Well i finally got home yesterday and got to open my box of new toys. I orderd the full skins and tubes pre-bent and the skins for the fender top from http://www.riverraider.com/
. Everything was great except since i was not home to take care of my new stuff someone spilled water in the box and i got some surface rust, no biggie flap wheel took care of it.
Before i go any farther i have to say im a wood worker and this steel stuff in some what new to me. So my welds are not the best but i can say i got good penatration and discolor on the other side using a 110 flux cored up to 1/4" steel. Besides who doesnt get that great feeling of satisfaction when you build something that you can call your own. Well at least half of it...
Everything layed out. There are 2 tabs that you cant see that get welded center of the tubes to the skins. This helps keep the tubes even down the side while you tack weld everything in place.
I already did the fender chop so the iner fender well was cut. You can find that mod in the forum. You can see some carnage on the side. 1 was last spring i slid into a tree during a muddy side hill at the wheel in. The other is well lets just say a night run.
OK this hurt for a second. The template is easy to use and i cut the hole with a angle grinder. There is a couple of spots that you need to cut about an inch in so if your wheel wont make it you can use a jig saw or ricipricating saw.
I was home alone and i got to tell you its not easy to get this beast up by yourself. Once i did and got it all lined up i clamped it down and marked the holes for the nut-serts. Then took it off again ahhhhhhhhhhh. Drilled 1/2" holes and you have to use a hammer to get the nuts to go in, tight fit! Well since I dont have the special tool, Kenny said i could use another bolt with a larger nut that will slide over the bolt. Then you use 2 wrenches 1 on the nut and 1 on the bolt to suck the nut-sert in.
This didnt work out for me to well. So i took out the trusty 110 and tacked the nut serts in place so they wouldnt spin and then the bolt trick worked. OK so its a bit ugly but i flap wheeled and rattle caned it afterwards.
If you weld have a fire ext handy!!!! The insulation on the inside between the walls got a little hot. I didnt have my carpet in so it was easy to put out. no worries no damage
The skin back on and tacked the tube and fender skin on in place. This will help keep the main skin the contour of the jeep.
After I tack welded it I took it off finished welding it and gave it a few coats of rattle can.