Sab-a-dab-a-doo! The back-country LJ build has officially started

[Apparition]

She's a beaute, Clark!

Better be, he already filled the shitter.

 

[RocknLJ]

Wait, isn’t it supposed to be color matched to the console?

 

[sab]

Wait, isn’t it supposed to be color matched to the console?

Yes, but Bambu said it'll take 26 weeks before my 10,000 roll minimum order of Khaki ASA filament ships. Stay tuned! [or not]

 

[RocknLJ]

Nice work as usual BTW!

 

[sab]

After a couple test prints to get the thicknesses dialed in and one aborted final print, a 20 hour print yielded usable (not the most aesthetically-pleasing) pair of dust seals for the cutting brake levers:

The design of those, since they are form-fitted, was pretty complicated and took me quite a long time to get right. What's next? Stay tuned...

 

[FarFire70]

And Bob's your uncle:
View attachment 663001

I'm very pleased with the results, especially given the effort it took to get here. All that's left is my attempt at dust seals for the cutting brake slots, but I'm not confident it'll work. Alas, that'll have to wait a few days. I'm going to go try to put some meat on the ground tomorrow and Tuesday in a cull hunt on a friend's beef cattle farm. I've been waiting (a long time) for some cooler weather because I don't like sweating when I hunt. There's a cold front moving in!

Stay tuned!

Looks great!! Congrats on overcoming the hurdles and getting a great product!

However, I have in mind a way to salvage this print, and I'm wondering what y'all experienced 3D printers think of this plan. As long as that mounting tab is the only damage and it doesn't cause the print to abort, I'll cut off the remainder of the tab, print a new tab with a mounting flange, use 27 clamps on the welding table to hold everything in place like I typically do, and glue the new tab on. So, as I've said several times, I may end up with a bonded, two-piece print after all. Thoughts? Will the bond be strong enough? It would be mainly loaded in shear, which is the best load case for a bonded joint.

Although as I caught up on this thread - I was very disappointed to read this part. 27? You thought that would be enough?





Been fun watching along - can't wait to see your next, even more complicated, prints to come!

 

[B00mb00m]

After a couple test prints to get the thicknesses dialed in and one aborted final print, a 20 hour print yielded usable (not the most aesthetically-pleasing) pair of dust seals for the cutting brake levers:
View attachment 663774

The design of those, since they are form-fitted, was pretty complicated and took me quite a long time to get right. What's next? Stay tuned...

Stumbled on your thread while searching for fastener organizers, did you get the cutting brake levers in?

 

[sab]

Stumbled on your thread while searching for fastener organizers, did you get the cutting brake levers in?

The console is in with the cutting brake levers, but nothing's bolted down, yet. I don't have axles in the rig, yet, so I can't do much more.

 

[sab]

As I've noted before, I've been distracted by other, more pressing things for the last few months. The biggest of those distractions is a massive steel stand that holds a 1,500 gallon water tank for our garden five feet off the ground. It's taken many, many fab hours (about 75 pieces in all), but I'm almost done - one more coat of paint (Sunday, 'cuz it's supposed to be rainy tomorrow.) Then I have to pour concrete footers for the legs, and I'm done!

So, today, while literally watching paint dry, I was able to continue modifying the Flux Offroad spare tire carrier. When I last posted about it in Post #768 (way back in October ), I was just getting ready to cut lightening holes in it. In between then and now, I cut some of the corner holes with the carbide annular cutter I purchased just for this project, but I didn't post on that. Today, I cut the remaining corner holes with the mag drill:

And with all the corner holes cut, I played "connect the dots" with the jigsaw to finish the cutting. Since this is 304 SS, which is hard on tooling, I bought four of these carbide jigsaw blades, hoping they'd do the job:

So, with the new tooling in hand, I set to work cutting them out, a task I've been dreading:

Those blades worked pretty good! I ended up using a compressed air nozzle blowing full-speed on the blade throughout the cuts because it ran very hot! To cut those five pieces out took about 90 minutes, four M18 High Output Batteries, and I used up three of the four blades in the process.

I then used the Dynabrade mini belt sander to clean up the tangent points, followed by radiusing with a pneumatic chamfering tool and hand sanding with some emery cloth to take the sharp edges off. The finished product, with the new tire plate mocked up:

Not quite as pretty as laser-cut holes, but it'll do! Stay tuned...

 

[NashvilleTJ]

View attachment 680806

As I've noted before, I've been distracted by other, more pressing things for the last few months. The biggest of those distractions is a massive steel stand that holds a 1,500 gallon water tank for our garden five feet off the ground. It's taken many, many fab hours (about 75 pieces in all), but I'm almost done - one more coat of paint (Sunday, 'cuz it's supposed to be rainy tomorrow.) Then I have to pour concrete footers for the legs, and I'm done!

So, today, while literally watching paint dry, I was able to continue modifying the Flux Offroad spare tire carrier. When I last posted about it in Post #768 (way back in October ), I was just getting ready to cut lightening holes in it. In between then and now, I cut some of the corner holes with the carbide annular cutter I purchased just for this project, but I didn't post on that. Today, I cut the remaining corner holes with the mag drill:
View attachment 680809

And with all the corner holes cut, I played "connect the dots" with the jigsaw to finish the cutting. SInce this is 304 SS, which is hard on tooling, I bought four of these carbide jigsaw blades, hoping they'd do the job:
View attachment 680810

So, with the new tooling in hand, I set to work cutting them out, a task I've been dreading:
View attachment 680811

Those blades worked pretty good! I ended up using a compressed air nozzle blowing full-speed on the blade throughout the cuts because it ran very hot! To cut those five pieces out took about 90 minutes, and I used up three of the four blades in the process.

I then used the Dynabrade mini belt sander to clean up the tangent points, followed by radiusing with a pneumatic chamfering tool and hand sanding with some emery cloth to take the sharp edges off. The finished product, with the new tire plate mocked up:
View attachment 680814

Not quite as pretty as laser-cut holes, but it'll do! Stay tuned...

But laser cutting has no soul, Scott…

 

[Woodrow]

Beautiful @sab. I think I am a middle ground between you and @gasiorv. Victor will get it done to wheel NOW and it will function well. You will get it perfect every time, and it will also function well but it takes a while.

I just put my extended rockers on for my rear stretch. They are powder coated and match the wheel well cuts in the armor nicely, but in the sunlight, they look like shit. Hopefully they will function well

 

[FarFire70]

View attachment 680806

As I've noted before, I've been distracted by other, more pressing things for the last few months. The biggest of those distractions is a massive steel stand that holds a 1,500 gallon water tank for our garden five feet off the ground. It's taken many, many fab hours (about 75 pieces in all), but I'm almost done - one more coat of paint (Sunday, 'cuz it's supposed to be rainy tomorrow.) Then I have to pour concrete footers for the legs, and I'm done!

So, today, while literally watching paint dry, I was able to continue modifying the Flux Offroad spare tire carrier. When I last posted about it in Post #768 (way back in October ), I was just getting ready to cut lightening holes in it. In between then and now, I cut some of the corner holes with the carbide annular cutter I purchased just for this project, but I didn't post on that. Today, I cut the remaining corner holes with the mag drill:
View attachment 680809

And with all the corner holes cut, I played "connect the dots" with the jigsaw to finish the cutting. SInce this is 304 SS, which is hard on tooling, I bought four of these carbide jigsaw blades, hoping they'd do the job:
View attachment 680810

So, with the new tooling in hand, I set to work cutting them out, a task I've been dreading:
View attachment 680811

Those blades worked pretty good! I ended up using a compressed air nozzle blowing full-speed on the blade throughout the cuts because it ran very hot! To cut those five pieces out took about 90 minutes, and I used up three of the four blades in the process.

I then used the Dynabrade mini belt sander to clean up the tangent points, followed by radiusing with a pneumatic chamfering tool and hand sanding with some emery cloth to take the sharp edges off. The finished product, with the new tire plate mocked up:
View attachment 680814

Not quite as pretty as laser-cut holes, but it'll do! Stay tuned...

Looking good! Congrats on getting back after the Jeep work. I'm hoping to do the same soon.


On another note:

 

[tobiism]

View attachment 680806

As I've noted before, I've been distracted by other, more pressing things for the last few months. The biggest of those distractions is a massive steel stand that holds a 1,500 gallon water tank for our garden five feet off the ground. It's taken many, many fab hours (about 75 pieces in all), but I'm almost done - one more coat of paint (Sunday, 'cuz it's supposed to be rainy tomorrow.) Then I have to pour concrete footers for the legs, and I'm done!

So, today, while literally watching paint dry, I was able to continue modifying the Flux Offroad spare tire carrier. When I last posted about it in Post #768 (way back in October ), I was just getting ready to cut lightening holes in it. In between then and now, I cut some of the corner holes with the carbide annular cutter I purchased just for this project, but I didn't post on that. Today, I cut the remaining corner holes with the mag drill:
View attachment 680809

And with all the corner holes cut, I played "connect the dots" with the jigsaw to finish the cutting. SInce this is 304 SS, which is hard on tooling, I bought four of these carbide jigsaw blades, hoping they'd do the job:
View attachment 680810

So, with the new tooling in hand, I set to work cutting them out, a task I've been dreading:
View attachment 680811

Those blades worked pretty good! I ended up using a compressed air nozzle blowing full-speed on the blade throughout the cuts because it ran very hot! To cut those five pieces out took about 90 minutes, and I used up three of the four blades in the process.

I then used the Dynabrade mini belt sander to clean up the tangent points, followed by radiusing with a pneumatic chamfering tool and hand sanding with some emery cloth to take the sharp edges off. The finished product, with the new tire plate mocked up:
View attachment 680814

Not quite as pretty as laser-cut holes, but it'll do! Stay tuned...

VERY nice job

 

[gasiorv]

Beautiful @sab. I think I am a middle ground between you and @gasiorv. Victor will get it done to wheel NOW and it will function well.

I don't want to ever miss an opportunity to go wheel because my Jeep is sitting on stands, it would drive me crazy. Mine is a toy to go play with and I treat it like a toy.

For others it is a piece of art, for some a daily driver, a resto, a project, a remembrance of a time, time to spend with others, a challenge, a teaching/learning moment, and possibly even a pay check. Whatever it may be, just have fun with it and enjoy the partake and don't take the actual object too serious. There will be an occasional curse word under the breath and a day where nothing goes right, but if you are smiling on most days, you are doing it right.

 

[sab]

But laser cutting has no soul, Scott…

100% true, but it sure looks pretty!

 

[sab]

Beautiful @sab. I think I am a middle ground between you and @gasiorv. Victor will get it done to wheel NOW and it will function well. You will get it perfect every time, and it will also function well but it takes a while.

I just put my extended rockers on for my rear stretch. They are powder coated and match the wheel well cuts in the armor nicely, but in the sunlight, they look like shit. Hopefully they will function well

Yes, it's admirable how quickly guys like Victor and Mac can get things done to go play. My brain's just not wired like that. Plus, I was cast in the fire of professional racing, where the vehicle has to always look good (the sponsors demand it) and DNFs are unacceptable.

 

[sab]

VERY nice job

Looking good! Congrats on getting back after the Jeep work. I'm hoping to do the same soon.


On another note:

View attachment 680882

Thanks, fellers! And, yes, FarFire, I used my clamps (but not all of them)!

 

[sab]

I don't want to ever miss an opportunity to go wheel because my Jeep is sitting on stands, it would drive me crazy. Mine is a toy to go play with and I treat it like a toy.

For others it is a piece of art, for some a daily driver, a resto, a project, a remembrance of a time, time to spend with others, a challenge, a teaching/learning moment, and possibly even a pay check. Whatever it may be, just have fun with it and enjoy the partake and don't take the actual object too serious. There will be an occasional curse word under the breath and a day where nothing goes right, but if you are smiling on most days, you are doing it right.

Like I said, Victor, I admire your spirit. Unfortunately, as an engineer, taking the object "too serious" is my way... On a serious note, I don't consider my LJ a toy; rather, it's a tool. A tool that gets me into remote places to do other things. Broken tools aren't very useful to me, so I treat it that way, both when building and using it.

 

[Apparition]

Like I said, Victor, I admire your spirt. Unfortunately, as an engineer, taking the object "too serious" is my way... On a serious note, I don't consider my LJ a toy; rather, it's a tool. A tool that gets me into remote places to do other things. Broken tools aren't very useful to me, so I treat it that way, both when building and using it.

Two engineers, two methodologies.

I’ll be the third and say get both. One to wheel and one to let sit in the garage with a stack of parts.

 

[ColoJeep]

Two engineers, two methodologies.

I’ll be the third and say get both. One to wheel and one to let sit in the garage with a stack of parts.

Did you get another LJ to sit next to the LS in the garage ?