WK Build Begins

[jsteves]

It looks great Tom! Could you mount the solenoid box under the hood somewhere and run an internal switch to the dash?

[Mtn WJ]

Nice work indeed. Cant wait to see the pics of it finished. Should look like the AEV WK. My guess it may even be beefier knowing Bob had something to do with it.

[Z]

It looks great Tom! Could you mount the solenoid box under the hood somewhere and run an internal switch to the dash?

I'm thinking of putting the solenoid box behind the grill - plenty of room and I have a handy shelf there! The problem is accessing the connector. If I replace the current harness with a trailer harness I could have a nice hinged-door receiver that I could stick anywhere - possibly on the winch cover. The cab isn't a bad idea but I'm trying to keep that as stock-looking as possible.

[Z]

I worked on templates for the end caps. These will be made out of 3/16" steel plate and will attach to the center section via countersink bolts. The bolt heads will be covered by a sheet metal center section.

The templates will be laser cut. The dotted lines on the templates are bend lines and will be perforated by the laser so that we can actually bend with garage tools (will probably need to cut some more with grinder, but the perforations should ensure straight lines). I've seen a few mistakes on theses photos that weren't apparent when the templates were on the WK, so the templates will be fixed before being sent to laser cutter.

[jsteves]

Nice! So are you not reusing the factory fascia?

[Z]

Nice! So are you not reusing the factory fascia?

Nope - want/need something more trail worthy. It's just nice that the factory covers my work in progress.

[mrgc]

Nice build only if you were in australia you can do something similar for my WJ, always wanted a neat way for some more protectection for the rear bar and an integrated winch at the front.

[Rangerwj]

any progress. i love this build cause its so clean. i cant wait to see ur bumper, should be sweet.

[Z]

any progress. i love this build cause its so clean. i cant wait to see ur bumper, should be sweet.

I now have possession of the end cap pieces - laser cut and etched 3/16" plate as well as some 12 ga. sheet metal for the center section.

I also scoured the u-pick-em yard for a washer reservoir to relocate it from behind the bumper to on the firewall. Found a good fit for my purposes from an Eagle Premier.

I now need to fab a mount for the washer and relocate the wiring and tubing.

Sometime in January I hope to finish the bumper. (I have to relocate the washer reservoir first 'cause we're going to tie a triangulated support from the subframe to the the corner of each endcap - the stock reservoir will be in the way of this support.)

[Cody]

Very nice Tom! I really like the WK's.

[CrawlerReady]

Tom that bumper is going to look great! Definitely the best WK I've seen by far

[MoonyJohn]

Yeah, I hope that bumper turns out good. I like it alot! Great WK

[Z]

Thanks for the encouragement, guys. Here's my next installment.

On my 4.7L '08 WK there is a nice spot on the passenger side of the firewall for a washer reservoir:



After scouring a u-pick-it wrecking yard, I found a reservoir from an '92 (?) Eagle Premier that fit my needs nicely - right size and convenient mounting tabs. Here's a shot of the reservoir as well as the bracket pieces:



The bracket assembled with pop rivets:



Front shot of the bracket riveted to the reservoir


Back shot of the bracket riveted to the reservoir


The Eagle reservoir didn't come with a sensor, so after test fitting to the firewall, I found the best location for the sensor was on the back, so I drilled a 7/8" hole for the sensor. (The Eagle reservoir's pump hole works without modification for the WK's pump)


Here's the complete reservoir with sensor and pump attached. I'm hoping the stock pump works fine in a horizontal instead of vertical orientation:


The reservoir (bracket) is mounted to the "firewall" via bolts in holes drilled through to the wiper grill area - pull the weather seal off, pull the grill up to get access to that area. The bolts are pushed through from the back, secured on the front with nuts. The bracket is attached to the bolts and secured with wingnuts (sooner or later the reservoir will need to be removed for spark plug replacement).


Final shot of the reservoir installed. It's filled with water, I'll test for a couple weeks to make sure it holds up and doesn't leak, then I'll lengthen the wiring and hoses and hook up to the Eagle reservoir. (The reservoir leans a little bit right now - if I get really bored I'll try to add support on the bottom to level it.)

[Matt]

If you get to many ideas Tom, you may need to start a business.

Looks great.

[Art]

i love watching this build! keep it up man!

[CrawlerReady]

So....I may have missed this somewhere...but why did you put in the washer fluid reservoir? Just wanted a second one?

[Kraqa]

So....I may have missed this somewhere...but why did you put in the washer fluid reservoir? Just wanted a second one?

ya, the bumpers look amazing!

but whats up with the washer res.

[dp96zj]

Sometime in January I hope to finish the bumper. (I have to relocate the washer reservoir first 'cause we're going to tie a triangulated support from the subframe to the the corner of each endcap - the stock reservoir will be in the way of this support.)

There ya go dudes

[Z]

There ya go dudes

That and with the new bumper the stock reservoir would be exposed and vulnerable.

[CrawlerReady]

AH...well very cleanly done

Looking good Tom!

[SirFuego]

Very nice, sir. Good night, sir.

[ZigsRig]

Tom,

This is a great solution to the problem... Plus, it looks bigger than the stock one.

Nice Work!

[Z]

Progress report. Got the end caps built and nearly ready for paint (they have a few rust spots - sandblast or just POR?)

Here's the structure we built - 2" thick wall square tubing:


End cap shots:








The end caps are held to the mounts via 6 grade 8 countersink bolts. There is also a mounting point on the back side that will triangulate to the subframe just aft of the radiator support.

I'll have a sheetmetal shop bend and cut a cover for the center section out of 12 gauge steel. An access port for the winch cable will be cut into the cover and be hidden (unless in use) behind a license plate holder. This cover will hide the counter sunk bolts.

[D-FRESH WJ]

that is very nice .... i like alot

[jsteves]

Tom, that looks great! I would just take a paint and rust removal wheel to the rust and then paint it.