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 Post subject: Custom ROCK RAILS
PostPosted: Fri Aug 01, 2008 12:10 am 
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So after doing Strawberry Pass Trail last week with the Nor Cal gang I dented my rock rails pretty good and decided I needed an upgrade. I like the Boulder Bars a lot but am way to cheap to go out and buy them so I made my own versions. Mine don't stick out as far which I like, but they do stick out enough to easily use a hi lift, use as a small step and will do a much better job of keeping rocks off my doors than my old ones.

I bought 2- 61" long 2"x2" square tubing that is 1/8" thick and cut the ends off with a bandsaw to 45 degree angles and welded on end caps. I chopped the old arms off my old rails and used them again. I like that they are one solid piece and they don't have a plate welded to the end of it that bolts to the frame. I extended them out 4" and then used 1/2" square tubing for side to side reinforcement. I angled them up tight against my rock panels for as much clearance as possible (I know it isn't ground clearance) and left the pinch weld bar attached to keep everything aligned to earlier specs. I ran out of wire for my welder and so wasn't able to finish the second rail but the first turned out great! All I need to do is add the 1/2" reinforcement bars after I pick up more wire, smooth out my grinds and then coat everything with primer and then finally with bedliner. Will post pics of the final product. The 2x2 square tubing cost me $53 and I already had everything else in my garage. Not too shabby I think. :wink:

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PostPosted: Fri Aug 01, 2008 12:17 am 
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Looks great Mike, can't wait to see them finished and hear how they work!

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 Post subject:
PostPosted: Fri Aug 01, 2008 12:42 am 
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Can you PM me the lengths of the brackets that connect to the frame :cry:

PLEASE :P :lol:


I made a drawing of what I am going to build, just want to cheat a little to speed things up! I am going to try very hard next week to build them, since we are shutdown for Hot August Nights :o

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PostPosted: Fri Aug 01, 2008 12:48 am 
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they look good now you just need to add a bar going across for the pinch weld, and just outta curiousity why 1/8" most use 3/16"

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 Post subject:
PostPosted: Fri Aug 01, 2008 11:55 am 
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jsc7002 wrote:
they look good now you just need to add a bar going across for the pinch weld, and just outta curiousity why 1/8" most use 3/16"


Look at the 2nd pic. There is a bar that bolts to the pinch weld. 1/8 is plenty thick enough for me, the 3/16 is only .0625" thicker.


06, I'll get you the measurements tonight. :wink:

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PostPosted: Fri Aug 01, 2008 12:18 pm 
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I think they will be fine - I agree it should be plenty


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 Post subject:
PostPosted: Fri Aug 01, 2008 2:25 pm 
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incubusmike wrote:
jsc7002 wrote:
they look good now you just need to add a bar going across for the pinch weld, and just outta curiousity why 1/8" most use 3/16"


Look at the 2nd pic. There is a bar that bolts to the pinch weld.quote]

:oops: sorry i wasnt even paying attention

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http://www.dpgoffroad.com/
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http://www.christianoffroad.com/
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 Post subject:
PostPosted: Fri Aug 01, 2008 6:11 pm 
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:D

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WANTS:
OME Coil Lift, Crager Soft 8's 16x8 4"bs, Custom Roof Rack, Steel Bumpers, Cobra 75X CB w/ Firefly, Lots O Lights, Lockers, Four X Diff Cover, One Bad Jeep


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 Post subject:
PostPosted: Sat Aug 02, 2008 1:58 pm 
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Finished product
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 Post subject:
PostPosted: Sat Aug 02, 2008 2:21 pm 
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so did you do the welding yourself?

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http://www.dpgoffroad.com/
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http://www.christianoffroad.com/
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 Post subject:
PostPosted: Sat Aug 02, 2008 2:21 pm 
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Yep.

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 Post subject:
PostPosted: Sat Aug 02, 2008 2:23 pm 
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wow a nice and speedy reply too! lol

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http://www.dpgoffroad.com/
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http://www.christianoffroad.com/
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 Post subject:
PostPosted: Sat Aug 02, 2008 2:25 pm 
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yep.

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 Post subject:
PostPosted: Sat Aug 02, 2008 3:04 pm 
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Looks great Mike, now make me a set!!

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245/75-16 Duratracs, Soft 8's, Ironman/clevis Lift, Monroe Sensa-trac rear shocks, JBA 3.5, GTP Hood Louvers, Roof Basket & Light bar, Mudd's Garage Rear Bumper
custom made items: cross rails, grill inserts, cargo shelf, lightbar, pin stripping & rock rails.
L.O.S.T. #DW090501


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 Post subject:
PostPosted: Sun Aug 10, 2008 5:49 pm 
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Wish I lived closer, so I could get a set too :D


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 Post subject:
PostPosted: Sun Aug 10, 2008 7:04 pm 
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nice job mike.

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 Post subject:
PostPosted: Tue Aug 12, 2008 2:56 pm 
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Thanks.

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 Post subject:
PostPosted: Tue Aug 12, 2008 2:57 pm 
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so have you got to go out and give them a good hard hit or two??

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http://www.dpgoffroad.com/
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http://www.christianoffroad.com/
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 Post subject:
PostPosted: Tue Aug 12, 2008 3:08 pm 
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Took it out this week in Vegas with the fellas down there. Only touched the rails once I think but scraped 2 times on the skids. So no real testing yet. Here is a link to my first trail run since I put them on.

http://www.lostjeeps.com/forum/phpBB3/vie ... hp?t=34931

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 Post subject:
PostPosted: Tue Aug 12, 2008 11:37 pm 
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Geezz at this rate I will never finish my rails :roll: I was trying to just pencil in the measurements as I went along but it is going to take for ever so I guess I am going to cheat all the way 8)

Now all I need is the measurements.....Mike can you help me out :oops: All I need is the distance from both ends to the supports and how far the 1/2" square tubing sits from the rail itself (the pinch weld bar...I guess) All help would be greatly appriciated, so that I can go to Slick Rock and play :cry:

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Life's Tough...It's Even Tougher If You're STUPID
2006 KJ Sport 3.7L 226cid V6 42RLE w/
Clevis Lift, Mopar Underbelly's, Tow Hooks, Tow Hitch, Custom Rock Rails, Debadged
WANTS:
OME Coil Lift, Crager Soft 8's 16x8 4"bs, Custom Roof Rack, Steel Bumpers, Cobra 75X CB w/ Firefly, Lots O Lights, Lockers, Four X Diff Cover, One Bad Jeep


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