05 Flame Red TJ Build

JMT said:
That gives me a lot to think about. Other than fumes during filling up, is there a drawback to relocating the filler neck so that it comes straight up through the floor of the tub in the trunk area?
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Define drawback. We all have our own sets of acceptable levels of execution that define how we do things. No-one who has requested the far easier path of putting the gas cap inside the rig winds up being happy with it. As such, I won't ever do it that way again. Others may not be as bothered or bothered enough to not do it or change it after it was done. That doesn't mean what I did is the best way or even a better way, it just means we like it better than something like this.
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JMT said:
I really like that custom tank.
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I have mixed feelings. It solved a problem, a series of problems. I am not a fan of the effort and cost of cutting up an already expensive tank but it is cheaper than starting from scratch. I wish it were a different design and the peak at the rear was flattened off to the same level I recessed the rollover vent valves so I could push the tank up.
JMT said:
The hoop is interesting too. The frame almost looks doubled up. Hard to tell what I’m looking at there. Certainly one of the coolest things I’ve ever seen.
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That is our standard coil-over hoop. I don't like back half kits, I much prefer the aesthetics of the OEM frame so I try to retain that look. I don't like cross braces between the tops of rear hoops so I build them on a doubled up frame section back there with a pretty robust gusset. Contrary to what some have said, I've never had a single failure or issue doing it that way. This will explain most of how I get by with doing it that way.
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The OEM rear crossmember is boxed in with a front plate. That stops the rear of the frame from being able to rotate inward and allow the hoops to move. The frame is doubled up to allow the frame to be completely cut through for the shock to swing into. The body mounts are picked up by c channels and the two side to side crossmembers that support them also act to prevent the frame arch from moving around. There is a lot of strength in that small area. In case the triangular bits of the body mount support crossmember look odd, this will help. The axle was pushed up to full stuff and then the crossmember was built around the upper arms to prevent contact.
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JMT said:
That hoop is so close to the wall. The filler tube is a work of art.
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The filler neck, filler hose, and gas cap all work, they aren't terrible looking, art it is not.
 
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mrblaine said:
Define drawback. We all have our own sets of acceptable levels of execution that define how we do things. No-one who has requested the far easier path of putting the gas cap inside the rig winds up being happy with it. As such, I won't ever do it that way again. Others may not be as bothered or bothered enough to not do it or change it after it was done. That doesn't mean what I did is the best way or even a better way, it just means we like it better than something like this.
View attachment 546048

I have mixed feelings. It solved a problem, a series of problems. I am not a fan of the effort and cost of cutting up an already expensive tank but it is cheaper than starting from scratch. I wish it were a different design and the peak at the rear was flattened off to the same level I recessed the rollover vent valves so I could push the tank up.

That is our standard coil-over hoop. I don't like back half kits, I much prefer the aesthetics of the OEM frame so I try to retain that look. I don't like cross braces between the tops of rear hoops so I build them on a doubled up frame section back there with a pretty robust gusset. Contrary to what some have said, I've never had a single failure or issue doing it that way. This will explain most of how I get by with doing it that way.
View attachment 546051
The OEM rear crossmember is boxed in with a front plate. That stops the rear of the frame from being able to rotate inward and allow the hoops to move. The frame is doubled up to allow the frame to be completely cut through for the shock to swing into. The body mounts are picked up by c channels and the two side to side crossmembers that support them also act to prevent the frame arch from moving around. There is a lot of strength in that small area. In case the triangular bits of the body mount support crossmember look odd, this will help. The axle was pushed up to full stuff and then the crossmember was built around the upper arms to prevent contact.
View attachment 546052



The filler neck, filler hose, and gas cap all work, they aren't terrible looking, art it is not.
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This is so much work. You have a different approach than those who do a frame back (e.g. motobilt), but you’re able to avoid the sacrifices. There’s a lot of unique things happening in your pics. The hoop and rear crossmember support to avoid frame twist, not supporting the hoops through the rear of the tub, doubling the frame for hoop support, the entire rear crossmember support system, the gas fill tube still on the driver side.

I don’t know if I could do all that. My son-in-law is learning to tig weld, so I think we could modify “a tank.” I really want to have a TJ at 101” WB. I’m willing to take the time to plan it out. Your example is an LJ, so a TJ would be different. I keep thinking about the possibility of a gas filler tube out the back near the taillight, but looking at yours I’m not sure that would be any easier. If I get corner blanks I can decide where I want it and the route to get there from the tank. I’m not happy with the depth of the GR Alien tank. It’s 13.45” deep, which is about 2” deeper than the Savvy gas tank skid and it’s only a 15 gallon tank. It’s still unseen what the outboard would look like relative to the rear of the tub, but there can’t be much room if any at all. Thanks for these great pics and more creative genius. Good perspective for thinking.
 
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JMT said:
This is so much work. You have a different approach than those who do a frame back (e.g. motobilt), but you’re able to avoid the sacrifices. There’s a lot of unique things happening in your pics. The hoop and rear crossmember support to avoid frame twist, not supporting the hoops through the rear of the tub, doubling the frame for hoop support, the entire rear crossmember support system, the gas fill tube still on the driver side.

I don’t know if I could do all that. My son-in-law is learning to tig weld, so I think we could modify “a tank.” I really want to have a TJ at 101” WB. I’m willing to take the time to plan it out. Your example is an LJ, so a TJ would be different. I keep thinking about the possibility of a gas filler tube out the back near the taillight, but looking at yours I’m not sure that would be any easier. If I get corner blanks I can decide where I want it and the route to get there from the tank. I’m not happy with the depth of the GR Alien tank. It’s 13.45” deep, which is about 2” deeper than the Savvy gas tank skid and it’s only a 15 gallon tank. It’s still unseen what the outboard would look like relative to the rear of the tub, but there can’t be much room if any at all. Thanks for these great pics and more creative genius. Good perspective for thinking.
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I do TJ's the same way, mostly. Rules and philosophy are the same. This is a TJ at 104 but no tank under the back.
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starkey480 said:
A medium amount of caution?
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Nope, an abundance of or a medium amount of caution means you are trying to worry about something that may or may not happen. I have a massive amount of experience and know what will happen based on having a rig fall off of 8 jackstands and wind up sitting on the frame with the control arm mounts removed. There aren't many places to get a jack under one when it does that, so I don't want to do that again. Plus, I actually cycle the suspension up hard against the bump stops to see what moves that shouldn't. Hard to do that if they aren't tied down.

It also came within about 1 degree of falling over on its side. I was jacking up the front crossmember to slide a quarter inch thick shim on top of that corner jackstand to level it out side to side. I didn't make it that far before they all tipped over toward me. I ran, I was not able to convince the floor jack to follow me. When it tipped forward, the front of the oil pan landed on the raised jack pad, the rig started over sideways about to land on its side when the floor jack got squirted out from under the pan. That allowed the other side of the frame to drop.

I won't even get under one that isn't strapped down or on tires on ramps or rims.
 
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JMT said:
This is so much work. You have a different approach than those who do a frame back (e.g. motobilt), but you’re able to avoid the sacrifices. There’s a lot of unique things happening in your pics. The hoop and rear crossmember support to avoid frame twist, not supporting the hoops through the rear of the tub, doubling the frame for hoop support, the entire rear crossmember support system, the gas fill tube still on the driver side.

I don’t know if I could do all that. My son-in-law is learning to tig weld, so I think we could modify “a tank.” I really want to have a TJ at 101” WB. I’m willing to take the time to plan it out. Your example is an LJ, so a TJ would be different. I keep thinking about the possibility of a gas filler tube out the back near the taillight, but looking at yours I’m not sure that would be any easier. If I get corner blanks I can decide where I want it and the route to get there from the tank. I’m not happy with the depth of the GR Alien tank. It’s 13.45” deep, which is about 2” deeper than the Savvy gas tank skid and it’s only a 15 gallon tank. It’s still unseen what the outboard would look like relative to the rear of the tub, but there can’t be much room if any at all. Thanks for these great pics and more creative genius. Good perspective for thinking.
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Maybe this is your sign to get a LJ and have two Jeeps. 😬


mrblaine said:
Nope, an abundance of or a medium amount of caution means you are trying to worry about something that may or may not happen. I have a massive amount of experience and know what will happen based on having a rig fall off of 8 jackstands and wind up sitting on the frame with the control arm mounts removed. There aren't many places to get a jack under one when it does that, so I don't want to do that again. Plus, I actually cycle the suspension up hard against the bump stops to see what moves that shouldn't. Hard to do that if they aren't tied down.

It also came within about 1 degree of falling over on its side. I was jacking up the front crossmember to slide a quarter inch thick shim on top of that corner jackstand to level it out side to side. I didn't make it that far before they all tipped over toward me. I ran, I was not able to convince the floor jack to follow me. When it tipped forward, the front of the oil pan landed on the raised jack pad, the rig started over sideways about to land on its side when the floor jack got squirted out from under the pan. That allowed the other side of the frame to drop.

I won't even get under one that isn't strapped down or on tires on ramps or rims.
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Man with how I used to see some guys lifting trucks at the shop, I'm blown away it never happened during my time there. Nothing nearly as in depth of what you do but still seeing people lift vehicles without regard to weight distribution, or locking in the arms, not that it does much for a 8,000 lb truck.... but still....
 
I’ve been busy thinking through my next steps. I’ve got a 5-year plan. It kind of has to be that way because I’ve still got kids and need the back seat. I may end up getting another car for a daily, but I really love driving the TJ.

Picked up a Fluxor front bumper. My wife was like, “What did you do that for? What’s wrong with that one (pointing at my rear bumper 🤣)?”

I didn’t get to wheel at all this Summer. Kinda had to be that way with family priorities. And now I’m going into the busy time of my year. It’ll be this way for nine months. I hope I can carve out some time in January for the rear caliper flip, outboard, and other odds and ends.

I bought seven cans of Aervoe paint which is apparently what @mrblaine suggests for a good aluminum color match. The bumper will stay aluminum and I’ll paint to steel corner guards with the Aervoe.

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I’m working with a friend at our local metal shop to fab up some mid-arm links. We priced it out. I’ll figure out the joints at some point and then we’ll make the links. It looks like a good deal. Hopefully by January. Then I can piece together the rest.
 
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JMT said:
I’ve been busy thinking through my next steps. I’ve got a 5-year plan. It kind of has to be that way because I’ve still got kids and need the back seat. I may end up getting another car for a daily, but I really love driving the TJ.

I didn’t get to wheel at all this Summer. Kinda had to be that way with family priorities. And now I’m going into the busy time of my year. It’ll be this way for nine months. I hope I can carve out some time in January for the rear caliper flip, outboard, and other odds and ends.
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It's cool that you've got a plan. I used to have one, but that's fallen apart with health issues and family priorities. Lately, I've been looking for a built Jeep to buy, but anything I've seen is just somebody else's problem. The inverse of that is me considering selling everything and walking away from Jeeps as a driver. I'd still have a Jeep, but it would be something like a CJ3.
 
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Irun said:
It's cool that you've got a plan. I used to have one, but that's fallen apart with health issues and family priorities. Lately, I've been looking for a built Jeep to buy, but anything I've seen is just somebody else's problem. The inverse of that is me considering selling everything and walking away from Jeeps as a driver. I'd still have a Jeep, but it would be something like a CJ3.
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Maybe you can just wait awhile and see where you are. You’ll need time for the ligament to heal. I injured my patellar tendon on both knees in February. I didn’t do exactly what I should have done till May 25 when I stopped all running, jumping, and bike riding. Last week I just started riding the bike again. Started with 2 miles, then 2, 4, 7. I’m hesitant to go over 8-10. I feel like I missed the whole summer. I want to be able to ski in December. I’ll have to keep rehabing. So little blood gets to tendons and ligaments. Takes a long time to heal. 🙁

You seem to be solving problems with the LJ and happy with the TJ, so maybe just keep going one day at a time. We’re here to support you.
 
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Irun said:
It's cool that you've got a plan. I used to have one, but that's fallen apart with health issues and family priorities. Lately, I've been looking for a built Jeep to buy, but anything I've seen is just somebody else's problem. The inverse of that is me considering selling everything and walking away from Jeeps as a driver. I'd still have a Jeep, but it would be something like a CJ3.
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My dad still wishes I'd bought him a 40's-50's jeep. But he also appreciates being able to hop in the 98 I bought despite his wishes and do absolutely nothing to it for the last 9 years besides let me do oil changes.

That said. I've been itching to do a frame off restoration on a ww2 Jeep. That kind of work reminds me of my grandpa showing me how to wrench
 
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Rickyd said:
That said. I've been itching to do a frame off restoration on a ww2 Jeep. That kind of work reminds me of my grandpa showing me how to wrench
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Definitely like the thought of working on something old. Rebuilt my first engine, air cooled VW, at age 10. The second was the same age, a CJ2. My Grandfather supervised from a lawn chair, with beer/s in hand!
 
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JMT said:
Maybe you can just wait awhile and see where you are. You’ll need time for the ligament to heal. I injured my patellar tendon on both knees in February. I didn’t do exactly what I should have done till May 25 when I stopped all running, jumping, and bike riding. Last week I just started riding the bike again. Started with 2 miles, then 2, 4, 7. I’m hesitant to go over 8-10. I feel like I missed the whole summer. I want to be able to ski in December. I’ll have to keep rehabing. So little blood gets to tendons and ligaments. Takes a long time to heal. 🙁

You seem to be solving problems with the LJ and happy with the TJ, so maybe just keep going one day at a time. We’re here to support you.
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I'm probably more upset than I should be. I've been training for Marathon #64, but that's done for this year. Whoever made up the "golden years" is full of crap. Getting old sucks when your body and mind are not in sync.

As for the Jeeps, they are therapy and I'll have to deal with not being able to do much for now.
 
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Irun said:
Definitely like the thought of working on something old. Rebuilt my first engine, air cooled VW, at age 10. The second was the same age, a CJ2. My Grandfather supervised from a lawn chair, with beer/s in hand!
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Briggs 5hp for me around the same age.

He supervised a 4 bolt main 350 at 14 in the living room. That motor is still running today
 
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