2004 LJ In Flux

I made the tire plate with three options. Partly because I wanted to see the tire in different positions.
Holes to the DS are for a centered tire , holes in the middle would be factory offset to PS, and the holes to PS move it 1.25” more to the PS.
Plate for reference, studs mounted in this location push the tire further to the PS.
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Tire centered.

Tire is bfg 35x12.50x17 for reference.


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Handle clearance in centered location. Opens fine, just close.
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How much it will open when tire is in centered position.
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I am in the middle of my first run of 5 kits. Hinges are $325 shipped and the carrier is $160 shipped. All 5 kits have been spoken for. Next run will be for 10 sets, goal is eventually have a few on the shelf ready to ship.

I take orders via email to [email protected]. I don’t take deposits and don’t bill till parts are ready to ship/picked up. Makes it simple.
 
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Fluxor said:
I am in the middle of my first run of 5 kits. Hinges are $325 shipped and the carrier is $160 shipped. All 5 kits have been spoken for. Next run will be for 10 sets, goal is eventually have a few on the shelf ready to ship.

I take orders via email to [email protected]. I don’t take deposits and don’t bill till parts are ready to ship/picked up. Makes it simple.
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Sounds good! This may have already been discussed, but is there any need to reinforce the hinge brackets on the inside of the tub? Similar to how the exogate does?
 
I’m running a 35x12.50x15 on a 10” wide steel wheel for my test mule. I have not seen any indications that in normal use it’s necessary.

I will also say that max strength is achieved with corner guards and a tailgate skin. Then the issue becomes the latch. The kit will include a aluminum spacer for the body mount factory rubber tire snubber. The spacer will need to be trimmed per your application. Tire needs to be slightly preloaded on spacer to prevent movement from starting.

Keyword slightly. I am working on a install video next week.
 
Fluxor said:
....

I will also say that max strength is achieved with corner guards and a tailgate skin. Then the issue becomes the latch. ...
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The other weak point that no one ever talks about or attempts to address is collapsing the end of the torque box above the right rear body mount.
 
Agreed, that’s why corner guards are helpful in more ways then one.

I could offer a small corner guard but it seems like the wrong answer. If your wheeling you really need full corners, just my opinion.
 
Fluxor said:
Agreed, that’s why corner guards are helpful in more ways then one.

I could offer a small corner guard but it seems like the wrong answer. If your wheeling you really need full corners, just my opinion.
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Rear corners won't do anything to reinforce that portion of the torque box. It's the weight of the tire between the body and the body mount isolater that can collapse the torque box.

This is different than tearing apart the little spot welds.
 
jjvw said:
Rear corners won't do anything to reinforce that portion of the torque box. It's the weight of the tire between the body and the body mount isolater that can collapse the torque box.

This is different than tearing apart the little spot welds.
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Sorry I misunderstood the torque box section you referenced. I gotcha, I would think a aluminum guard or cover plate in that section would help with that issue.
 
Fluxor said:
Sorry I misunderstood the torque box section you referenced. I gotcha, I would think a aluminum guard or cover plate in that section would help with that issue.
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The weight on the hinges needs to be transferred to the top of the isolater in a way that bypasses the torque box.
 
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Also got the aluminum front bumper prototype back from laser cutting. Fit up looks good. Should be able to get it welded and test fit next week sometime.

Should work with factory swaybar. Should work with anti rock swaybar as well. I have a buddy that has one, I’ll need to get it test fit.

All aluminum is 3/16” 6061 aluminum and the lower corner brace/rash guards are 3/16” P.O. Steel. They wrap around the bottom section providing support for hits to the lower section.

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Fluxor said:
Also got the aluminum front bumper prototype back from laser cutting. Fit up looks good. Should be able to get it welded and test fit next week sometime.

Should work with factory swaybar. Should work with anti rock swaybar as well. I have a buddy that has one, I’ll need to get it test fit.

All aluminum is 3/16” 6061 aluminum and the lower corner brace/rash guards are 3/16” P.O. Steel. They wrap around the bottom section providing support for hits to the lower section.

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Nice work Flux. Love that you’ve incorporated those key design elements of the Savvy, and put your own touch on it.

Do you think you could make the rash guard cover more of the corner, a la Savvy?
 
PNW_LJ said:
Nice work Flux. Love that you’ve incorporated those key design elements of the Savvy, and put your own touch on it.

Do you think you could make the rash guard cover more of the corner, a la Savvy?
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Thank you sir! I have always had a great deal of respect for the older savvy designs.

I can make the corner go around it just adds more complexity to rash guard. Are you wanting it go further onto the end cap or wrap around the bottom of the end cap?

I’ll mess with some ideas and post them for discussion.
 
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Fluxor said:
Thank you sir! I have always had a great deal of respect for the older savvy designs.

I can make the corner go around it just adds more complexity to rash guard. Are you wanting it go further onto the end cap or wrap around the bottom of the end cap?

I’ll mess with some ideas and post them for discussion.
Click to expand...

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Excuse the mid-work break drawing, but how about something like this?

It would fully protect that welded corner most likely to be hit, and might be more aesthetically pleasing IMO.
 
Fluxor said:
Also got the aluminum front bumper prototype back from laser cutting. Fit up looks good. Should be able to get it welded and test fit next week sometime.

Should work with factory swaybar. Should work with anti rock swaybar as well. I have a buddy that has one, I’ll need to get it test fit.

All aluminum is 3/16” 6061 aluminum and the lower corner brace/rash guards are 3/16” P.O. Steel. They wrap around the bottom section providing support for hits to the lower section.

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View attachment 511682

View attachment 511683

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View attachment 511688

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I really like that "harder core" corner upgrade. The way you extended the steel out, and bent it back to contact the frame cross-member is genius. I would probably try to extend the top a little bit too, to protect the leading edge corner, but that will be a complicated piece with the extra radius there. However, it is steel, so you could have a second piece welded in.
 
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Mike_H said:
I really like that "harder core" corner upgrade. The way you extended the steel out, and bent it back to contact the frame cross-member is genius. I would probably try to extend the top a little bit too, to protect the leading edge corner, but that will be a complicated piece with the extra radius there. However, it is steel, so you could have a second piece welded in.
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Thanks Mike, I appreciate the compliment and input. I can make running changes to the rash/bash guard. It’s a balancing act. It all just cost money. Lol.
 
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