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Going Commando

Thanks guys 🤘 I ran into some issues with the axles going in the Commando, but finally got that sorted out! I'm just about done with painting the chassis and the front and rear end should be ready for pickup here in the next few days I'm hoping. Motor/trans are all painted up and just need to do a quick spray on the leafs to get everything looking fresh for reassembly. I know I've said it before... 😅 Soon I will post up a little progress update with pics!

Don't wanna derail too much on this thread, but I'll post up a few more progress pics on my housing once I get a little more to show. I've begun welding up the knuckles and just waiting on a few parts from Send cut send to show up before I can wrap them up and press in some ball joints.
 
Very cool build!! You are very talented!! I would like some more information on the knuckles that you built. I'm guessing they are built to run 05+ outers with ball joint eliminators?
 
Blase said:
Very cool build!! You are very talented!! I would like some more information on the knuckles that you built. I'm guessing they are built to run 05+ outers with ball joint eliminators?
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Yes and no lol The inner C and knuckle is based off 05+ geometry (12.5 deg inclination), but I didn't wanna be cornered into a 8 lug only bolt pattern. The knuckle will be a hybrid that uses a 99-04 Unit to allow 5 and 6 lug wheel options. I know the argument most will make is that I'm now limited to a smaller u-joint, but all goes back to my use of the rig. It's a hardcore mountain jeep at the end of the day lol the chromo 60 stuff in the KP setup I have in there now has held up to everything I've asked of it so far. If there becomes a strength issue I could always go RCV's if stuff starts breaking. At the end of the day its more or less for fun and just trying something new out.
 
Since it seems like I love to get off topic here's some more progress on the axle build. Finally got the upper and lower ball joint housing machined and welded up to their receivers. Once that was done the knuckles could finally get welded up 🙌 3D printed the arm so I can set the lower double sheer tab, but haven't made it that far yet.
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Not the correct hardware, but couldn't help but bolt it up. Planning to use 5/8" 12pt fasteners

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Thank you for sharing the work you do. Not only is it inspiring but it is flat out the most Artistic fab I have ever seen on a rig. I can't be the only guy out here who takes a deep breath every time I imagine welding up one of those parts lol!
 
Meddler1 said:
Thank you for sharing the work you do. Not only is it inspiring but it is flat out the most Artistic fab I have ever seen on a rig. I can't be the only guy out here who takes a deep breath every time I imagine welding up one of those parts lol!
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I appreciate it! When it comes time for the welding that's my sigh of relief lol the "hard part" of fitting is over and I can relax!
 
I couldn't weld that well in my best of dreams--holy crap what art work, absolutely beautiful and amazing work is all I can say!!!
 
So is the 3D print just for mock-up? Is that going to be an aluminum arm in the end and it was easy enough to transfer the file to 3D print?
 
fl0w3n said:
So is the 3D print just for mock-up? Is that going to be an aluminum arm in the end and it was easy enough to transfer the file to 3D print?
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It'll actually be steel because I plan to weld in the boss to correct the angle. I would love to do 7075 but the stock material would just have to be so large to start with and I'm cheap.
 
Holy Chit it's been a minute... Yes, I've made some progress and yes I forgot to take a tone of pics. :shaking: Painting the chassis was a complete shit show and ended taking it down to to get blasted to start fresh. Once blasted, it got a good coat of self etch and ended up using Rustoleum bed liner from a can for final coverage (Same product I used on my jeep) Gloss Dark Grey was the secondary color I used on everything else.


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I was originally thinking of side exit exhaust, but ended up going all the way out back so now I need to move fuel pump farther up on the rail to get away from exhaust. Other than that, I need to finish running brake lines and then I can push the jalopy back outside and tarp it to bring in the tub to start prepping that for reinstall.
 
Since it seems like I love to get off topic here's some more progress on the axle build. Finally got the upper and lower ball joint housing machined and welded up to their receivers. Once that was done the knuckles could finally get welded up 🙌 3D printed the arm so I can set the lower double sheer tab, but haven't made it that far yet.
IMG_20221117_064955042.jpg

Simple'72CJ said:
IMG_20221122_111216986.jpg


IMG_20221122_111124216.jpg


IMG_20221122_145655157~2.jpg


IMG_20221122_145714078.jpg


IMG_20221123_061621741.jpg


Not the correct hardware, but couldn't help but bolt it up. Planning to use 5/8" 12pt fasteners

IMG_20221123_062750581.jpg


IMG_20221122_145648449~2.jpg
Click to expand...
WOW!! I mean just WOW. Blown away by the skill it takes to design and then execute a custom set of inner and outer knuckles like that. I'm assuming these were all designed in CAD before Mfg. started? Any idea if you've saved any weight over 99-04 knuckles?
 
Blase said:
Since it seems like I love to get off topic here's some more progress on the axle build. Finally got the upper and lower ball joint housing machined and welded up to their receivers. Once that was done the knuckles could finally get welded up 🙌 3D printed the arm so I can set the lower double sheer tab, but haven't made it that far yet.
IMG_20221117_064955042.jpg


WOW!! I mean just WOW. Blown away by the skill it takes to design and then execute a custom set of inner and outer knuckles like that. I'm assuming these were all designed in CAD before Mfg. started? Any idea if you've saved any weight over 99-04 knuckles?
Click to expand...
Yes, I did lots of CAD work to get a design nailed down and then ran multiple FEA's to pin point stress points in comparison to a factor '05+ inner C through a bunch of different loading scenarios. Sadly I don't have a '99-'04 or '05+ laying around to compare weight but I'm hoping its pretty substantial. Since it uses '05+ Inner c geometry I'd love to get a weight of a fully loaded knuckle with factory caliper and rotor. This housing is getting vented 13.250" rotors, aluminum hat, and 6 piston Aerolite's which is gonna save a ton of weight right there I would imagine. As the housing sat in the last photo it weighed 221 lbs if I remember correctly. Overall, the axle as whole should be quite a bit lighter and even if its not it's been a fun little project to pick away at.
 
I assume that Rustoleum bed liner can take a beating better than regular Rustoleum paint? My plan has been to roll on Rustoleum Pro Paint on everything on my rig inside and out.

All I care about is a paint job that looks good from ~5 miles away, but want it to be tough.
 
gt1guy said:
I assume that Rustoleum bed liner can take a beating better than regular Rustoleum paint? My plan has been to roll on Rustoleum Pro Paint on everything on my rig inside and out.

All I care about is a paint job that looks good from ~5 miles away, but want it to be tough.
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I painted my cage with Rustoleum 2X Satin and its chipping like crazy... The chassis has held up great, only a few spots where its coming off but in the expected areas (sliders, tow points, rear bumper, etc.). It has a light texture to it, but if you can get past that its fantastic. Easier to clean than you would expect and lays super nice and touching up is seamless. I would definitely recommend picking up a can and doing a test on some scrap or what not to make your own opinion, but I'm definitely a fan!
 
Are you going to be running conventional BJ's? Or, are they the deletes and I'm just a blind idiot?
 
Cowboy63b said:
Are you going to be running conventional BJ's? Or, are they the deletes and I'm just a blind idiot?
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Im kinda torn to be honest. I wanted to see how install went with regular ball joints first and see if there were any issues with binding. Part of me wants to run whats installed currently and just keep an eye on it for wear and do a delete kit down the road. We will see though, I may get a wild hair.
 
Simple'72CJ said:
Im kinda torn to be honest. I wanted to see how install went with regular ball joints first and see if there were any issues with binding. Part of me wants to run whats installed currently and just keep an eye on it for wear and do a delete kit down the road. We will see though, I may get a wild hair.
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I'm in the same boat. I've been wanting them for my J20, and since I'll be using the same front axle in my C104, I can do do a direct comparison with age.
 
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