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CJ5 wild stretch and full build (Big Booty Judy)

Odds and ends today. Made the final filler panels for the center console and closed it out. Ready for bodywork and paint.
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and then started making additional braces for the upper shock towers in the front.
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I just wasn't satisfied with the mounts and was afraid they would crack.
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And then used some squarebody, body mounts as reinforcement washers for the front and mid body mount points.
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Things are getting closer to paint.

Was able to get the coilovers on today on all four corners, and set ride height, plus use the forklift to check for overall travel. Judy's got some long legs under her.

All corners are oversprung, unfortunately.
So I will have to take some measurements, do some math, and figure out the optimal rates and see about exchanging the springs for a correct set.

But, every step forward is progress, even when it feels like a step backwards sometimes.
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This is a pretty wild shot for me to see it all drooped out
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At ride height the fuel skid sits just over the height of the bottom of the rear axle tubes, so it shouldn't drag too bad. Departure angle is great as well.
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Now I just have to find a spot to mount the resi's
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Front travel is pretty wild too.
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Made a dumb thing today. Press dies for my aluminum crusher corners I have yet to build. Should be good up to 3/16 A36 steel. Made out of 4" sch80 pipe.
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the 4" pipe matches the cj corner radius
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and the other 2/3 of the pipe made for a nice transition ramp. The spacing and depth allows me to press past 90*. They still need cleaned up and oiled, but will save a ton of frustration building the corner blanks since nothing will fit with the stretch.
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3/16 aluminum armor in progress
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Made plate extensions to be seam welded to the rear armor sections. These will end up painted body color.
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same for the passenger side
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Still need to build the sliders. Those will be steel, but haven't settled on a height yet, so I left the aluminum long.
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and I peeled an orange especially for you guys.
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Started back in on the side armor today, lot of aluminum work.
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turned out pretty solid after sanding with a random orbital and 80 grit paper. Trimmed the bootom to meet with the rocker armer when i get to it.
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I dig it.
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My setup to try and keep everything flat. The passenger side was cake, the drivers side cracked down the entire weld. Prep, bevel, everything was the same. Same bottle of gas and same batch of wire. I ground and re-beveled with a carbide burr. It still has pinholes, but it's good enough. Still not sure why it did that.
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still looks pretty good though.
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Then I started in on the rear flares
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Still need to sand, and weld on a backing plate (these will be bolt on, and help clamp the side armor down, plus replaceable, if they're ever damaged.
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I'm digging these too.
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Front for comparison.
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They're a hair wider than the fronts for more tire coverage. The slider will have a mini "flare" to meet the bottom of the front portion of the rear flare.
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Awesome progress, the die for the corner guard is cool. Lucked out the radius matched something readily available.
 
Got some more done on the flares this weekend, made and welded the flanges to bolt them on and help sandwich everything.
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and finished both sides.
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Gratuitous side shot
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Started the tire carrier
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37s are still pretty big.
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rough fit up
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tabbed and tacked in.
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More carrier progress. For the record, I am not a fan of stinger style carriers. But they make sense. Drops the tire to the ground to make it easy to load/unload, carries the weight better, tire is more secure and acts as a ramp/extra bumper for the rear, so it got one.
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These little plates were a pain. Inside top got interior sandwich plates,with weld nut to hopefully keep it from cracking the sheetmetal. Two different offsets to keep it off the body.
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upper arms and mounts tacked in.
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About a 1/4 inch of clearance between the gate and the tore when up.
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and a side shot to show it off.
 
I really need a plasma table, because laying out and pilot drilling, then step drilling all these damn holes sucked
...
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But, it was worth it
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then at least an hour of running tge press to dimple die all these holes and different size dies
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I think it turned out pretty clean though.
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Now the carrier is actually finished. I added a third brake light and a license plate mount and light to keep it legal. Third brake light will help pull more attention at stops and hopefully keep some idiot from hitting me.
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I'm not exactly happy with vintage air after receiving the VUZ-A compact 2 heating/AC/Defrost unit. Everything about it nicely built, I will say that. But I bought their 70$ mockup unit that was supposed to replicate size and mounting locations to simplify installation. Actual unit was slightly larger, and completely different mounting as compared to the mockup, as seen below. Luckily I was still able to make it fit, though hoses are going to be extremely tight.
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mounts on front are left and right, high mount, rear right mount, as compared to mockup was non existent. Picked up 4 screws for the motor outlet port for mount
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mockup has left rear mount that matched actual unit. Rear right did not exist, front was a low center strap mount. Low center strap was included in new unit kit, but did not fit any mounts.
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rear mount setup and made to fit original fabricated mounts
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new front mount secured to 2 locations under front of dash.
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As mounted. It is tight. Hoses are going to suck.
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Started this process last as well, drilling, chamfering, and setting stainless ⅜-24 Phillips head screws for the armor attachment.
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Bought a cheap, carbide cutter chamfer tool off Amazon. It wrked phenomenal for this application.
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holes are spaced 6" on center. Figured that should be plenty.
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I guess I should check the fit up of my actual VA ac unit. I also built my mounts off of their mock up unit. I built the mounts and have just had the actual unit sitting in the box just waiting for final assembly.

Thanks for the heads up:beer:

Armor looks great.
 
I guess I should check the fit up of my actual VA ac unit. I also built my mounts off of their mock up unit. I built the mounts and have just had the actual unit sitting in the box just waiting for final assembly.

Thanks for the heads up:beer:

Armor looks great.
I was pretty shocked how completely different they were. I had to spend another couple hours carefully fitting and making new mounts. It was also a lot longer than the mockup, which really had me concerned it wouldn't fit (it also makes the hose connections really tight)

Thanks!
 
Started this process last as well, drilling, chamfering, and setting stainless ⅜-24 Phillips head screws for the armor attachment.
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Bought a cheap, carbide cutter chamfer tool off Amazon. It wrked phenomenal for this application.
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holes are spaced 6" on center. Figured that should be plenty.
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Did you plan out that perfect phillips screw head alignment, or happenstance? :flipoff2:
 
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