WK Build Begins

[fpkites]

Very nice Tom! Looking forward to seeing it in person.

[KDUB]

Very well done. Looking forward to seeing it in it's complete form. X2 on the wire wheel clean up and some spray paint finish.

[Z]

I'm not sure the wire wheel will get into the pitted areas, but I'll try. Prior to spraying with primer I did strip everything with a flapper disc - maybe I got it all with that. I washed the WK last night - I suppose that if any rust still exists it'll eat through the primer rather quickly and I can use the wire wheel.

Another question - to straighten up some lines I'd like to affix 12 gauge sheet to one plane of the end cap and then flapper-disc a smooth transition on 3 sides (I need to leave the 4 side straight). I can't weld it - would epoxy or JB weld be strong enough to attach 12 gauge to 3/16 plate and hold under the duress of the flapper wheel? (I'd fill any small gaps with body putty).

[D-FRESH WJ]

i personaly think that the flap disc would just rip it off or tear it off .. youd have to get the epoxy spread pritty good . at the body shop we put door skins on with a heavy duty light wate epoxy.

[ZigsRig]

Any more progress on this bumper Z?

[Z]

Any more progress on this bumper Z?

Sheet metal guy is fabbing the center section - on Saturday I saw what he had done so far and it is an absolute thing of beauty. It's amazing what you can do with 30 years of experience and the right tools.

While at his shop he showed me one of his "real" projects - it was a safety gantry - roughly the size and configuration of a street lamp with extra reinforcement. This project cost $100K and it's sole purpose was to prevent a workman from falling (unrestrained) 6 feet. $100K to prevent someone from falling half a story. Seems to me like a hard hat with a chin strap would be a little cheaper.

I also figured out how to re-line my fender well - vinyl lawn edging.

[Matt]

While at his shop he showed me one of his "real" projects - it was a safety gantry - roughly the size and configuration of a street lamp with extra reinforcement. This project cost $100K and it's sole purpose was to prevent a workman from falling (unrestrained) 6 feet.

It must be a government project.

Sounds like the bumper is coming along great, can't wait to see it.

[PassRunnerZJ]

Would cutting the lining and re-attaching it be out of the question? That is what I ended up doing with my front inner-liners. If you knew someone that worked in a frizbee factory you could probably get some scrap sheets.

Look and see if there is a plastics mfg somewhere close that could supply sheeting or (just came to me) pick 'n pull and look at some front truck inner-linners.

[Z]

Would cutting the lining and re-attaching it be out of the question? That is what I ended up doing with my front inner-liners. If you knew someone that worked in a frizbee factory you could probably get some scrap sheets.

Todd -

I don't have any friends in China (Frisbee manufacturer).

I actually like the idea of the vinyl lawn edging - 5-6" strips of pliable, durable vinyl that I can plastic rivet into place. When I'm done it'll kinda look like an armadillo under there.

[ZigsRig]

cant wait to see it....

I'm still exploring my own winch route...

im trying to figure out who made this...

[Z]

Yeah, I was looking for something a little more elegant than that. It's not too bad a solution, though.

[jsteves]

That would block a lot of air flow!

[Z]

That would block a lot of air flow!

Actually not that much. The winch is taking place of the bumper, which would be blocked anyway. There's a big void underneath that mount that would let in a bunch of air. The obstruction in front of the grill doesn't seem to be too bad.

[jsteves]

Actually not that much. The winch is taking place of the bumper, which would be blocked anyway. There's a big void underneath that mount that would let in a bunch of air. The obstruction in front of the grill doesn't seem to be too bad.

Not your design...the pic posted above.

[Z]

Not your design...the pic posted above.

I know - but it's roughly the same design. The only difference from an airflow perspective is the bits that stick out up top.

[jsteves]

The angle is awkward but it looks like the solenoid, light bar, and lights block quite a bit of air flow. I would get one with the seperate solenoid, mount it under the hood or behind the bumper and NOT put on the lights, bar, etc.

[ZigsRig]

Though I do not have a winch on there yet... I haven’t had any issues with overheating at all, at any speed. I’m just wondering how this would affect my jeeps cooling (especially at low speeds) compared to stock. Even towing my ATV trailer, in the 90's down to the sand dunes I never got the temp gage out of its normal operating zone. I wouldn't think the winch being in the way would cause that much "blockage" to increase the heat in my engine to a critical level...

Oh, and i wouldnt have lights on there... not my thing. I have another solution coming for that

thoughts?

[mikskillz]

hey man - nice build. Id like to do the same thing to the rear w/ the 33" spare. I can;t stand mine on the roof but right now its my only choice.

Your front bumper is a little too much for my purpose right now but i wanted to ask you about the stock bumper on the 08.

From the 1 front shot in this thread it looks like you removed the lower air dam. How do the fog lights mount to the front fascia? the approach angle is terrible and i'm trying to find the best way to improve it as much as i can but still keep the unique 08 front grill.

http://www.cardomain.com/ride/3071817

let me know if yo have any insight - many thanks

[Z]

Center cover is almost done. Went for a test fit today - the cover needs a few tweaks to get the fit just right (close the gaps), but here's the current status (I love it):

[Z]

hey man - nice build. Id like to do the same thing to the rear w/ the 33" spare. I can;t stand mine on the roof but right now its my only choice.

Your front bumper is a little too much for my purpose right now but i wanted to ask you about the stock bumper on the 08.

From the 1 front shot in this thread it looks like you removed the lower air dam. How do the fog lights mount to the front fascia? the approach angle is terrible and i'm trying to find the best way to improve it as much as i can but still keep the unique 08 front grill.

http://www.cardomain.com/ride/3071817

let me know if yo have any insight - many thanks

If you look at the AEV WK at that site the lower valence is all black. That entire (black) piece comes off, but there's still fascia material around the center section (where the removable black valence angles upward). The fog lamps are attached to the fascia that's hidden behind the attached valence.

The approach angle with the valence removed (and 4" of lift and 33" tires) is actually very good, though I do have a few scrapes on my fog lamp lenses and outer edges of the fascia.

[ArloGuthroJeep]

I may have missed it Tom, but any plans for protection of the lower radiator?

Bumper looks great

[Z]

I may have missed it Tom, but any plans for protection of the lower radiator?

Bumper looks great

4xGuard skid plate (currently remove) protects that.

[fpkites]

Almost factory Tom, looks great.

[ZigsRig]

Looks great Z...

Cant wait to see the finished project!

[mikskillz]

If you look at the AEV WK at that site the lower valence is all black. That entire (black) piece comes off, but there's still fascia material around the center section (where the removable black valence angles upward). The fog lamps are attached to the fascia that's hidden behind the attached valence.

The approach angle with the valence removed (and 4" of lift and 33" tires) is actually very good, though I do have a few scrapes on my fog lamp lenses and outer edges of the fascia.

yea - Russ over at 4XGuard showed me a shot w/ the valence off. I like the look of the black on mine so i want to try and keep it around the lights and just below the tow hooks. I might try and just trim that lower lip off that hangs down below where the front fender ends. hopefully that will give me increased approach angle and still keep a finished look.

I'm worried about my fog lamps too but those are replaceable, i guess so is the valence too for that matter but why beat it up if you can avoid it.

anyway that bumper you have going looks real nice.

ganna keep watching this post - good luck and thanks for the insight