Alex01 Silver Sport Build Thread

I used the welder to build up material around the holes, quick taps on the trigger, then used the grinder to make them flush filling in pin holes if needed. The next step would have been sanding, bondo, paint, but I skipped the bondo since they will be hidden anyways and it was more of a thing to do.
If you or anyone else has sheet metal holes that require a backer, copper is what I’ve used in the past and is the choice material for giving the backside something that the weld won’t stick to.
 
If you or anyone else has sheet metal holes that require a backer, copper is what I’ve used in the past and is the choice material for giving the backside something that the weld won’t stick to.
I bought a couple of copper backers off amazon with magnets in them. I used it for about a 1/4 of the holes since they had enough room in the back. It definitely makes it easier.
 
Passenger side slider is mocked up.

In the second photo you can see how the backer is cut on @Chris's jeep to accommodate the GR fenders. (Before chris swapped fenders)
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I bought a couple of copper backers off amazon with magnets in them. I used it for about a 1/4 of the holes since they had enough room in the back. It definitely makes it easier.

Okay you need to test out your Jeep in the snow.... You can come weld all the holes in my tube for me. Did you remove any of the paint around the holes before you started to weld the holes? Got an approximate what you had your settings at on the welder?
 
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Okay you need to test out your Jeep in the snow.... You can come weld all the holes in my tube for me. Did you remove any of the paint around the holes before you started to weld the holes? Got an approximate what you had your settings at on the welder?
Lol, maybe once I get fenders back on. My Stepdaughters's dad/family is in Everett so a trip to Washington isn't completely off the table.

The welder was set to 16 gauge on my welder. I have a Miller 211 so it automatically dials the voltage and speed. I grinded the paint off just hair around the hole before welding.
Those are very similar.

This is the one I used the most
https://www.amazon.com/dp/B000VHZHBO/?tag=wranglerorg-20
I also have this one but didn't use it for this project.
https://www.amazon.com/gp/product/B07PRKFD23/?tag=wranglerorg-20
 
Why are you all switching fenders ?
I believe Chris did because he's convinced he's going to smash them on the rocks and wants no flare. I did really because I wanted corner armor, which led me to think I didn't really love the look of the rear MC fender so I figured Genright was the way to go. This then lead to the thought that the MC slider would need to be modified to make work with the GR flares/fenders and may look odd with the savvy corner armor. Which finally turned into why not just change EVERYTHING.

The GR is aluminum and the MC was steel was another factor and so was if I modified the MC stuff then I'd kill any value it had.

Long story short I have an expensive addiction and really enjoy working on the jeep.
 
Also, out of GR, Savvy, and MC only GR and Savvy make aluminum corner armor without the cutouts for the tailgate hinges. With the hinge section uncut I could drop the MORryde bracket on the side of the jeep.
 
Lol, maybe once I get fenders back on. My Stepdaughters's dad/family is in Everett so a trip to Washington isn't completely off the table.

The welder was set to 16 gauge on my welder. I have a Miller 211 so it automatically dials the voltage and speed. I grinded the paint off just hair around the hole before welding.

Those are very similar.

This is the one I used the most
https://www.amazon.com/dp/B000VHZHBO/?tag=wranglerorg-20
I also have this one but didn't use it for this project.
https://www.amazon.com/gp/product/B07PRKFD23/?tag=wranglerorg-20
You know who else is in Everett? Me and @Squatch :cool: Don't forget to wave as you're cruising through
 
At some point I need to take off my GenRight sliders, put the new ones on, and maybe I can weld-up that area that was cut out of the ones that are currently on it to accommodate the GenRight flare. Not sure if that's possible or not, but we'll see.
 
You know who else is in Everett? Me and @Squatch :cool: Don't forget to wave as you're cruising through
I'll hit you guys up next time we venture up there. I need to make sure @Squatch put my OEM body mount bolts to good use.
At some point I need to take off my GenRight sliders, put the new ones on, and maybe I can weld-up that area that was cut out of the ones that are currently on it to accommodate the GenRight flare. Not sure if that's possible or not, but we'll see.
It's aluminum so it will take someone who knows how to do it. It's not as easy as welding steel from what I gather, it will be ground flush though so I guess the welds don't need to be pretty. That's so tiny I can't imagine someone would charge you much. An hour of shop time, assuming it's the minimum, and material Max.
 
That would be from a body shop though right? I don't recall my jeep having an accident on the carfax so it must have slipped through the system. It does look like it was repainted at some point though.
Fiberglass is easy IMO, previous owner could have hit a rock or had a rust issue on that side, cut out the holes and fibered it, nothing wrong with it if it’s done correctly but I don’t think a body shop would have done it
 
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I'll hit you guys up next time we venture up there. I need to make sure @Squatch put my OEM body mount bolts to good use.

It's aluminum so it will take someone who knows how to do it. It's not as easy as welding steel from what I gather, it will be ground flush though so I guess the welds don't need to be pretty. That's so tiny I can't imagine someone would charge you much. An hour of shop time, assuming it's the minimum, and material Max.
I’ll see if I can find a component aluminum welder in that case 👍
 
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I’ll see if I can find a component aluminum welder in that case 👍
I'll see how clean my cut goes. It it isn't a butcher job I'll hang onto the piece for you.
Fiberglass is easy IMO, previous owner could have hit a rock or had a rust issue on that side, cut out the holes and fibered it, nothing wrong with it if it’s done correctly but I don’t think a body shop would have done it
They must have had some skill. I didn't know it was there and soon enough it will be covered again. Thanks for the info.
 
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Also, out of GR, Savvy, and MC only GR and Savvy make aluminum corner armor without the cutouts for the tailgate hinges. With the hinge section uncut I could drop the MORryde bracket on the side of the jeep.
I wish I would have know that before spending hours making an alum. filler to go behind the tailgate support to make it match the corner. I may look at removing both parts and drop a couple lbs