Nashville TJ's Build - Continued

That'll Buff said:

Finally at the "end" of this thread, ...

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Wow - That was quite the commitment! Thanks for doing so - it's been a cool ride.

I spent a little time this afternoon designing a new cover for the junction block. Here is the prototype - first draft, and it fits perfectly. I feel like I'm getting the hang of Fusion and the Bambu - not to mention it is crazy fun as well.



The inside profile matches the block, and I provided a recess in the roof to accept the tops of the studs. That really keeps it from moving around:









Now that I have the overall fit nailed, I'll work on a way to secure it. This is so much better than the original.

srimes said:

I feel like we (as a group) didn't give you enough congratulations on finding this PERFECT use of scrap material.

Tell us more! How long have you been holding on to it? What was the original use?

I mean really, how often does this happen? More grandchildren is great an all, but THIS is something truly special!

Oh yeah, congrats on the grandkids too.

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Although I know you are joking around a bit, I'll answer because I was equally, and pleasantly, surprised. I have no idea how long I've been holding on to that piece of scrap, and I also have no idea from where it came. My small pieces, tabs, plugs and the like, I drop into this drawer (the bigger, longer stuff is on a shelf). It's eight inches deep, and I'm not exaggerating when I say there must be 200 pounds of metal in there. This stuff always comes in handy - but I do generally have to cut on it a bit...



Oh yeah, and thanks...

gasiorv said:

Being that I model and analyze structure all day (currently I mostly review other people's designs and analysis and provide final approvals). I have no desire to go home and design and model on a computer which is why the garage (with no computer) is my relaxation. For me the last thing i would want to do is fire up solidworks at home to work on my jeep. It is where I practice just old school fabrication which I think probably helps me see the techs perspectives a little more at work. But it is interesting to see what you are all doing with the fusion software and the 3d Printers as a hobbyist. I don't want to do it, but it is pretty cool to see.

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Wait ‘till the home 3D printers get big enough to print you a few body panels, Vic, then you will change your tune….

So I'm beating my head against the wall trying to come up with an elegant way to fully secure the new cover for the junction block, when my very good friend Occam comes rolling up to the shop in his Razor. He says to me, "Why don't you simply replace two of the mounting bolts with stainless screws, coming up through the fender, into the beefy part of the cover."



"Great idea, Occam," I say. "And a very simple solution."

So, I spent about 2 minutes adding two holes to the model, and did the final print in ASA.



Worked like a charm, and more importantly - fits the color scheme.



Since the cover has that recess which accepts the tops of the studs, even secured on only one side it will not move at all. It is dead solid.