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TJ comp cut, stretch and tube fenders


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#21
Big G

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I didn't take many pics doing the driver's side, as it's the same as the pass.
Here they are completed with the first coat of Bondo brand "Plastic Metal"
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I wasn't happy with how the filler was going to be sitting out in the open, not to mention the 1st part of it was going to be sitting level, and I was affraid it would drip back out... so 3.5" pipe with 22deg cut, some scrap 3/16th and lots of welding and grinding later;
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The liquid metal kinda sucks. I'd get one shot to spread it and it would start to harden up. I JUST made it with one tube... though I'll need a 2nd pass. It was nice to be able to trim it after a half hour with a utility knife
2003 Jeep TJ
6" susp, 1"BL, 6.0L, built 4L65E, 241OR, shaved 14 bolt w/Detroit & Dana 60 w/ARB, 4.56s, 40" Krawlers.

#22
Twister

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are those grinder marks all over ?

#23
Big G

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Yeah, I hit up the surface with the flapper wheel. There seems to be some kinda coating... almost like a paint. Just scuffing it up for my own paint job. I sanded that coat and gave it another coat, another sand, and another coat last night. Tonight's final sand and primer!
2003 Jeep TJ
6" susp, 1"BL, 6.0L, built 4L65E, 241OR, shaved 14 bolt w/Detroit & Dana 60 w/ARB, 4.56s, 40" Krawlers.

#24
Big G

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Not much progress... I hate this part of building stuff... drying takes for EVER!
2 coats of primer, brushed on!
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Color tomorrow
2003 Jeep TJ
6" susp, 1"BL, 6.0L, built 4L65E, 241OR, shaved 14 bolt w/Detroit & Dana 60 w/ARB, 4.56s, 40" Krawlers.

#25
Big G

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Topcoat
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my solution for nutserts that always end up spinning
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installed
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2003 Jeep TJ
6" susp, 1"BL, 6.0L, built 4L65E, 241OR, shaved 14 bolt w/Detroit & Dana 60 w/ARB, 4.56s, 40" Krawlers.

#26
Big G

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Lights installed
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2003 Jeep TJ
6" susp, 1"BL, 6.0L, built 4L65E, 241OR, shaved 14 bolt w/Detroit & Dana 60 w/ARB, 4.56s, 40" Krawlers.

#27
Big G

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Got my link materialUppers 1.75X 3/8 wall
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Lowers 2X1/2 wall
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Forgot to lay out the JJs... tomorrow. LOL
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2003 Jeep TJ
6" susp, 1"BL, 6.0L, built 4L65E, 241OR, shaved 14 bolt w/Detroit & Dana 60 w/ARB, 4.56s, 40" Krawlers.

#28
Big G

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Wanted to go out and get some supplies, so I threw these on in a couple min.
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Don't laugh, they're temporary.
2003 Jeep TJ
6" susp, 1"BL, 6.0L, built 4L65E, 241OR, shaved 14 bolt w/Detroit & Dana 60 w/ARB, 4.56s, 40" Krawlers.

#29
Stainless

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Those fenders turned out great. Good job!

S

#30
Big G

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Well Jeep Jam came and went. I decided not to try to complete the stretch and coilovers in a hurry, or even worse, not complete them in time.

All shined up
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on the ramp... 1150 with the rear shocks having about 2" of uptravel (don't ask) LOL
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On the trail with the Mrs lookin' hot
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2003 Jeep TJ
6" susp, 1"BL, 6.0L, built 4L65E, 241OR, shaved 14 bolt w/Detroit & Dana 60 w/ARB, 4.56s, 40" Krawlers.

#31
Big G

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Started into it 1st thing home... well after a couple hours of pressure washing. LOL

I guess they were closer then I thought. LOL
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before
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nice shot of my stand extensions and axle dolly
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and as she sits now.
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Working tomorrow night wich means I get two weekdays to work at her!
2003 Jeep TJ
6" susp, 1"BL, 6.0L, built 4L65E, 241OR, shaved 14 bolt w/Detroit & Dana 60 w/ARB, 4.56s, 40" Krawlers.

#32
Twister

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looked like it was working well. The longer links will be that much nicer and create a better arc for travel.

#33
Big G

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Yeah it did work well. Made me a little squirmish about ripping into it mid season.... oh well. The grooved Krawlers worked like magic on the rock... I was amazed... and that was at 10psi. I may try 8.

Well, 6 cutting discs, 8 grinding discs, one grinder and 4 hours later the axle housing's clean. That wasn't fun. Frame tomorrow. Pics after.
2003 Jeep TJ
6" susp, 1"BL, 6.0L, built 4L65E, 241OR, shaved 14 bolt w/Detroit & Dana 60 w/ARB, 4.56s, 40" Krawlers.

#34
Big G

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and to give you an idea how much room I'm working with
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Frame #1 cleaned... should be able to finish side #2 tonight.
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2003 Jeep TJ
6" susp, 1"BL, 6.0L, built 4L65E, 241OR, shaved 14 bolt w/Detroit & Dana 60 w/ARB, 4.56s, 40" Krawlers.

#35
Big G

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Well the yoke guard didn't fit over the yoke so I had to buy a 1.5" socket and get disapointed in my crappy little Mastercraft impact. LOL Ended up using a 2', 3/4" drive ratchet and beat on the end with a 5lb maul while holding the yoke with a pipe wrench... it worked.
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Notched the crossmember/ skid for the new brackets... I'll have to reinforce before re-instal.
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Welded and primed some brackets
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2003 Jeep TJ
6" susp, 1"BL, 6.0L, built 4L65E, 241OR, shaved 14 bolt w/Detroit & Dana 60 w/ARB, 4.56s, 40" Krawlers.

#36
Big G

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The exhaust was right in the way of the brackets... so they had to go. Here's the pass side... I bent it away, but may still cut the cat out and re-pipe
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Driver's side. This is going to be an incredible PITA to re-pipe. There's absolutely minimal room between the d-shaft, t-case, crossmember and bracket.
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Axle's in place on tires... just waiting on a 2nd set of eyes to place and measure for links.
2003 Jeep TJ
6" susp, 1"BL, 6.0L, built 4L65E, 241OR, shaved 14 bolt w/Detroit & Dana 60 w/ARB, 4.56s, 40" Krawlers.

#37
Big G

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So, after some measuring and head scratching, it appears that with my current setup even if I french the frame clear to the inside wall... I'll only have 3/4" of clearance between frame and tire for the coilovers. So, some solutions that came to mind were; wheel spacers, different offset wheels, or running single rear wheel hubs on the 14 bolt. I'm going with the hubs. Should give me another 2-3" per side. I'll just worry about tire coverage later. This also has me wanting to go full width in the front to match
2003 Jeep TJ
6" susp, 1"BL, 6.0L, built 4L65E, 241OR, shaved 14 bolt w/Detroit & Dana 60 w/ARB, 4.56s, 40" Krawlers.

#38
Optimus primer

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Were did you get your link brackets?

#39
Mr.Duck

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Those look like TMR brackets.
Do you buy them Pre-welded?
I bought un-welded, not the easiest
FAWK THAT

#40
Big G

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My buddy made them on CAD and had them tacked together when I got them. He'd made at least one internal weld before full assembly.
2003 Jeep TJ
6" susp, 1"BL, 6.0L, built 4L65E, 241OR, shaved 14 bolt w/Detroit & Dana 60 w/ARB, 4.56s, 40" Krawlers.




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