Juggy project 2010

[Rugger99]

Here are a few shots of how the Jeep currently sits. I am slowly getting work done to it. Should have the cage ready to finish welding in another week or two. End goal is for a 115" wheelbase, airshocks at all 4 corners and the rear will be all tube that ties into the frame and cage. I still have some spreaders, gussets and door bars to finish on the cage. The tires are 42" Iroks.

[Rugger99]

Few more...

[florida bronco]

Om my god you killed the awesome tj

[Rugger99]

It will be back...hopefully better than it was before. Once you cut the frame, there is really no going back....lol.

[smebyspeed]

sweet, im about the start a YJ juggy, waiting on the tube now

[SwamperCJ]

It will be back...hopefully better than it was before. Once you cut the frame, there is really no going back....lol.

Didn't you go down this road before?:D

[Gary4]

Lay with it bro. it's a time treasured event.

[Rugger99]

Didn't you go down this road before?:D

Lol....yeah, but this round is a bit more on the cut side. it is coming along, slowly but surely.

[Rugger99]

Making some progress...a few pics below. There are several pieces of tubework finished and just waiting on a chance for Greg and I to tack them in place before removing the cage and doing the final welding. These pieces are not in any of the photos below. Hoping to be done by the end of August.

[SwamperCJ]

Looking good!

[Rugger99]

Thanks....hopefully I will have another update by the end of the weekend.

[Rugger99]

Got a few more items knocked out on the Jeep. A few pics for your enjoyment...

[BADACJ]

That thing is going to look really good when completed. That's some nice fab work there John, real nice. I'm glad somebody else is partaking in a project besides me. Mines just not a Jeep or a 4 wheel drive for that matter. Looks Good....

[Rugger99]

Thanks Matt...since I started this project, I have learned that bending tube can be both frustrating and rewarding at the same time...lol.

[toobad4u]

Quick question for ya. Did you have a reason for putting center hoop brace bars that way? Together at the top and spread out at the bottom? It is an interesting idea, but I'm not sure it will actually offer you any structural support. I know it is early in the bending stages, but is doesn't look like you are planning on putting any braces from the bend of the center to the crossbar. Just an observation.

Stephen

[Rugger99]

Stephen,

There were several rigs at both KOH 2009 and KOH 2010 (that took some hard hits) that had B-pillar supports similar to what I am going to run. They are bent at the top for a bit of additional head room. The bracing will continue directly below where the support tubes meet the harness bar and continue down to another piece of tube that runs horizontal between the two B-pillar legs. The design will be much more apparent once Greg and I get all the pieces welded in on the 22nd of this month. I have a bunch of tubing bent/notched that just needs to be tacked into place and then finished welded, kinda hard to have all of the pieces in place without a welder....yeah, Greg is my welder bitch...lol.

[Rugger99]

Greg and Gary came over today and between the three of us, we got alot of work done on the Jeep. A few pics below.

[Rugger99]

Few more... Once again, thanks Greg and Gary...your help and insight are definately appreciated.

[Gary4]

Enjoy helping Jon. We did alot of fabbing, cutting, grinding, and welding. Project is coming along nicely.

[florida bronco]

looks great guys! i see lots of welding, good thing it was a nice cool florida weekend!

[Rugger99]

looks great guys! i see lots of welding, good thing it was a nice cool florida weekend!

yeah, we never even broke a sweat...lol.

[swamp donkey]

boys...sorry i did'nt make it. i did'nt get home till after midnight...so twenty hours up and offshore fishing to boot. my ass was whipped. still sore:D

but on the upside, i got to spend the day fishing with a retired major general of the army. "retired" in march. he was in charge of logistics for Iraq. I've never seen a man brutalize a fifty pound amberjack the way he did.....:D

pete

[TILEMAN]

Yea, 50 lb amberjack, we caught a buzz; does that count? I got a sunburn in the garage. Never seen such a thing.

[Rugger99]

Got a few more pieces of tubework knocked out today on the Jeep. Couple of pics for your viewing pleasure...lol.

[Gary4]

Bout time for some control arms.

[Red Tintop]

It's lookin real good Jon!

You need to finish it up so we can start planin my exo...

[Rugger99]

I'm trying to get this finished...taking a wee bit longer than I had anticipated...lol.

[TILEMAN]

I'm trying to get this finished...taking a wee bit longer than I had anticipated...lol.

Lets get busy

[Rugger99]

Lets get busy

I'm headed out to the garage in a few minutes. Scott, we can get an exo knocked out...how does your schedule look for...ohh...2012?...lol.

[Red Tintop]

I don't know about the schedule, but that fits my budget :D

[Rugger99]

Got a few hours today to work on the Jeep, so here are the latest progress pics...enjoy.

[Gary4]

Helluva jungle gymn

[Rugger99]

Helluva jungle gymn

Smartass....lol. When are we going to get your cage done ?

[Rugger99]

Greg (Tileman) and I worked our collective asses off yesterday. The rear backhalf/cage is 90% finished and the rear axle is set at 115" WB and the four link just needs the lower arms built to finish it up. Few pics for your viewing pleasure.

[TILEMAN]

hotis all i have to say

[Rugger99]

Yeah...it was a bit warm..lol. Thanks for all of your help, couldn't do it without ya man.

[TILEMAN]

Anytime....

[Gary4]

Jon I'm ready as soon as ya'll are. Your back half is looking great. I'm talking about the jeep smart ass, lol.

[Rebel Zuk]

loving it

[Rugger99]

Thanks Grayson...can't wait to get it finished.

[BADACJ]

That upper link truss looks bad ass. Who came up with the idea?

[swamp donkey]

ask gary....

looks good jon.

[Rugger99]

Matt, the truss is made by PolyPerformance. I was fortunate to receive it from Gary for next to nothing, seeing as he had an extra one due to a shipping error on PolyPerformances part. Pete...your alive...lol. Thanks for the complimant.

[Gary4]

Lord works in mysterious ways.

[Rugger99]

As does "Father Gary" ....lol.

[SwamperCJ]

You guys are doing great work, wish I was there drinking a few beers helping you along the way!

[Rugger99]

Thanks Scott...we will be working on mine and Garys July 3rd if you want to swing down for a couple of cold ones.

[Rugger99]

Spent yesterday working on the Jeep, with the assistance of Greg and Gary. The links are done, all cage/back half work is completed (minus mounting the fuel cell and skins) and I still have to get the seats mounted and several loose ends to tie up. Some pics below. The links are 2" .250 DOM with 1.25" heims at each end.

[Rugger99]

I spent several hours trying to figure out a way to tie the A-pillars in to the frame and not loose any clearance under my rockers. The main difficulty to this is the fact that I am still using the Rubicon Express skidplate, which covers the side of the frame and makes it difficult to run a piece of tube to tie in the A-pillar and not limit the ability to remove the skid plate. I ended up internally sleeving the bottom of my A-pillars (1.75" .120 DOM) with 1.50" .250 DOM. This was run through the tub and rocker guards. The tube was welded to the rocker guards and then a piece of 3/16" plate was cut with an 1 5/8" hole. This plate was bent and slid over the tube and welded in place. The excess tube was cut flush to the plate. Another weld was put between the tube and plate and then ground flush. Then, holes were cut in the firewall and a piece of 1.75" .120 DOM was run through the firewall and ties into the A-pillar and to the frame. Hopefully the photos below will help explain what I did. I feel that it is a strong set up, but what opinions do you guys have ? Any constructive criticism is appreciated. Also, Gary and Greg were very helpful with ideas…the final result is a combination of ideas from all three of us.

[Rugger99]

Today I got the links in place, mounted the air shocks and cycled the suspension to see what I might need to adjust. I was pleasantly surprised when the lower links cleared the end of the frame (I was thinking that I would probably end up having to notch it for clearence) and the airshocks did not bind at all while the axle and suspension were cycled. I also talked to Jess today and was relieved to hear that my driveshaft made it to his shop in one piece...should have that back within the next week or two. A few pics for your viewing pleasure.

[Rugger99]

few more...

[TILEMAN]

Damn we do good work when were not drunk.......:D

[Gary4]

I agree bro. you do , do better work when your not drunk. Looking good.

[jeepNfool]

Man that thing looks good....

[florida bronco]

i really like the angle for the top mount on the airshock. looks lined up with arc of axle articulation. great work as always guys.

[Rugger99]

Thanks Bob....I was looking at it after it was fully welded and thinking that I would end up having to re-do the axle airshock mounts. I was very happy when I finally got around to cycling the suspension and saw that everything worked with no binding or clearence issues. And, for the record....it has been a team effort, could not have done it without Greg and Garys physical help and feedback/ideas.

[Rugger99]

I haven't had much time to work on the Jeep lately, but I have managed to get a few things done. I still have the door bars and misc. tabs to add and tie in the A pillar mounts to the frame. Windshield needs to be replaced as well.... I have managed to get the tubes all painted, wiring harness cleaned up, fuel lines run and I have all of my brake line parts in and ready to put on. I am undecided on whether I should make some skins for the rear or not.

[Gary4]

Coming right along Jon.

[swamp donkey]

what are you wanting to make the skins out of? as you know i've got a full sheetmetal shop we can use...i don't have any aluminum....just galvanized steel. say the word and i'll find out out about alum sheets...

how thick? how will you attach?

the Jug is lookin awesome. great work ya'll....

[Rugger99]

I will probably do 1/8" aluminum and attach the skins with tabs/bolts. Thanks for the offer and I will let you know.

[swamp donkey]

i'll do some checking monday about flat sheets. usually 4 x 8' or 5 x 8' sheets. my sheer, brake, finger brake, and pan brake will all handle that.

you need to decide on finish quality....big price diff on aluminum.

mill finish...picture the back of a street sign
polished....mirror, and i think there is one in between...

pete

[Rugger99]

Pete...I will call you today.

[Rugger99]

Took it for a spin today after replacing a bad fuel pump. Got the door bars on and once my harness belt tabs and small tabs get here, the last bit of welding will get finished up. I also decided to get rid of the windshield and frame and tied the A-pillars to the frame at a secondary location. I still need to go through the Jeep from front to back, checking everything over to make sure I didn't miss anything.

[swamp donkey]

leave it to a LEO to be able to drive that rolling menace to society thru tallahassee

prolly shook-up some-o-dem NE folks....messed up a calm sunday morn.....

sweet jon.

here's it hitting "old school"......
http://i71.photobucket.com/albums/i145/lang96/twistin030.jpg

hence...."Jon's Hole". still is. always will be.

here's his best bud...greg:
http://i71.photobucket.com/albums/i145/lang96/4-28-07004.jpg
greg can be aggravating.

as you can tell...i was looking at old photos tonight...
here's one to remember...
http://i71.photobucket.com/albums/i145/lang96/twistin007.jpg
gary stretching his wing...ya'll remember that pic.
http://i71.photobucket.com/albums/i145/lang96/thefourhorsemen.jpg