk" it to the vertical plane. Helps tremendously.
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If you have an inverter machine, try leaving the point. If I'm remembering correctly, transformer machines will want pure tungsten and a ball on the end. Inverter machines do not.

I have a inverter machine and a pointed tungsten seems to keep a nice tight arc and better control. I still suck though.
 
Made a little progress on Judy today. Managed to get the cage stuffed back in the body and out of the way til the body goes back on. Managed to knock out the final tie in reinforcement plate for the rear hitch. And built the skid plate for the rear fuel cell so I can begin building the fuel system. All in all a good day
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piece by piece
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Good clearance at full stuff.
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did the calcs on it and looks like I'll end up right around 20 gallons. Not bad, not great, but not bad.
 
Through the sides of the cage (I'm 6ft and fit through easily) or over the harness bar from the front doors. Kids will mostly be the only passengers, others will have to suck it up and climb in.
 
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No updates on the jeep. Been upgrading the motorhome (cut down the old CRT TV cabinet and turned it into storage, and been readying the golf cart for a grand canyon trip this past weekend. Hopefully will be back on this in the next few weeks, but have to get caught up on yard work (weeds are going nuts!).
 
Finally! An update. Been busy with a ton of other house projects and cleaning but since I'm caught up and I had the day, I was able to jump back on the jeep. Started the fuel cell with the aid of CAD. (Cardboard aided drafting) looks like it'll be around 20-22 gallons. Time to order some other parts.
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Do you have room for some hard rubber spacers between the alum fuel tank and the skid? I'd want them on all 4 sides and on the bottom. Would ensure the two don't touch. A little mud and crud mixed with a bit of contact and the alum tank will loose the fight every time. I'd add a few small drain holes in the bottom of the skid so anything that did get in has a place to get out.

Skid and tank look great. Very nice work:beer:
 
gt1guy said:
Do you have room for some hard rubber spacers between the alum fuel tank and the skid? I'd want them on all 4 sides and on the bottom. Would ensure the two don't touch. A little mud and crud mixed with a bit of contact and the alum tank will loose the fight every time. I'd add a few small drain holes in the bottom of the skid so anything that did get in has a place to get out.

Skid and tank look great. Very nice work:beer:
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I do, and I will, just haven't gotten that far yet. Was going to put 5 drain holes in the skid, two at opposing corners will have recessed tank drains (with a short protector welded around the skid holes) rubber in the bottom of the skid and on the sides, and 2 stainless straps over the tanks to keep it from moving.
 
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