Building tube fenders for a jeep

[LXCam]

It's always good to have help!

It sure is even if the little ****** can't weld yet.

Well this weekend didn't quite take off the way I had hoped. The grandkids spent Friday night but with both of them sick, didn't get any sleep. Then Saturday morning after my daughter got here finally headed out to the shop only to find I didn't have the tubing I needed for the frame spacers. So there went a couple hours running down to the supply house.

Getting home I immediately cut up all the frame brackets....too short. After debating on if I wanted to proceed went ahead and started prepping everything for Sunday morning and called it an early day.

Sunday started out great. I met up with duck who was one city over and we had a great breakfast together. Getting home I jumped right into work mode only to then remember after welding up the pilot hole frame bracket and drilling the first set of holes that both mandrels I have for my good 1" broaches were fobbarred. At that point the day became a mixture of progress and disappointment.

But I did get the frame brackets all ready to go, drilled to 9/16" for a little fudge factor. I ended up having the turn down the 1"OD x 1/2"ID DOM tubing to 7/8" since I ended up having to drill the frame with a unibit instead of how I was going to do it. Those will be tig'd to the frame.......right after I find my missing welding extension cord









This is the pilot hole jig. I really should have used 1/2 and then used drill bushings instead but found out my kid burned up the last bit of 1/2" plate I had here on a project that I had completely forgotten about.

 

[bad_idea]

I'm glad I'm not the only one that has weekends like that. Sorry to hear it was your turn.

 

[zmotorsports]

Looks good Cam. Those spacers should definitely keep the frame from collapsing. I'm assuming you'll have anti-seize in them to prevent seizing.

Keep the progress pics coming bud.

 

[LXCam]

I'm glad I'm not the only one that has weekends like that. Sorry to hear it was your turn.

Ya the past 5 days just haven't worked in my favor that's for dang sure.

Looks good Cam. Those spacers should definitely keep the frame from collapsing. I'm assuming you'll have anti-seize in them to prevent seizing.

Keep the progress pics coming bud.

They will have when all is said and done. The ID is dead nuts on for a shoulder bolt so I'll ream it ~.020 roughly at finally assembly. When possible I attempt to keep all Fit-up work as tight as possible to mitigate "whatever" from growing/shrinking/moving etc. Then modify as needed at the latest stage possible. As it was I hated drilling the plates to 9/16 this early in the game but it was so much easier to do using the power downfeed on the mill then it would have been afterwards.

I got today free and have been in the shop since a little after 4. It's just not fair with most everyone sleeping in on a Monday like this. "Get up ya lazy damn people, I got **** to do!!"

 

[LXCam]

Little headway today. Got the passenger side stanchions done. I'm still damn unhappy with myself about the width of the frame plates but it works nonetheless. I also found out the even in the short distance of 3" OC for the frame bolts the frame bellies as much as an 1/8" difference. I'm glad I didn't just cut all my spacers at once and did the individually.

To hold the spacers tight I used a 1/2" drill guide on the inside of the frame and a 1/4" bolt and furniture rectangular washer thingymabob in order to tack them in place.



Once that was out of the I just did a fusion weld or I should say some form of that. I really **** at tig, but I can make it stick



Once I got my act together with the pilot hole guide and changed up a couple things after my learning curve for the back bracket, the front turned out on the money and the bolts all went in without even a tap.







As embarrassing as it is not making them wide enough it works. But I had to tig the center portion by the bolt for clearance.



After I got those all welded up, back on they went. I feel pretty damn lucky that nothing moved and I was able to maintain a perfect space between the top of the rail and the bottom of the body.



After I get the other side to this point I'll then make up my mind on how far in or out to place the rail. I'm thinking I won't do that until I create the actual step though. And as much as I want to just do the step right now I'm forcing myself to finish the other side so I can pack up all the **** I got out.

 

[zmotorsports]

Nice Cam. [emoji106]


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[LXCam]

Bit more progress today but I would once again like to ask othe crowds input on finishing the end of the rails in the next post please.

The drivers side is all set up with the stanchions cut to length and well as the bottom matched to the angle of the rail and just needs to be capped. I also pushed the rails 1/2" into the body side. I thought about going more but didn't like how it looked with the rail caps angled so I'm going to leave it here.

I'm happy with the angle at the rear unless it's just stupid looking so please feel free to be honest here. Once it's cut, I ain't going backwards...intentionally anyhow

Marking the bottom of the stanchion to the angle of the rail.





The rear

 

[LXCam]

Now for the front. It's a toss up between matching the rear angle or do a radius.

 

[LXCam]

Oops, picked a couple wrong pics. I should also add I plan on matching that angle for the steps mounts too.

 

[LXCam]

And so comes another night of "sleeping on it". I finished up the end caps with a piece of 1/4, recessed it half way in and melted it good so I could radius it to match.





And now my son and I are battling it out in the width of the step. I want to go with 3" wide simply because I've got the tubing here. He's deadset on the 2" wide. Honestly I do think it looks better but I feel the 3" will be both stronger and a better foothold for the tread plate I'll put on the top.

 

[Boosted1]

Nice work as usual.
To chime in on the step width, after having lived with a wider step for the last 1.5 years, it is nice to have. I'd voted for wider.

 

[LXCam]

Nice work as usual.
To chime in on the step width, after having lived with a wider step for the last 1.5 years, it is nice to have. I'd voted for wider.

Thanks again boosted.

I can't tell you how many times I mocked up different widths, heights and outward spacing stepping in and out of the jeep. I liked the feel of the 3" better. The best look was higher and more inward but that didn't leave enough toe insertion with hiking boots to be safe. I've given considerable thought to doing a sawtooth grill out of bar but don't want to create a shin eater either. As it is this step is 18" off the ground and I'm concerned about a slip. Since the owner isn't a young man I've asked him to confirm what height he's comfortable stepping up too. He says 19" so I'm trying to get it as reasonably low as possible.


Hum, decisions, decisions

 

[LXCam]

Today went pretty good.

Started off this morning cleaning up a bit and then got right down to designing the step support in solid works.



Once all the angles were fingered out it I debated heavily on if I should build the step on the bench or on the ride. The ride made the most sense since these things are starting to get just a bit awkward and the last thing I wanted was to get even the most minor twist. So that meant I needed to build a jig to hold the step in place so I could mark my cuts and then build to the step.

Considering how these brackets all tamper to a whole slew of odd ball angles it'll make for one hell of a box. I couldn't figure out what this shape would be called. So I've decided to name it a hemorrhoidazoid

 

[LXCam]

But before I could go to town boxing this out decided to do something I hope will look decent when it's all wrapped up. After checking out various antislip products just wasn't set on any one type to take some of the slip out of this step. One thing I was dead certain about was I did not want to create a shin skinner.

Pulling out some of the tread plate I had here decided to widow the step so the back plate was recessed into the tube with the tread portion proud of it. Well a little time on the mill and walla, a hole. I then filled the tube with a chunk of solid bar for good measure. If this gets bent, they'll be a hell of a story

With that done and jigged up I covered up the side of the jeep with a welding blanket. Well most of one anyhow, it might be time for a new one. Once that was done I could cut in the outside angles and start on the last bits to this puzzle.

 

[zmotorsports]

Cam, I guess I didn't visualize the step being that much lower than the actual rocker panel. How far off the ground will the actual step be and will he catch it on terrain? How does he wheel his Jeep?

Great work all in all just didn't wrap my head around the step being lower than the rock rail itself.

 

[LXCam]

Cam, I guess I didn't visualize the step being that much lower than the actual rocker panel. How far off the ground will the actual step be and will he catch it on terrain? How does he wheel his Jeep?

Great work all in all just didn't wrap my head around the step being lower than the rock rail itself.

18" and I have no idear. He says he just puts around the desert but I'm starting to have my doubts what his plans are. Scope creep is starting to take a firm hold.

I'm not worried about it, if he can damage the hemorrhoidalzoid box design of these steps I'll fix'm for free. All though it doesn't look like it they finish out a 1/2" inwards of the fenders and are still 2" above the skid plate.

I've got all the 1/8" boxing ready for both sides. Now I just need to cut the inside piece and bracing out of 1/4". I should have the drivers side whipped out by tonight.

 

[zmotorsports]

I hear ya on scope creep, but damn those are going to be some sweet looking steps.[emoji481]

 

[LXCam]

I hear ya on scope creap, but damn those are going to be some sweet looking steps.

Thanks Mike, I really do appreciate the compliment. I was starting to think I lost everyone and I might have, damn the bad luck. But as long as you're hanging tuff I feel good

 

[bad_idea]

I'm still following along. The quality of work is top notch. I'm beginning to think this is more of a favor than a paying job. The amount of time you have invested in these would kill the budget for most builds. I mean that as a compliment, not to be taken as an insult.

 

[LXCam]

I'm still following along. The quality of work is top notch. I'm beginning to think this is more of a favor than a paying job. The amount of time you have invested in these would kill the budget for most builds. I mean that as a compliment, not to be taken as an insult.

Thank ya bad

Favor, well sorta. since I had free rein with this project I took it overboard. It's one of those resume deals. When we get out to az I'll be firing back up my performance shop. And since I'll be right dab in the middle of 4x country figured wtf, this couldn't hurt to have under my belt.

Well I've had enough for the day. This will need to come off to finish up the welding and burnishing. But for anyone that had a hard time following along (I know I did,lol) this should land the plane.

 

[zmotorsports]

Looks great Cam. Top notch all the way. I sure hope the owner truly understands the amount of work that has gone into them and definitely NOT quality of work out of the normal off road shop.


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[Boosted1]

Top notch work!
Looks about 4x as strong as most aftermarket versions.

 

[LXCam]

Looks great Cam. Top notch all the way. I sure hope the owner truly understands the amount of work that has gone into them and definitely NOT quality of work out of the normal off road shop.

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He's happy with everything Mike. Like I mentioned early in he raced class 8 for several years so he has a firm handle on the concept of one off work and the time it can eat up.

Top notch work!
Looks about 4x as strong as most aftermarket versions.

Thanks boosted.

You know those times when you can be your own worst enima

Well that piece of 1/4" bar I used to cap the center section is bugging the **** out of me, it's gotta go. I'm really sorry I had welded the ends for life but not as much as I am the inside welds for the step. With the maze of clamps and that jig I couldn't get a good clean shot on welding that area and I can't stand how it looks. Since it's going to be the one weld that everyone will see needs to be redone.

 

[bad_idea]

Reflow it with TIG. No need to grind it out.

 

[LXCam]

Reflow it with TIG. No need to grind it out.

Well that's a good idear bad...I-umm.


I couldn't stand the mess anymore and pulled everything outside today and cleaned up big time. I have my blast cabinet is a good spot for the shop but a really bad spot for servicing the filter. So while it was out I had a go at it.

Ya know, I might need to reconsider how often I clean this thing.

 

[zmotorsports]

Hey Cam, that filter looks like you could have gotten a few more parts blasted before cleaning.

I try to clean my filter on a regular basis but I hate to admit it looks nearly as bad when I finally get around to it. Each time I tell myself never again, that is until the next time.

As for the welds, I know what you mean. The ones no one will ever see seem to be the ones that turn out the best and the ones in front of everyone's eyes end up looking like garbage.

 

[Bigblue&Goldie]

This is the internet, just post pictures of the pretty welds. Nobody in the real world will ever even notice your worst welds!

 

[bad_idea]

This is the internet, just post pictures of the pretty welds. Nobody in the real world will ever even notice your worst welds!

More truth has never been spoken. Only us guys that do this kind of work notice welds. My wife is always rolling her eyes at me because I critique welds out in town. It amazes me the welds that hold in structural applications. I close my eyes when in line for a roller coaster.

 

[fnieto]

Cam, those are over the top! Excellent work brother.
Happy Thanksgiving!

Paco

 

[Duker]

I will jump on the bandwagon as well and second the comment that they look great! That step would even work for an old fart like me getting in and out!


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[LXCam]

Hey Cam, that filter looks like you could have gotten a few more parts blasted before cleaning.

I try to clean my filter on a regular basis but I hate to admit it looks nearly as bad when I finally get around to it. Each time I tell myself never again, that is until the next time.

As for the welds, I know what you mean. The ones no one will ever see seem to be the ones that turn out the best and the ones in front of everyone's eyes end up looking like garbage.

The last couple of times I went to blast something small I thought ya-know it might be time. That reality only set in when I realized I was curling a 20lb weight when I slide the filter off the rod. That pile was just from dropping it sideways on the slab to get the bulk of it out. You should have seen the dust cloud when I started blowing it off, most spectacular I must say.

And btw I gotta add that normally there is nothing from HF that I have much respect for. But that vacuum did a impressive job of packing that filter.

This is the internet, just post pictures of the pretty welds. Nobody in the real world will ever even notice your worst welds!

Ya but...

More truth has never been spoken. Only us guys that do this kind of work notice welds. My wife is always rolling her eyes at me because I critique welds out in town. It amazes me the welds that hold in structural applications. I close my eyes when in line for a roller coaster.

....I know those inside corners are going to be the perfect spot to wipe the dog **** off the edges of your boots. But damn-it I just can't let'em go, covered in dog **** or not they must be fixed.

Cam, those are over the top! Excellent work brother.
Happy Thanksgiving!

Paco

Thanks much Paco. I hope you and the family have a great thanksgiving

I will jump on the bandwagon as well and second the comment that they look great! That step would even work for an old fart like me getting in and out!


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And thank ya too Duke. It was ole decrepit farts much like yourself I had in mind with the design.


Hahahaha, have a great weekend bud and happy turkey day to you and the family

 

[zmotorsports]

More truth has never been spoken. Only us guys that do this kind of work notice welds. My wife is always rolling her eyes at me because I critique welds out in town. It amazes me the welds that hold in structural applications. I close my eyes when in line for a roller coaster.

My wife rolls her eyes at me constantly when I do this as well. We were standing outside a local restaurant the other night waiting for some friends to arrive and I was looking at the welds on the railings and commented about it looked like a flock of seagulls had **** all over. I think I was the only one who thought it was funny.

 

[Duker]

Cam, just dropping in your say Happy Thanksgiving! You can have 5 minutes off the back to the Jeep!


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[Boosted1]

Like several other people have mentioned , I think your welds look just fine.

 

[zmotorsports]

Cam, I would like to wish you and your family a very Happy Thanksgiving bud. Take the day and relax and enjoy it.

 

[LXCam]

My wife rolls her eyes at me constantly when I do this as well. We were standing outside a local restaurant the other night waiting for some friends to arrive and I was looking at the welds on the railings and commented about it looked like a flock of seagulls had **** all over. I think I was the only one who thought it was funny.

I stopped commenting on stuff around the wife a dozen years ago. But I guess 20+yrs of saying something conditions a person regardless. When she sees me looking at whatever she'll ask me (sternly) "ok what??" Even though I only say "nothing hun, just looking".

Cam, just dropping in your say Happy Thanksgiving! You can have 5 minutes off the back to the Jeep!


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Thanks brother. But here I am pre-dawn sitting in a nice clean shop just iching to make a mess right now

Yesterday we had the GBs so nothing got done and I have until noon before we're leaving. Hummmm

Like several other people have mentioned , I think your welds look just fine.

This is almost impossible to explain. But have you ever noticed that when the first in your face thing (doesn't matter what it is) looks "not right" you start picking stuff apart. But if the lipstick on the pig looks good right off the bat ya don't? Well I smudged my lipstick and it bothers me.



Happy turkey guys, I hope everyone has a great weekend

 

[LXCam]

Well yesterday only brought me 3-4 hours of effort on the heep build. But at least I got the drivers side all welded up and rough ground. I ran out of band file belts and 3" flap wheels to detail it better. I also round filed the flat filler plate at the steps and tossed a piece of 3" flat stock in that forming jig I used to flare the rail. It worked ok as the angle is an exact match but the radius, hum not so much. To me it really didn't look bad so I went for it anyhow. I think it gives it better flow with the overall design.

As for those welds that bugged me so badly. Well that turned into a disaster. I tried the tig, but it was just too much for my petite little diversion 180 so I ground out the original welds and grabbed the mig. WELL I totally screwed the pooch here as I lost sight of the seem and made a bigger mess. At that point I did what all crappy Welders do, I ground it out. Considering the inside of that 1/4" piece is fully welded to the step and the internal T'd support will be calling it a day. It ain't going no where.

I could have really used one of royces super fancy wang dangled multi adjustable do all vises for the finish welding. Talk about awkward, this piece if anything is heavy. I even dropped the damn thing when trying to get it back on the jeep, talk about fast feet - get the F outta of the way

 

[LXCam]

Well we can scratch the passenger side off the list. Boy that was much easier to do the majority of the fit-up and welding on the bench without the frame supports.

And I'll tell ya what. The $500 I spent on that 600N was worth every stinking dime









And I redeemed myself this time around.

 

[zmotorsports]

Step turned out freakin' awesome Cam.

 

[LXCam]

Step turned out freakin' awesome Cam.

Thank ya much Mr Mike!

Now there's only a couple more pieces to make. One is a mount for the highlift jack which should be fairly simple. But he hit me up for a front skid plate to protect the steering linkages. I've been thinking about this for the last couple months but I'm undecided on a design.