$100 rear corner armor - JKowners.com : Jeep Wrangler JK Forum
 
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post #1 of 9 Old 06-22-2015, 07:48 AM Thread Starter
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$100 DIY rear corner armor

Posted in my build thread, but figured I'd toss up here as well. I stretched the rear of my 2-door JK 8" and as a result, couldn't reuse my MetalCloak Exo Skins (but this is still relevant for non-stretched JKs, just pointing out why I made the armor). Decided to make my own corners. Stole a page out of the Poison Spyder book and made it in two parts and welded together for a seamless finish.

I chose 10 gauge steel. 3/16" was too heavy and hard to work with and 1/8" was too thin. The 10 gauge flexes just enough the follow the curve along the side of the Jeep.

I used my MetalCloak skin as a partial template and then located the wheel well rearward. I didn't want the massive opening you typically see on a comp cut. For the cut I used a plasma cutter.

For the compound corner, I used my press brake to make multiple parallel bends. Not as many as I would have thought though. The bending took maybe 30 minutes. Nothing fancy here, I have the Harbor Freight 20 ton press and Swag Finger Brake kit.

All in, it took me about 2 hours to make the corner. I reused the existing mounting holes from my MC armor, which made things easier. For the rear, I just tossed in nutserts like the PSC armor would use. I've done so many nutserts that it took me about 5 minutes to drill the holes and put the nutserts in. I recall my first time when it took hours...

I still have to cut the openings for the gas fill and brake lights (going to use the round PSC lights). Also have some more body trimming to do.

All in, it will take around $90 in steel. I'll be making the fenders in a few weeks probably.












Last edited by Invest2m4; 06-22-2015 at 07:57 AM.
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post #2 of 9 Old 06-22-2015, 09:00 AM
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Very sweet setup, are you planning to add rear LED's?


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post #3 of 9 Old 06-22-2015, 09:47 AM Thread Starter
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Quote:
Originally Posted by geberhard View Post
Very sweet setup, are you planning to add rear LED's?
Yep. Just going to get the lights that Poison Spyder uses in their corners. No sense in recreating the wheel - especially since that's all I've done for the last six months, haha.
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post #4 of 9 Old 06-22-2015, 09:47 AM
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Got any before and after pictures?

Cost point is definitely nice. Is there remove for the tire travel? Looks to hit the back edge.
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post #5 of 9 Old 06-22-2015, 10:26 AM Thread Starter
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Originally Posted by Treader View Post
Got any before and after pictures?

Cost point is definitely nice. Is there remove for the tire travel? Looks to hit the back edge.
Check my build thread for pictures.

No issue with tire clearance. And I'm running 40s with a ton of up travel. The upper truss links are within 1/4" of going through the floor.

What you can't see is that I actually had to cut some of the corner away and raise it up. The body used to be lower. Basically, if you follow the arc of the wheel well, it met the corner about an inch above where it was stock. I just made it so it looked like I didnt cut anything.
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post #6 of 9 Old 06-22-2015, 10:27 AM
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Looks damn good!

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post #7 of 9 Old 06-22-2015, 02:17 PM
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Like it!
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post #8 of 9 Old 07-20-2015, 04:18 PM
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Definetely in for a set of these if you get around to making them.
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post #9 of 9 Old 07-20-2015, 06:04 PM Thread Starter
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Quote:
Originally Posted by Danthephotoman View Post
Definetely in for a set of these if you get around to making them.
I had thought about making more, but decided it just won't work as there is no way to consistently reproduce the compound corner in a way that people would be happy. One challenge is that it curves vertically and horizontally. I had to wrestle with it in the finish stage a bit to get it to fit right. Worked great in the end, but definitely a challenge. I wonder if River Raider shapes the vertical curve in theirs? I've heard those can be a bit of a challenge as well.

Making skins like the MetalCloak ones that stop at the corner would be easy. Or, starting with the AEV builder corner and adding the side would as well. The latter option probably isn't worth it as it starts to get close to the cost of PSC Crusher flares. Unless someone wanted a custom cut, which PSC won't do.
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