Ground-up Flat Fender Build

So... we are working on a flatty. Well we have wagoneer axles and a Chevy drivetrain, but there will be some flatty. In all reality I'm just building a 4x4 that will look like a jeep. Not much jeep, but still a fun build. Hopefully I can retain the nostalgia of the icon while still having a modern and reliable 4x4. Enjoy!

Tuesday, March 27, 2012

Just a glimpse of what this jeep's future holds.

Fenders

I welded up my tow bar mounts. Also good for winch points.
Finished up the skeleton of the highline fenders.

Wheel opening match much better now and I can use more of the available wheel travel.

Thanks for the tailgate dad-in-law. A very nice addition to what is shaping up to be a jeep with some serious character.


I won't cut the hood until I'm absolutely sure I'm happy with the fenders. It is probably pointless to resist though because it looks soo good and I really need the room.

I will probably mount this light bar here for the time being. The front end doesn't look quite so wide and out of proportion now, but it is still pretty wide. I had forgotten how much narrower the body of a flat fender is. On my yj these axles were near stock width. 

Sunday, March 25, 2012

As they say, "OMG".
I took the plunge to get some space for those tires to move.

I will be saving this. Watch for it's special appearance.



OBA pulley
Pumped cleaned up with new clutch installed.

Working on filling in sheet metal and closing in the back area.


A little flex 

Mini light bar with some old lights I've had laying around

Starting mock up of the fenders and realized that I have no where near enough tire clearance. It really stands out against the nice big wheel wells in back. I think I've got a fix though.




Wednesday, March 21, 2012

Overdue Update

I wasn't happy with how my corners turned out and once the inner fenders were attached I couldn't remove the side panels. I built some new ones and am much happier. I just put the seam in a similar spot to factory jeep bodies so it doesn't look too out of place. The two pieces of "angle" are a thicker sheet metal and were used for the seams and for rigidity.

The shape of the new corners is better for mounting lights and much closer to a factory body line.

This is the seam side of the side panel where the corner will bolt up.


You can see some of the inner fender here as well as the hitch receiver that I added recently. It's a tight fit, but I didn't want it to stick out too far.

I have some clean up work to do on the tool boxes, but the two on the outside are for my dual battery setup and the middle one is for tow straps or whatever else. I thought having a toolbox in the floor was an original jeep idea and would be cool to have. It also gives me a totally flat rear cargo area (higher than normal to clear the fuel tank).

Some lights I've had laying around for years. Probably out of my old cj5 from high school, but I don't really remember where they came from. I also had to cut the fuel filler out of the old corner and re-weld it into the new one. 


Friday, March 16, 2012

More Floor

It goes together like patchwork. Hope to finish this up in the next few days. 



Also got some goodies in the mail today. Not that I have time to work on this yet.

Wednesday, March 14, 2012

This project took me forever. It is by far the hardest part to date that I've built. The worst part is that I don't even know yet if I'm going to keep it. I would like to get a custom fit radiator between the headlights. We'll see. The free s10 radiator is appealing though. 
It's a tight fit in there and making the the electric fan work was quite a chore.

The bulk of the work went into this shroud and fan setup. It has to be offset to clear the water pump pulley.

This picture may not show that well, but there is probably a half inch of clearance. A narrower radiator would fit between the headlights and allow for a bit more room, but a narrower radiator would have to be thicker and may end up in the same spot with no room to offset the fan. I'm going to move on for now, but will have to come back to this at some point and make an expensive decision on whether to buy a custom radiator.


Saturday, March 10, 2012

Friday, March 9, 2012

A friend put this together in auto cad and then I had it cut at the water jet. I can clock the tcase flat now.


Also had these cut for the eventual tow bar.


Also went to the wrecking yard and got some bump stops and a brake booster/master cylinder.


Wednesday, March 7, 2012

Bumper is mostly done. I'm pretty happy with the simplicity of it. Scott, is this Warn worthy? Jeeps and the 8274 just go together don't they?

Still have some blending to do.


Finished up all the mounts for my steering box. Only need to box in the bracket.



The jeep is ending up a little lower than I had hopped for. I may have sunk the spring hangers a little too deep in the frame. It may be perfect, but I won't really know until it is nearly finished. Here is a shot with me standing next to it for reference. I'm 5'8" and my head is even with the cage here.


My jeep cruising pose. I don't tell too many people this, but I sit here for hours making vrroooom sounds.