Re-Imagining our "Beast" build. 4.7- Solid axle- bed conversion

[simplesam88]

So I'm sitting in the shop with my buddy and we're feeling pretty good about what we've done so far. We start talking about all the steps we've taken to get there. We get stuck on what a pain it was to fit the motor. The stupid spacer plate between the engine and Trans. We must have taken the engine in and out 3 times before we figured out the starter moves to the passenger side and that the spacer plate is critical for that and how that stupid rear engine seal needed to be repla....oh crap. There it is on the workbench.

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Here is a good shot of the engine from under with the new engine mount location.

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[simplesam88]

So this thing has always been an awesome rig to drive. It was mostly tired from all the miles. Never trailered always driven to each trail. Early on we removed all the suspension and sent the big pieces out for powder coatings, had the kings rebuilt, and got all new bushings. Since it was in the air already, lets put it back on its own wheels.

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[simplesam88]

Oh yeah, there's the matter of a cooling fan. The new motor is taking up a lot more space. We trimmed the shroud way back. And I fit in a high performance thin fan. We then ran the motor at idle for about 45 minutes. Seemed to stay very cool.

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So now that that's out of the way lets get back to that bed project. The spare tire is going to mount on the new back wall I'm building, so I need to build a mount from the old one that used to be on the bumper.

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[simplesam88]

Thing is with all this it still doesn't have the look of a truck bed. The inside of a truck bed actually looks finished. Well my dad's a tv repairman so I have an awesome set of tools (ok it's a bad movie reference). Here was my solution. I fabbed up some new side walls and a raised floor bed. This will allow some drain holes under it and greatly improve the look.

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Wait, did someone add hinges? What's going on here? Why would there be hinges down there and what happend to the fifth door hinges on the left?

 

[simplesam88]

Ok, so clearly it can't be a truck bed with a fifth door. I struggled here a bit. Problem 1. The hinges need to be really small because we don't want much fold under when the tailgate opens.
Problem 2. Standard barrel hinges like a truck won't work because there is no support to attach to on the driver's side.
Problem 3. Liberty tailgate is round and will interfere with bumper area.
Problem 4. Door handle is on the right and operates downward.
Problem 5. Shop is out of beer. Ugh

 

[simplesam88]

1. Searched a local wrecking yard and looked at several vehicles. I settled on an early 90's BMW X5 tailgate hinges. Small and very strong.
2. I only need to weld in a striker plate on the drivers side. But ill use chevy tailgate latches to secure it.
3. I modified the the bottom of the door using a complex body tool (Ok it was a 2x4 and a hammer).
4. this took a little thinking. I made a "T" fulcrum from aluminum as it has minimal bend compared to steel and won't rust.
5. I convinced the wife, for hydration we would all be happier with more beer.

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[simplesam88]

So now lots of body work, I'm here to tell you. I've sanded off every corner of this rig with my fingertips included. But i did apply a nice base coat primer.

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You might be wondering about those holes from the old window hinges up top. Well, we were thinking about adding some serious back up lights for night wheeling. So I reinforced behind them and relocated the holes to match the mounts.

 

[simplesam88]

Well, we're almost caught up. the big body work is done. I still need to finish some welding on the tailgate and get it back on KJ. The next step after this is to prep this thing for paint.

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[simplesam88]

Lets be honest here. Is the body work perfect. nope. it's pretty good though. I never really spoke much about the roof, but i spent hours fixing where the ribs meet the back. Not done properly, they become perfect little bowls to hold water and rust out. Not anymore on this rig. Now to bring out everyones favorite paint prep tool, the DA with 80 grit, then again the DA with 150 grit.

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Now to mask this up and spray some sealer.

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I think its the moment we have all been waiting for: Jeep Color code PUA or commonly known as GOBI, using transtar bedliner. Now, if you havent done this before and you are going to do a color change. I highly recommend a door jamb and window moulding spray out of your color in regular paint first. This will greatly help your coverage in the hard to reach areas afterwards.

 

[simplesam88]

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[simplesam88]

You ever look at something and say "it looks really close, but, it's missing something"?

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[simplesam88]

I'm thinking here. it looks better for sure, but there is something that will put it over the top. Lets start here.

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Body Mouldings, that the difference. If this was a vehicle that a manufacturer made, they wouldn't leave it looking like this. they would finish it. so I must too.

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[simplesam88]

Well were almost caught up to real time now. Not before I speak a little to these mouldings. So a few months ago I reached out to people to see if someone could help me make some mouldings for this rig. You can not believe the prices I was quoted. If you watch a lot of youtubers you will notice that Bamboo labs is sponsoring everyone (well except me). Their stuff is really nice, but I cannot spend 2 grand for a 3d printer and I dont want to pay someone a grand to make mine. So.. I bought an inexpensive large format 3d printer made by Elegoo, called the Neptune 4 pro. Then I spent a few nights learning how to use Onshape online. I bought about 40 bucks worth of cheap filament and made a few versions of what you see above. Then, I spent another 50 bucks on 2 rolls of abs plastic. Then took them in the shop, stapled, screened, glued, melted and finished them. a lot of pictures are about to follow.

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[simplesam88]

OK, thats it for a while. You are caught up to where we are. I have a group of buddies showing up in a week from all over the country. 2 of them will be focused on building the rear bumper. Myself and the other friend, will be working on the interior. There are lots of mods planned on for the inside of this thing. More 3d printing. Metal CNC cutting and custom wiring for a bunch of accessories. Side note, there isnt a giant horsepower difference between the V8 and the V6, but there is more than 100 foot pounds of torque added. The tires on this thing have a serious traction issue. Then again these are 5+ year old tires and most the weight is off the back of it. Still it is really a Beast to drive. Feel free to ask questions or comments. Ive got thick skin if you dont line something and never so confident that I dont like a new idea.
Oh, I almost forgot. There are videos and real time updates on my instagram. @andys_shop_and_lounge
Fair warning, its not just KJs. I do other jeeps and 4x4s too. I only like interesting projects.

 

[KJowner]

That's an amazing project, looking forward to seeing more.

 

[RonT]

Wow. You are a Navy Seal-level Liberty Build Warrior! Nicely done , sir.

 

[BigMopar440]

Watching this one for sure. I am very interested in the details of swapping in the 4.7.

 

[Luke]

Exxxxcelent!

 

[Pasky]

congratulations, great work

 

[DefCon2]

That is really impressive fab work. Combine it with the engine swap and it becomes all the more impressive. It sounds like the original hacks cooked up a bonafide sh** sandwich. The problem is that it is very hard to change the type of sandwich. But you've made it a gourmet sh** sandwich.