Build Thread The '80 FrankenJeep frame off reassembly

[Alec79CJ]

I can handle all things drive train, suspension, and chassis related, by I know I like to see things completed efficiently...there's no such thing as quick body work so i had to farm that portion of my build out to someone else!

You look like you're off to a good start though!

 

[shum8]

I can handle all things drive train, suspension, and chassis related, by I know I like to see things completed efficiently...there's no such thing as quick body work so i had to farm that portion of my build out to someone else!



You look like you're off to a good start though!

I guess it would be a huge understatement to say efficiency was NOT my goal..... LOL. It all falls back to the fact I'm too cheap to pay someone to do what I think I can do, but I don't seem to mind paying someone to fix what I screwed up though - is that dumb or what????


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[Belizean]

I think that just means you don't mind taking a chance or risk which is good. No guts no glory as they say

 

[shum8]

Cut a small piece off the sheet of steel for the security box - to test my theory........ I don't own a break, and don't want to pay to have it formed, so I improvised. The scrap is rather reflective due to rust removal with a grinder.... will media blast the final product. Anyway, I cut a kerf about 2/3 thru along the bend line, grabbed a couple pairs of vise grips, and added a little grunt. Formed a nice, tight 90 degree corner with a nice small outer radius - just what I was looking for. Run a bead of weld along the bend, and it oughta look pretty good. Granted the gap on the test bend is rather large, it did allow proof of concept. Material was free, cutting wheels are cheap, allows welding practice ( and we all know how much of that I need LOL ), and allows a very tight outer radius. Here's what the test piece looks like:







I'll get a couple screen shots of the box design - it's about done. I'll throw a few up here tonight or tomorrow.




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[shum8]

Ok - here's a few more pics JFK the overhead box - in wireframe it's hard to tell from which direction you are looking, but it really doesn't matter. Here's all the guts with the door partially open:



Here's the locking section (yellow) from the pistol box

Here's a side hit with all the layers on and visible

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[gert]

That looks pretty sweet, do you have the CAD software on your home computer for your vinyl cutter?


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[shum8]

Both AutoCad and the vinyl cutting software are on my work computer and laptop. The part that caused me the most thinking juice was how to have a strong but hidden hinge. Now that I've got it drawn up, I'll be building it all by hand. Should be interesting........


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[gert]

For sure that sounds fun


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[shum8]

Cut a piece off the full sheet big enough for the box....... got the pattern drawn out (yeah, I know it's purple - I was at work. It's "buliten board" paper. Or purple layout paper)....... now just need to get the piece trimmed down to size, cut the kerfs, fold it up, and weld. Sounds easy when you say it fast LOL.




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[shum8]

Had a couple hours this afternoon after mowing the yard and set out to get the box folded up. Didn't have all the pieces so wasn't ready for welding, but wanted to get the flat cut out and formed. I've always claimed to not be a welder, so now I'll add that I'm no metalworker either.... that being said - here's what I got done today:

Laid out the cut lines and bend kerfs and went after it with the grinder...





Once I got the cutting done, I grabbed the vice grips and parallel clamps, added some muscle, and viola:









Once I get the rest of the pieces cut I'll media blast em all, get it all welded up, and start on the door..... this just might work......


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[Belizean]

You are looking like a metalworker to me. Looks real nice!

 

[shum8]

Did some more cuttin and grindin today. Since the main "shell" is formed up, I needed the bottom rear part of the shell, and an internal piece that will hold the locking mechanism. Once they are formed, I'll probably have to hit 'em with the grinder to make em fit right, but no biggie. Here's the two pieces drawn out....




Used a piece of angle as a straight edge to make the center cut for the bend kerf, then from each side of the kerf, cut the chamfer by holding the grinder at 45 degrees.....





Clamped it down, used the vice grips as leverage, and added a little push....





The other piece has two bends, one from either side. I got the small flange done, then a storm rolled in...... I didn't take many pics of the first piece but took a few more on this one.

And this kinda shut down productivity for a bit....




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[Belizean]

Looking good. We are to a little piece of that action later and tomorrow

 

[shum8]

Got a little more done this morning - no noise, no smell, just a couple cups of coffee, a donut, and some math. Got the fine tuning marked off for the grinder, and the holes and cutouts for the smaller box pieces -



Glad I remembered to do this BEFORE I weld them in...... normally I would have had a Homer moment when I realized I had done it backwards.


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[HackFabrication]

Glad I remembered to do this BEFORE I weld them in...... normally I would have had a Homer moment when I realized I had done it backwards.

 

[Belizean]

Lol

 

[mdeluca]

Nice work...! be sure to explain your welding set up. I'd be real interested and thankful for the knowledge.

 

[shum8]

Thanks- I'm just running a Miller 135 MIG welder. Since most of my heavy welding was done at a buddies house with his much beefier MIG, I picked this one up on the cheap, and it had seen little use. My problem with this one is at its max, it has a 20% duty cycle, and I've always been leery of overhearing it. Recently I've started pushing it, making much nicer welds, and it's done very well. I don't remember the wire dia off the top of my head, but I'll get it this afternoon. And I'm just using straight CO2 for shielding. It has done well on thinner gauge steel, and I'm anxious to get this box welded up. I got the two additional box pieces ready axceptfor a few minor tweaks...









The four hole in the outer piece is the start of the hole giving access to the combination buttons.

If the rain will give me a break, I'm hoping to get the box welded up so I can start on the door.....


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[shum8]

Didn't rain, so I got the shell welded up...... and the bracket that will house the locking mechanism. I was hoping to get the bracket welded in the shell, but I had to give up an hour or so for work so it will have to wait. Here's what I got done, and I'm gettin ready to mount the guts tot he bracket for a test fit.....







I probly should just wait till I get it done and post everything together, but at least this way I can post it while it's fresh on my mind....

I just realized I didn't take any of the outer surface.... let's see if I can take a couple before editing privileges go away...





I hit the edges with an orbital sander - media blast is next before paint...

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[gert]

Man that looks really good, you are inspiring me to make my own under seat storage


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