Birty Dastards Jeep Club

Tech Forum => Workshop => Topic started by: ponyracer1 on February 20, 2005, 11:12:21 PM

Title: Long day of fabrication
Post by: ponyracer1 on February 20, 2005, 11:12:21 PM: Spent a LONG day slaving in the garage, this rear bumper is the design I'm sticking with as a base for my tire carrier. Fabbed from 1/4 wall 6X3 mild steel. The tabs you see are what the tire carrier is going to hinge on, also has a 2X2 receiver welded into it that is capable of pulling more weight than my jeep is. ( mainly designed for my 16' quad trailer or recovery point) I removed the factory rear body mount, it will now be intigrated into the bumper mount as it is MUCH stronger than trying to mount the bumper and the body in the same area, both with too small of brackets. Mounts using two 1/2 diameter grade 8 bolts per side, as well as the factory lower bolt that screws up into the frame.

I'm unhappy with the front bumper I made, it will be for sale once I put a prerunner type bar on the front. Or I would sell it as is right now.

Stay tuned to this post as my bender should arrive in about 2 weeks and I will update here as new pics become available.

Let's hope this works...

http://ponyracer.myphotoalbum.com/view_ ... m02&page=1 (http://ponyracer.myphotoalbum.com/view_album.php?set_albumName=album02&page=1)
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Post by: ponyracer1 on February 23, 2005, 12:57:33 PM: Anyone got a yj/cj and a tj to compare? I'm getting ready to build some corner armor and I'm wondering if they have the same profile on the rear corners? I'm going to fab 2 jeeps worth, one for me, one for sale. I may do more if I know they'll fit more than just the tj. I know the plate and the lights are different, I'm just wondering about the overall radius.

I'm going to do something like these, prob with a little more fender coverage, and maybe angle the top instead of bringing it straight across?? What do you guys think?

http://www.spydercustoms.com/index2.html (http://www.spydercustoms.com/index2.html)

Look at crusher corners and crusher flares
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Post by: ponyracer1 on March 06, 2005, 08:39:44 PM: Got a few more pics uploaded. Check out the new design for the bumpers!!! Trents going to have the first one's in a few weeks!!
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Post by: greggmo on March 06, 2005, 10:05:13 PM: smashin. reckon that reciver should hang your jeep up a treat.
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Post by: greggmo on March 06, 2005, 10:18:43 PM: ps. that rear one wont fit on a yj, no way hosay. :(
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Post by: ponyracer1 on March 06, 2005, 10:47:17 PM: Once I get my hands on a YJ for a few hours, I'll figure something out. How much different is a CJ from a YJ in bumper mounting areas? Anyone got some dimensions? Frame width/height, bolt holes on top and bottom, etc.
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Post by: greggmo on March 07, 2005, 12:24:35 AM: cj and yj are almost identical, the one on the tj in the picks that you have made, will not fit at all. the springs hang from where you have mounted the bumper to the chassis. you would need to keep the end plate that you have removed on the tj where the origional one fits.
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Post by: Bubba on March 07, 2005, 07:22:54 AM: hey my litle poney are you gona do tube flat fenders for cj yj tj now that would be sweet bash plates seem a bit yawn to me
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Post by: ponyracer1 on March 07, 2005, 09:35:21 AM: My little pony, my daughter had a bunch of those. I'm doing tube fenders that are as wide or wider than stock to keep you road legal. kind of like the ones on poison spyder customs website, (with add on flairs) except mine will be one piece and not have that ugly joint at the front. Once my bender shows, I'll do a set for mine and upload some pics. Should be in the next few weeks as long as it QUITS FRIGIN SNOWING EVERY TIME I GO OUTSIDE TO WORK, is it spring yet?
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Post by: ponyracer1 on March 07, 2005, 09:38:50 AM: Thanks for the info greggmo, I'll come up with something once I can get a yj to play with. I can gaurantee that it will be about 100 times stronger than stock.
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Post by: ponyracer1 on March 16, 2005, 11:23:44 AM: IT'S HERE!! IT'S HERE!! THE BENDER HAS ARRIVED!! Guess I know what I'm doing this weekend. Stay tuned for pics....
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Post by: paul on March 16, 2005, 11:45:41 AM: ooooooooooooooo!!!!!!!!!! lucky you is it elton john or george micheal? :lol:
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Post by: ponyracer1 on March 16, 2005, 03:44:46 PM: Was that a bad gay joke or did I miss something?
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Post by: Anonymous on March 16, 2005, 04:03:23 PM: Bad gay joke I reckon
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Post by: MK1 on March 16, 2005, 04:08:52 PM: I agree, bad gay joke. Made me laugh though!

Are the Yanks not familiar with the term 'bender'?
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Post by: Manda on March 16, 2005, 04:08:55 PM: Most un-p.c. in fact.
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Post by: paul on March 16, 2005, 04:21:58 PM: glad it made you laugh mark that was all it was ment to do!!!!!!!! should have used the word fag he might have got then!!! to much seriousness about at the moment!!!!!
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Post by: MK1 on March 16, 2005, 04:26:12 PM: Manda.

Please don't ever mention the term or words again. (P.C. or political correctness). It's taking over the country.
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Post by: ponyracer1 on March 16, 2005, 06:18:44 PM: OK THATS IT!! IM TAKING MY TOYS AND GOING TO J33P WHERE THERE'S NONE OF THIS WHITTY BANTER!!

Just kidding, No I was unaware of what the term bender meant. Learn somthing new everyday though. Elton John? You mean he's a...bender? I never would have geussed.....
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Post by: MK1 on March 16, 2005, 06:24:21 PM: Pony.

Just remember. You like to spend all weekend in the garage playing with a PIPE bender.

Remember this additional word and all will be fine. :lol:
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Post by: trent on March 16, 2005, 06:29:55 PM: A weekend all alone in the garage, just you and your own personal BENDER

oh err missus :?
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Post by: Anonymous on March 16, 2005, 07:08:10 PM: Stop being silly now you lot or all your posts will be deleted and you'll be thrown off the site :shock:
Oh sorry wrong site
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Post by: paul on March 16, 2005, 08:01:18 PM: Please don,t bannish me out into the cold!!!! i,m just a poor workin boy who likes to have a joke!!!!!
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Post by: Anonymous on March 16, 2005, 08:32:19 PM: well you are in luck, we like that sort of thing on this site even if other sites dont
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Post by: ponyracer1 on March 16, 2005, 09:44:29 PM: Yup just me and my bender, shame you all are so far away or you could come play with my bender to. I'll post some pics of the new toy on my pic site in the next few days, as well as my new jerry can holder.
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Post by: ponyracer1 on March 27, 2005, 04:59:31 PM: Well I spent my weekend turning a 98 TJ into a 48 willy's, check out my site and let me know what you think. I still have a little work to do but for the most part there done. Built from 1 3/4 CDS (rollcage tubing) and 2 mil flat sheet.

Now I just have the cage to finish, the rear flairs, the front bumper, the rear bumper/tire carrier, nerf bars, and oh hell this thing will never be done.
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Post by: trent on March 27, 2005, 07:05:39 PM: That tj's looking tough :shock:

Flat fenders look good :lol:
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Post by: Anonymous on March 27, 2005, 10:11:19 PM: I did not know that Elton was in to jeeps :smt043
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Post by: ponyracer1 on April 04, 2005, 08:45:27 PM: Got a neat trick for tail lights for TJ owners. Check out my site for pics, may work for yj/cj but cut at your own risk!! Best part is it's FREE, NADA, ZERO, ZILCH, FREEBIE!!!!

All you have to have is balls of steel (or a buddy that will do it for you while you have a pint!!) or a project jeep like me.
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Post by: ponyracer1 on April 16, 2005, 05:05:44 PM: Got a bunch more stuff done on the jeep today, still not ready enough for Ribesford but she'll go next time for sure.

The link to my site is on the first page if you want to check it out.
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Post by: Anonymous on April 22, 2005, 11:52:25 AM: Hi, I'm new to Birty Dastards and have stumbled across this 'chat'. Really interested in your fabricating, what sort of price for a TJ bumper in your pictures?
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Post by: Anonymous on April 22, 2005, 12:10:00 PM: Greetings Matt welcome to birtys
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Post by: MK1 on April 22, 2005, 01:10:02 PM: Chat! some might call it utter bollocks!!!

Hello and welcome.
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Post by: paul on April 22, 2005, 01:46:20 PM: I like it Mark!!!! it,s my turn to laugh now !!!!!:lol: :lol:
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Post by: Anonymous on April 22, 2005, 02:08:57 PM: Utter bollocks isn't that in Mongolia??? :? :?
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Post by: greggmo on April 22, 2005, 07:03:00 PM: welcome mate. ive seen the bumpers made for trents yj and they are a very good job. i am sure pony will answer soon enough.
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Post by: ponyracer1 on April 22, 2005, 10:23:41 PM: If your a Birty I'll do either a front of rear for 150 quid. The price includes the following:

1. You choose the width, trents is a full coverage 57" wide model front and rear. The new front on my TJ is only 44" wide. (see pics on my site, link on first page)
2. You can also choose the angle you want and the distance from the end of the bumper you want it to start. I believe we did Trents 8" in from the end.
3. Shackles, I have recently started using 1"X2" or so solid steel for shackles, with a 7/8 hole which works well for the 3.25 ton shackles.(same ones on the front of mine).
4. Pushbars, Trent got a pushbar because I had some tube laying around and he's a hell of a nice guy. If you want something special it can be done but the tube's not cheap. Best idea is to source your own tubing. 1 3/4 CDS ONLY (45mil dia, 2mil wall)
5. 2X2 reciever hitch in rear with added step/bracing plate.
6. Free mounting, and primer.

Basically you tell me how wide you want, what angle you want and I build them. Once completed you come over and we pull your stock ones and mount the new ones. Once the mounts are fully welded on I coat them in red oxide primer. If you want them top coated, bring your paint and we can spray them then.

Worked very well on Trents, if you have any questions I'm sure he'll help answer them.

I have got my latest shipping of tubing so this weekend I'll be finishing the roll cage and the rear bumper that matches the front.

Oh yea and If anyone wants a matching one like mine it will be 275 quid each. Trents took about 4 hrs of work EACH, my FRONT ALONE took 8 1/2 hrs of work, and it's dirty nasty work that I don't enjoy. Let me know, thanks Phill
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Post by: ponyracer1 on April 22, 2005, 10:26:16 PM: oh yea, thanks for the compliment Greg, Parts By Pony, Hmmm got a nice ring to it.

But I still prefer Young's Custom Fabrication, I'll update my pics this weekend, check out my wind screen banner.
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Post by: Anonymous on April 22, 2005, 10:39:34 PM: Must say Trents did look the dogs reproduct ive bits
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Post by: greggmo on April 22, 2005, 11:13:50 PM: i do think the £150 is a little over priced for home made stuff no matter how good they turn out. think if you start talking around the £100 mark you will do much better. if this is un economical to do i think maybe your stock is costing you too much to start with.or you are making a killing. no offence but if you do want to sell home made stuff, you must come in at a good price atleast to get started.
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Post by: ponyracer1 on April 23, 2005, 07:54:45 AM: The stock isn't that expensive, it's only about 100 quid a stick which is about 4 bumpers worth. It's the labor that brings up the price, and all the other bits like the shackles and the pushbars. After everything is said and done I have nearly 50 quid invested in every bumper I make. Which covers, material, welding wire and gas, sanding discs, etc. So At the end of the day I'm making 100 quid for 4 to 5 hours of shitty, dirty work.

I'm going to try to get into the garage this weekend and build a couple to list on ebay, If they sell I know my price is about right. If they don't then maybe I'll reconsider but they still won't go for less than 125, any less and it's not worth it to do.
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Post by: greggmo on April 23, 2005, 08:01:25 AM: so you gona start this up as a buisness or is it just a hobby?
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Post by: Mike Pavelin on April 23, 2005, 08:46:40 AM: Pony, have you got the right size tube for a 2" reciever socket? I need a piece to convert my XJ tow hitch.
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Post by: ponyracer1 on April 23, 2005, 03:21:01 PM: Greg for now this is a second job, when I return to the states It will become a full time job. Remember the only difference between "homemade" and "store bought" is a sign on the door and a showroom.

Mike, yes I have some 2X2 square stock. you need the part that slides into the bumper that carries the hitch right?

Also I include one piece of that with any of my rear bumpers.
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Post by: Mike Pavelin on April 23, 2005, 05:10:00 PM: I need tube that is just over 2x2" internal that the 2x2" hitch slides into, I only need a small length to modify my UK tow hitch so I can use the US drop hitch and other reciever hitch attachments.
If you've got some, let me know how much you want for a 12" length and how much it weighs and I'll pay you to mail it to me.
Thanx.
M.
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Post by: ponyracer1 on April 23, 2005, 08:34:16 PM: All I have is the metric size, the 2X2 reciever (part with the ball) will slide in but the problem is the Metric stuff isn't perfectly square so you may need to clearance your ball mount to slide in. If you want it perfect with no work I've heard that JC Whitney sells just the peice you need. Sorry I can't help.
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Post by: trent on April 23, 2005, 09:10:36 PM: Mike, i have a section of receiver hitch from ponyracer.
If you want to try it out on yours let me know and maybe we can meet up!
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Post by: Mike Pavelin on April 24, 2005, 09:41:42 AM: Thanks, Pony.

Trent, you're based nearish to me aren't you?
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Post by: trent on April 25, 2005, 05:07:26 PM: Yes, i'm not that far from romford!
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Post by: Mike Pavelin on April 25, 2005, 05:33:55 PM: Why not meet up at the Essex Jeep meet, The Bell, Rettendon, 2nd Monday of the month, you can meet more Essex Jeepers.
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Post by: Anonymous on April 25, 2005, 07:20:42 PM: Carefull Trent think this is a threat

You'll end up with at least 3 Jeeps on your drive as a result :D
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Post by: Anonymous on April 25, 2005, 08:05:34 PM: Been away for a few days, thank you all for your kind 'Welcomes'. Pony racer I will be in touch shortly regarding bumpers. My TJ is probably going to FTE in about a month (or sooner if Steve finds the time!) to have 4.56 gearing and ARB's fitting. Once I get it back I'd like to organise a winch bumper - To open a new can of worms, which winch do you guy's favour, I've got a Warn XD9000i on my landy (yes I'm afraid I swing both ways) which seems to do the job, get another or something else ? Regards Matt
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Post by: ponyracer1 on April 25, 2005, 08:13:20 PM: My money's going to be spent on a 10.5 mile marker hydraulic. If you MUST go electric, 4wd has a decent deal ($569) on a 9.5i superwinch that's set up to use rope because where the brake is. (doesn't heat the drum and wear down your rope) Or so I've been told.

Bumps are no problem, send me a pic of what you want and we'll take it from there. Be a bit easier because I can use my TJ as a template.
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Post by: Anonymous on April 25, 2005, 08:21:13 PM: The last TJ I had came with a Milemarker already fitted and although it was a bit slow (only ran off standard power steering pump) it was very strong and quiet. - Wouldn't have a clue about fitting it though - is this another of your specialist subjects Ponyracer ?
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Post by: Manda on April 25, 2005, 08:35:04 PM: 4WD aren't getting any Superwinch EPi9.0's in until end of July.

But there is a smashing company - P G Winches they have them in stock. The charge about £20.00 delivery. To purchase from 4WD would have worked out almost identical without the duty/VAT, Quadratec also had them in stock but wanted as much with delivery again without duty/VAT.

http://www.winchrepairs.co.uk/index.html (http://www.winchrepairs.co.uk/index.html) (don't be mislead by "repairs", they are brand new)

A few facts about EPi9.0:

Holds 125 foot cable
4.6hp motor
3 stage planetary gearing
Weight 114lbs/51.8kg
Automatic 100% load holding
Gear Ratio 156:1
Empty line pull = 47.1 fpm drawing 33 amps
6000lbs line pull = 9 fpm drawing 230 amps
9000lbs line pull = 6.4 fpm drawing 350 amps

Comes with roller fairlead, pulley block and 15' remote.

We just bought one they seem awesome, easy off and easy on.
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Post by: Anonymous on April 25, 2005, 08:45:26 PM: Manda, is there an issue using the EP9 with Plasma rope?
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Post by: greggmo on April 25, 2005, 08:53:03 PM: it all depends on what you want to spend. the only draw back with the hydraulic ones is that if you have a stalled or drown engine you aint pullin jack... at least with lecky ones you can use just batery if its a desperate situation. shop around and get some spec to compare before you spend...
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Post by: Anonymous on April 25, 2005, 09:15:34 PM: I'm sure the pros and cons of electric winches over hydraulic has all been gone through before - in all honesty an electric winch wont run for long without the alternator charging anyway. The advantage I see of electric over hydraulic is the expense of hydraulic and the ease with which electric are fitted. - However I am new to the idea of certain winches not being compatible with plasma rope and would be interested in more info (on either electric or hydraulic - although I gues hydraulic dont get hot ?)
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Post by: greggmo on April 25, 2005, 09:51:46 PM: any winch with the brake in the drum will potentialy cook the plasma. the ep9 has an end brake so is ideal for synthetic ropes. have a look on the superwinch site. the other thing is that you can get a sleve for synthetic winch ropes.
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Post by: cuffm on May 07, 2005, 09:28:49 PM: Ponyracer,

Its nice to see another flat fendered TJ in the UK, certainly looks like you made a nice job of them. In my case I opted for Poision Spyder flares with sacrificial extensions made of rubber - jeep gets badly abused! Like yours, my TJ is going through some radical surgery, you can see pics of here (http://http://www.j33p.org/board.cfm?ID=1719), we certainly appear to have similar ideas, I flush mounted my rear lights a few back, full write up here (http://http://www.j33p.org/feature.cfm?ID=9). As my metal fabrications works skills are non existant current Jeep surgery is being performed by Ivor Daniels, he has worked on several challenge style vehicles including the Orange Rangey featured in TOR a few months back.

Mike C
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Post by: ponyracer1 on May 07, 2005, 10:18:49 PM: I did see your jeep on the "other" site, looks very nice!! I love the rear mounted winch. Was actually thinking of going down that road myself till I lost me damned mind and ordered a Harley. Sadly the TJ must now find a new home. She should be up for sale in the next month or so.
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Post by: ponyracer1 on May 22, 2005, 11:46:47 AM: Loaded some new pics on my site. Almost in "ready for sale" condition. MOT will be done in the next couple of weeks.