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DO NOT OPEN IN PUBLIC, YOU WILL BECOME INSTANTLY ERECT!!!

Overview Gallery Discussion
Now that the Xtreme Offroad filming is out of the way I can break from my holding pattern and start banging some stuff out. First on the list is finishing the rear seat mount tie-ins.



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Other side is notched, cut, and waiting to be burned in tomorrow. I am just notching with a chop saw and angle grinder for now but may wind up getting a decent notcher before I start the cage.
 
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Soft top came in today. Ordered a bunch of stuff from Classic Parts of America. Got a 12,000 lb Engo winch with synthetic line coming. Got the other side of the seat tie-ins done.

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Now I can start getting the replacement bedside ready for install so I can get the soft top on and then start the cage work.
 
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Was the Engo in stock? Took me 6 weeks to get mine as it was on a national backorder.

The Engo fit's nice in the A-bomb but you'll need some longer bolts to mount the winch through the hawse and A-Bomb. Took some time to find the right bolts because the bolt head need to be smaller than normal to get in the smaller counter sunk holes in the hawse. Finally found the correct bolts at Autozone on one of those "help" racks on the floor.

Just one of those dumb things that had me running all over town trying to find the right parts, hopefully this helps.

Look good btw :waytogo:
 
skunked said:
Was the Engo in stock? Took me 6 weeks to get mine as it was on a national backorder.

The Engo fit's nice in the A-bomb but you'll need some longer bolts to mount the winch through the hawse and A-Bomb. Took some time to find the right bolts because the bolt head need to be smaller than normal to get in the smaller counter sunk holes in the hawse. Finally found the correct bolts at Autozone on one of those "help" racks on the floor.

Just one of those dumb things that had me running all over town trying to find the right parts, hopefully this helps.

Look good btw :waytogo:
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Hmm, not 100% about stock but the 12K model w/ synthetic was on sale for $470 shipped which is about $15 cheaper than the normal price of a 10K model w/ synthetic ($485). They had the 10K model w/ synthetic on sale for $430 shipped. Since they are running a sale I would assume they had them in stock, maybe?

Thanks for the heads up on the bolts. I will make sure to keep Autozone in mind when the winch arrives. Would socket cap allen bolts work at all? I have access to lots of those at work . . .
 
truck-oholic said:
Hmm, not 100% about stock but the 12K model w/ synthetic was on sale for $470 shipped which is about $15 cheaper than the normal price of a 10K model w/ synthetic ($485). They had the 10K model w/ synthetic on sale for $430 shipped. Since they are running a sale I would assume they had them in stock, maybe?

Thanks for the heads up on the bolts. I will make sure to keep Autozone in mind when the winch arrives. Would socket cap allen bolts work at all? I have access to lots of those at work . . .
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Yep, same winch I got at $475 shipped. There was a nationwide backorder on the winches, hopefully they're all caught up. Yes, a socket allen will work but the ones I found were the standard black ones that would rust.
 
Plan for this week is to finally get my tubing bender built. Building one of the Got Trikes benders that will look something like this

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Also very strongly considering buying one of Rogue Fab's Versanotchers for the cage build.

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It's around $400 shipped but it seems hard to beat for the features and quality of design. Still hard for me to pull the trigger though since I usually cheap out on tools or build my own like this bender. Wish I could find a used one and save a little money but I could always sell it when I am done with the cage work and recoup some cash.
 
Broke down and ordered the versanotcher over the weekend. Started making a moveable notching station out of some free materials I had kicking around. This thing is BEEF!

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The other jaw of the vise isn't installed here.

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Also still have drill some holes and bolt the base of the vise to the pedestal.

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Took the opportunity to practice some vertical welds. Each leg of the "windmill" got this same treatment.

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Made the top pedestal with a piece of 2x2 box steel to sleeve inside the main tube. Going to drill two holes in the main tube, weld some nuts, and use some 1/2" bolts as set screws to make the top pedestal height adjustable and also removable if I ever want to make some other "drop in" accessories like a bench grinder or ????

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Tube notcher came in today. Please excuse the mess in my garage right now, I have a couple things I am working on simultaneously.

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Picked this up from Harbor Freight today to help get my tubing bender built. Have to drill a bunch of more precise holes that I wouldn't be able to do with hand drill. I set the drill up for it's slowest setting 220 rpm since I am drilling a bunch of 5/8 and 7/8 holes in 1/2 or thicker steel.


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Also got in an order from DIY4X. I have a lot of neat stuff planned for my roll cage that should make this build pretty unique . . . just wait to see what I do with the six shooter cage flanges.
 
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Ok, here is the final product for the notching station stand.

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This is max height. The pedestal is adjustable by 8" and the 1/2" bolts act as set screws that take out the play in the sleeved tubing so everything is nice and solid.


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This is minimum height where it will probably stay most of the time. My 5 yr old son welded up these flange nuts for the set screw bolts. Ok, I positioned the gun and he pulled the trigger but it still counts in my book. Really looking forward to when I can let him do it all on his own. :D
 
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Mirrors for the half doors showed up today. Thanks skunked for tipping me off to them!

For the money I am quite pleased but I will have to do something to tighten up the swing arm since it is loose enough that wind from driving on the road will probably push it out of adjustment.

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Plan for the rest of the weekend is to get the tubing bender built.
 
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FWIW they held up to the 55mph highway test yesterday. Little JB Weld in the threads will fix that if needed right :dunno:
 
skunked said:
FWIW they held up to the 55mph highway test yesterday. Little JB Weld in the threads will fix that if needed right :dunno:
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Maybe mine are a little looser? I took a screwdriver to the screw that goes up through the swing arm and there wasn't any more to get out of it. I was definitely thinking of some kind of epoxy in/around the swivel if it doesn't want to stay but I guess we will have to wait and see once this thing is driveable . . . several months from now :rolleyes:
 
Here is some bender progress.

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The bike fork looking piece is a 45 degree brace for the uprights which have all the holes drilled in them

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Holes are 7/8" diameter and done on 1-1/16" centers

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Man that was a lot of holes to drill. Have a couple more to do on the swing arms and jack mount pieces tomorrow.
 
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Got the last of the holes drilled for the tubing bender build. Should be doing a good bit of cutting, grinding, & welding this weekend.

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In order left to right you have the two uprights, the two swing arms on top of each other, pieces for the jack mount, main die pin tabs, & more pieces for jack mount.

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Tonight's task was the swing arms. I welded them on top of each other to make a perfectly mated pair by drilling them at the same time.

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I used 4 7/8 bolts to line everything up and make the necessary clearances. I moved them around several different times to make sure all holes didn't have any misalignment issues

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Also got my Thomson shaft cross pins from Mcmaster.



So, in total, I had to drill the equivalent of 42 7/8" holes, 6 5/8" holes, & 4 1-3/8 holes in material ranging from 1/4" up to 3/4" :eek1:

Definitely labor intensive and very happy to be done with that part of the bender build.
 
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This is good info. I have the same plans, all the materials but haven't dove in yet. Also need to acquire a drill press or use the one at work.

Any issues with the drill bits dulling out or have they held up. The drill bits are not cheap and I would hate to have to buy more.

Thanks in advance.

-Mike
 
Heavyleft said:
This is good info. I have the same plans, all the materials but haven't dove in yet. Also need to acquire a drill press or use the one at work.

Any issues with the drill bits dulling out or have they held up. The drill bits are not cheap and I would hate to have to buy more.

Thanks in advance.

-Mike
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Yeah, after that many holes the bigger drill bits were definitely getting dull which slowed it down a lot at the end. I went ahead and bought the $30 silver demming drill bit set he recommended from Harbor Freight. I ran the drill press at 220 rpm for the drill bits and 300 rpm for the hole saw. He says he went pilot, 1/4", 5/8", 7/8" but that didn't seem to work too well for me so I went 3/16, 1/2, 5/8, 3/4, 7/8 so one more step than he did.

I also opted for the little milled bushing set for the swing arm that he sells on his website for $60 so if you don't buy that or have it made then your holes for the main die pin and the ram-to-arm bolt will be smaller, 1" & 5/8" respectively. I almost bought his predrilled kit because I knew that the drilling was going to suck and I didn't already have a drill press but I always look at stuff like that in this light. Cost of predrilled kit plus shipping would probably be $400 but $60 of that is the bushing set so $340. For $340 I bought a drill press that I will now have for general use and all of my material. I am all about saving some money and building my tool arsenal.

I am into the bender for about $500 including the 1.75" pro tools die I bought used (not including cost of drill press). If I wasn't doing this I would definitely consider buying Rogue Fab's bender for $600 which includes die but you do have to pay shipping from OR and still buy your Harbor Freight 8 ton bottle jack so you are looking at about $800 for that setup but you do not have to do any drilling, just bolt and weld a couple pre-indexed pieces together.
 
truck-oholic said:
Yeah, after that many holes the bigger drill bits were definitely getting dull which slowed it down a lot at the end. I went ahead and bought the $30 silver demming drill bit set he recommended from Harbor Freight. I ran the drill press at 220 rpm for the drill bits and 300 rpm for the hole saw. He says he went pilot, 1/4", 5/8", 7/8" but that didn't seem to work too well for me so I went 3/16, 1/2, 5/8, 3/4, 7/8 so one more step than he did.

I also opted for the little milled bushing set for the swing arm that he sells on his website for $60 so if you don't buy that or have it made then your holes for the main die pin and the ram-to-arm bolt will be smaller, 1" & 5/8" respectively. I almost bought his predrilled kit because I knew that the drilling was going to suck and I didn't already have a drill press but I always look at stuff like that in this light. Cost of predrilled kit plus shipping would probably be $400 but $60 of that is the bushing set so $340. For $340 I bought a drill press that I will now have for general use and all of my material. I am all about saving some money and building my tool arsenal.

I am into the bender for about $500 including the 1.75" pro tools die I bought used (not including cost of drill press). If I wasn't doing this I would definitely consider buying Rogue Fab's bender for $600 which includes die but you do have to pay shipping from OR and still buy your Harbor Freight 8 ton bottle jack so you are looking at about $800 for that setup but you do not have to do any drilling, just bolt and weld a couple pre-indexed pieces together.
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I got the milled bushing set as well. His instructions are a little to be desired but I was able to get them deciphered in an order that makes sense to me.

Looking forward to seeing how you like it in the end. You've officially become my guinea pig on this....LOL. Looking good so far.

-Mike
 
The packet has all the info you need but it would be better if the figures and cad drawings accompanied the building instructions and were referenced better so it was more step by step. Would not be an issue if it was printed off since you could just flip back and forth easily but its a pain to have to scroll between multiple pages on the computer.
 
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