New Armor Choices In Development - (more new pics)

Boiler · **Posted:** Mon Aug 17, 2009 3:18 am

My plans this week include tweaking my exhaust, finishing prototype belly skid, trying to round up some hitches and modifying the gas tank skid to clear most of them. Gas tank skid will probably get a bit more expensive because of this... :cry:

CRD Joe · **Posted:** Mon Aug 17, 2009 3:19 am

Ok, that plate is the way it is because it encompasses the coil conversion and the control arms. I like it. If youre guys are going to do something like that sans control arms Im in. Ill wait until you can get us some prototype pics.
I was going to pick up a couple Skid Rows, but Ill wait now.

Tom

Boiler · **Posted:** Mon Aug 17, 2009 8:32 am

Yeah, his control arm mounts facilitated the whole setup. I just liked the idea and ran with it. Yep, its that idea minus the control arm mounts.

We're basically doing a 1-1/2" tall by 2-1/2" wide tube frame with multiple spanning supports. This frame will get bolted to the "frame" that hangs down from the unibody, as well as the crossmember. The TC crossmember is 1-3/4 to 2" tall, depending where you measure. Our plate will bolt to our frame, leaving our skid 1-3/4" tall. So, it will be flush with the crossmember in some spots, and be slightly higher up in others. The crossmember will be the lowest point, not our skids.

It might seem like a waste to effectively lower the frame rails 1-1/2", but the stock exhaust sticks down approximately that amount, and all around the transfer case area you've got sheet sticking down about an inch (near the crossmember)

I've already found small changes that I plan to make for the production skids, but I'll show my personal ones that we're building as concepts soon.

CRD Joe · **Posted:** Mon Aug 17, 2009 6:16 pm

Hey Boiler, what do you think of that exhaust set up?

Tom

CRD Joe · **Posted:** Mon Aug 17, 2009 6:20 pm

Get rid of that bloody cat and there's pleny of room.

Boiler · **Posted:** Thu Aug 20, 2009 1:40 pm

Little update here. I measured out a MOPAR hitch and it basically cut right across the corner of my skid. I've made modifications to the design, mocked up the changes on my rough prototype, and it still fit the gas tank. Tomorrow I'm having full blown aluminum parts made and we plan on welding it up early next week.

We're working on the rear skid tonight, having the main plate waterjetted tomorrow, and mounting it on Saturday. Hopefully it will be in place next week too.

Next weekend I'll have access to a few hitch types and gas tank sizes to confirm the gas tank skid design or determine what changes need to be made, if any.

dgeist · **Posted:** Thu Aug 20, 2009 2:26 pm

Boiler wrote:

Sorry, I've been watching a movie

Anyway, I just wanted to let everyone know that we're still here, we're working on some really cool new stuff. I'll try to update every week or two. Pictures of anything will be a couple weeks out. I do have some CAD though...

I'm curious what the "boat-style" rocker panel armor will look like. have any pre-production art you can share?

Dan

Boiler · **Posted:** Thu Aug 20, 2009 3:31 pm

dgeist wrote:

I'm curious what the "boat-style" rocker panel armor will look like. have any pre-production art you can share?

Dan

I think the whole boat style terminology was the wrong choice of words. What I meant was that the bottom of the rocker guard will be enclosed with plate, so as to not hang up on rocks between supports and also to protect the floor of the jeep.

I don't have much drawn for the rocker yet. I'm still bouncing around ideas. I do have the frame and pinch modeled. I'll probably work on it more next week after this push to get the belly & gas tank skid made.

CRD Joe wrote:

Hey Boiler, what do you think of that exhaust set up?

Tom

The cat and the pipe look like they might clear. It is very difficult to say though, due to the camera angle. It's even hard when you're under there looking at it. Basically to use the skid you're going to want everything 1/4" to 1/2" or more above the frame rails. If you take a straight edge from frame rail to frame rail it makes it a lot easier to see how close stuff is.

It sounds impossible to people that have mufflers, but if you have a muffler that is 12-14" long, you can have the entire muffler behind the skid, instead of above it.

There are some exceptions: if whatever is lower is sticking down where there isn't a support, you've got an extra 1-1/2" to play with.

Inc · **Posted:** Mon Aug 24, 2009 12:59 am

Any updates?

Boiler · **Posted:** Mon Aug 24, 2009 7:34 am

I was having my waterjet guy form the bottom pan. We built a 1-1/2" radius punch & die and tested with it in the press brake at work, but he's got a cnc backstop + he's already cutting out part. It will come to us ready to weld.

I gave him the program on Friday and he got the parts cut, but not formed. I'm supposed to pick them up today.

We reworked our rear skid a little saturday due to being so close to the new muffler setup. Shortened it 3/4". I'm ordering the plate cutting today, so the plan is to weld up the gas tank skid by thursday, then finishing the belly skid thursday in time for me to leave town on Friday. Saturday I'll meet with the Illinois group and take advantage of their model year varieties. I'm planning on fitting the gas tank skid to multiple gas tanks and hitches if they let me. Sunday night or Monday of next week I should have a real solid update.

Boiler · **Posted:** Mon Aug 24, 2009 3:20 pm

Went to pick up my tank skid parts today, and they were formed about 1/4" away from where I specified and I wasn't happy. they measured stuff and told me it was our die. I hemmed and hawed and eventually the owner said "lets try it again and compare"....boom, on the money. Totally made my day. Will definitely have the final prototype done this week now.

CRD Joe · **Posted:** Mon Aug 24, 2009 4:54 pm

Looking forward to some pics.

Boiler · **Posted:** Mon Aug 24, 2009 5:00 pm

Ok, I'll take pics of the parts before we weld them tonight. I'll lay them out in a nonsensical pattern just to mess with people...

CRD Joe · **Posted:** Mon Aug 24, 2009 5:13 pm

Well shoot Boiler you can wait until its in the truck if you want.

Inc · **Posted:** Mon Aug 24, 2009 10:37 pm

Sweet man. I'm looking forward to these.

Boiler · **Posted:** Tue Aug 25, 2009 2:01 pm

Well, we were up late putting it together last night. Tony still has to weld the inside welds on the MIG today. I don't think we're working tonight so it may be a day or two til I get pics. He started putting it together yesterday before I remembered to get part pictures.

Edit: I was planning on grinding smooth the welded corners, but I think it looks bad @$$ as is, but then again maybe I'm biased...

JJsTJ · **Posted:** Tue Aug 25, 2009 9:10 pm

Tease.

Boiler · **Posted:** Tue Aug 25, 2009 9:15 pm

Well, my camera cord got smashed between my office chair and the wood floor, and my wife tried to plug it in anyway. Jacked up the camera. So I have to use Tony's and that takes scheduling... :roll:

Boiler · **Posted:** Wed Aug 26, 2009 11:45 pm

Well I worked alone tonight, so no pictures. I did put the gas tank skid on by myself by hand. It was the first real fitting with the final design and it fit like a glove! Holes were perfect front to rear, about 1/8" narrow side to side in that the bolts don't land in the centers of the slots. I'll correct that. It could have been about 3/16 narrower and still fit though.

The modifications to clear towbars fit the tank perfectly, and make it look really cool. Will clearance test it with multiple tanks and towbars this weekend.

I polished a corner of it and OMG...when I get back in town next week I'm going to buff and polish the whole thing and clearcoat it. Though right now its dull and dirty and matches my silver Jeep very well. I'm very excited, it turned out great.

I know I know, this thread is useless without pics...I'll try to get Tony to take one or two with it mounted tomorrow. I'll take the rest when I take it down for polishing. Tomorrow I'll be busting my rear on this belly skid, but I don't think I'll get it done for this weekend. Both my plate and all my fasteners are late arriving.

Inc · **Posted:** Thu Aug 27, 2009 2:03 am

JJsKJ wrote:

Tease.

X 1 Kagillion.

New Armor Choices In Development - (more new pics)

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