1. Registration trouble? Please use the "Contact Us" link at the bottom right corner of the page and your issue will be resolved.
    Dismiss Notice

Varg In Jeep's Clothing

Discussion in 'Builds and Fabricators Forum' started by ITLKSEZ, Aug 20, 2015.

  1. Dec 10, 2015
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor 2021 Sponsor

    USA
    Joined:
    Oct 25, 2006
    Messages:
    5,577
    Thank you for teaching me how to make much better parts
     
  2. Dec 11, 2015
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
    Joined:
    Aug 13, 2015
    Messages:
    6,384
    I reached a major milestone last night with the B230 engine actually sitting in the Willys frame under its own support! Only 2 week's worth of staring, pattern making and fab work to make this engine cradle and motor mounts.

    Front:

    [​IMG]

    Rear:

    [​IMG]

    Passenger's side:

    [​IMG]

    Driver's side:

    [​IMG]

    Here's what I ended up with for ground clearance.

    [​IMG]
     
    Last edited: Sep 20, 2017
    Valentino84 likes this.
  3. Dec 11, 2015
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor 2021 Sponsor

    USA
    Joined:
    Oct 25, 2006
    Messages:
    5,577
    Holy Carp!
     
  4. Dec 21, 2015
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
    Joined:
    Aug 13, 2015
    Messages:
    6,384
    When I started this 6 years ago, I designed the cage mounts to double as body mounts, and built massive rubber-bushed outriggers off the sides of the frame. Well, 3a frames are so weak, the lightest of weight twists the frame in a massive way. There's no way my plan will work without some sort of structural improvement.

    I designed a removable (although I never plan on removing it) crossmember to tie the frame together that will go under the transmission, and will have holes in it to accept the exhaust on the passenger's side, and the wiring and fuel lines on the driver's side. It would also have a flat landing with sleeves to mount a carrier bearing for the 2-pc front driveshaft. There are captured nuts underneath for the belly pan.

    [​IMG]

    [​IMG]

    I made some matching plates with captured nuts and frenched them into the frame. 2 weeks worth of work culminated yesterday for a perfect fit.

    [​IMG]

    I test-fit the carrier bearing and it really didn't end up where I'd hoped. Too high.

    [​IMG]

    I decided to cut out that section of the crossmember and drop it as far as I can. I can always shim it up if I need to. This...

    [​IMG]

    [​IMG]


    ...turned to this. (The welds on the underside look goofy because I was filling the massive gaps I made from grinding that piece out.)

    [​IMG]

    [​IMG]



    Much better.

    [​IMG]

    Next up is the t-case mounts.
     
    Last edited: Sep 20, 2017
  5. Dec 21, 2015
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor 2021 Sponsor

    USA
    Joined:
    Oct 25, 2006
    Messages:
    5,577
    really nice, cool engineering and fabrication.
     
  6. Dec 21, 2015
    homersdog

    homersdog Tulsa, Ok 2023 Sponsor 2022 Sponsor 2021 Sponsor

    Tulsa, OK
    Joined:
    Jan 8, 2012
    Messages:
    2,131
    Incredible design & craftsmanship! You need to be doing this for living. Again.
     
  7. Dec 21, 2015
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
    Joined:
    Aug 13, 2015
    Messages:
    6,384
    Thanks guys! If someone would pay me to do this, I wouldn't hesitate. Good times.


    Here's a shot of the driver's side.

    [​IMG]
     
    Last edited: Sep 20, 2017
  8. Dec 22, 2015
    tymbom

    tymbom Member

    Siskiyou Co.
    Joined:
    Jun 13, 2012
    Messages:
    770
    Stuff like that is why I love forums like this... Giving me ideas...
     
    ITLKSEZ likes this.
  9. Dec 23, 2015
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
    Joined:
    Aug 13, 2015
    Messages:
    6,384
    I started working in the t-case mount last night. I tacked the basics together, fit it, and realized the stiffener cups (they'll all get gusseted together) are way too tall and will interfere with the front driveshaft flange. Redo.
     
    Last edited: Sep 21, 2017
  10. Dec 23, 2015
    fesser

    fesser Napa, CA 2022 Sponsor 2021 Sponsor

    Napa, CA
    Joined:
    Oct 16, 2014
    Messages:
    541
    I really like how you incorporate curves into your parts. They end up looking better than factory. When I try my hand at fabrication the parts usually have nothing but 90 degree angles. You do very nice work.
     
  11. Dec 23, 2015
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
    Joined:
    Aug 13, 2015
    Messages:
    6,384
    Thank you.
    I think a lot about the Shaker design philosophy when building this stuff -

    “Don’t make something unless it is both necessary and useful; but if it is both necessary and useful, don’t hesitate to make it beautiful.”
     
    Bajatransit and Whitetail59 like this.
  12. Dec 29, 2015
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
    Joined:
    Aug 13, 2015
    Messages:
    6,384
    I finally got caught up on shoveling and plowing the white stuff and had some time last night to work on this t-case mount.

    [​IMG]

    All of that webbing is necessary to stiffen the plate because I don't have the clearance to add any gussets on the backside of the mount.

    [​IMG]

    Hopefully I'll have time to finish this mount and move onto the driver's side tonight. I still have no clue what I'm going to do on that side.
     
    Last edited: Sep 20, 2017
  13. Dec 29, 2015
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor 2021 Sponsor

    USA
    Joined:
    Oct 25, 2006
    Messages:
    5,577
    I really like the gusseting and the unique way you have deign these parts. It gives me ideas and I can only hope I am patient enough to build them when I need them.
     
    ITLKSEZ likes this.
  14. Dec 30, 2015
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
    Joined:
    Aug 13, 2015
    Messages:
    6,384
    This is going to make for an interesting floor. :)

    I got the frame plate cut out, nuts welded inside the frame and the support arms made. I had to go high to get up and over the exhaust. I tucked the bushing mount in the recessed corner area of the D300. I managed to keep the whole mount lower than the highest point of the t-case, so although the tunnel will be high and wide, it will be flat.

    It gets boxed and welded tonight.

    [​IMG]

    [​IMG]

    I have an interesting idea to incorporate a narrowed version of the under-seat toolbox....
     
    Last edited: Sep 20, 2017
  15. Dec 31, 2015
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
    Joined:
    Aug 13, 2015
    Messages:
    6,384
    I got the t-case mount finished last night.

    [​IMG]

    [​IMG]

    And I got the driver's side mount mocked up. I'm working on the templates for the bushing-to-frame connections.

    I decided to work off the trans/t-case adaptor for two reasons. One, to distribute the stresses over a wider area (rather than just two or three bolts), and two, because the thought of making another wildly intricate mount doesn't sound like fun at this point. :p I have my limits.

    [​IMG]
     
    Last edited: Sep 20, 2017
  16. Dec 31, 2015
    tymbom

    tymbom Member

    Siskiyou Co.
    Joined:
    Jun 13, 2012
    Messages:
    770
    Are you planning to box the frame?
     
  17. Jan 1, 2016
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
    Joined:
    Aug 13, 2015
    Messages:
    6,384
    Yes, but absolutely last. I have a lot of captured nuts to weld inside the frame for belly pan, gas tank, fuel pump, exhaust, etc... mounts. I want to make sure all of that is complete before I close it up. All of the high-stress plates I'm tacking in now are fish-mouthed 3/16", and the rest of the boxing will be 1/8" and stitch welded in behind them.
    Thanks for watching! I'm always curious if anyone is out there. :)
     
  18. Jan 1, 2016
    homersdog

    homersdog Tulsa, Ok 2023 Sponsor 2022 Sponsor 2021 Sponsor

    Tulsa, OK
    Joined:
    Jan 8, 2012
    Messages:
    2,131
    I'm following this everyday, you're doing excellent work.
     
  19. Jan 1, 2016
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor 2021 Sponsor

    USA
    Joined:
    Oct 25, 2006
    Messages:
    5,577
    You give me the directions to build better stuff into my mounts for sure. So, your Dana 300 and the mount for it is going to stick up proud of the floor under the passenger seat by a lot. Its something that had not occurred to me to do. Nice stuff as i am sure you are aware of. I am a huge fan of captured/weld nuts. If you buy the actual weld nuts from mcmaster or whatever they seem to work a bit better. What happened to the rest of that front fender?
     
    ITLKSEZ likes this.
  20. Jan 1, 2016
    tymbom

    tymbom Member

    Siskiyou Co.
    Joined:
    Jun 13, 2012
    Messages:
    770
    Yeah I'm watching your build closely. You have me trying to figure out how I can improve my engine mounts and transfer case crossmember... I don't like how my transfer case is hanging down, but I'm using a Ford 9in rear, so I'm not sure I can go up anymore. So I'm thinking about at least making it a little more sleek and tough under there... Keep up the good work. I look forward to each update
     
New Posts