Discussion in 'Builds and Fabricators Forum' started by timsresort, Dec 27, 2020.
congrats on getting to this point!
That thing is schweet!
Moving on it's own power! Congrats!
What an accomplishment that's is going to be a real nice wheeler when done.
Yessir. That’s one B/A machine. Oughta tackle just about anything.
This is awesome Tim, congrats!
Thanks everyone for the compliments. I am excited to get it in the rocks, but that will be at least May. It's not meant for anything besides the Sierra Nevada trails we frequent. I think it's a good compromise for the Rubicon, not too big, not too small. And best of all, a classic, that it belonged to Nick's Grampa Jim.
Tim do you have a p/n or link to that double-barrel wire loom & brake line frame clamp?
That's actually 2 stacked. I used these, Sam has different sizes, sometimes I sleeve brake lines with a piece of fuel line.
Thinking about the cage, I decided it will be too expensive to use all that DOM at 8 bucks a foot, so I am going with conduit- free and easy! For weight savings I am using 1" EMT. I think it will be fine.
Just kidding. But it would be cheaper. (And obviously dangerous). I cut some 2-1/2" angle for the rear fender top support, and started my CAD (conduit aided design) program.
I think everyone I asked liked what we called the "smitty" design, so that's what I'm trying. This is so I can eyeball the design on the jeep, and will also serve as a bending template.
The radius will be smaller on the DOM, but this gives an idea of the look.
One issue with the A-to-C design is that the sides are closer to the side of the jeep, so the top bow is close. I sat in it and there is still more head room after having to lower it to clear the bows.
But if you use conduit you can also run the wires to your four speakers and subwoofer inside!
That's right. Sound over Safety!
To get the bender to make the right bends in the right places, I am trying this bending program. Apparently what the pros use, and I have some learnin' to do.
I managed to get a template that (I think) will work. We will see how it translates from screen to 2 semi-sober brothers trying to get the plan right side up.
Loaded and ready for a bend-fest tomorrow.
Just act like you have a stick of 1.25 GRC in a side winder!!!
And instead of welding, I could thread it!
I would still weld it, I hate the smell of cutting lube!!
I got and used the software several years ago when I was making cages for road racing. Frankly, I was still much better at laying it out on a big piece of cardboard or soap lines on the cement floor. For compound bends I used rod and 'picked a side' for it to represent.
For someone like me, who has been bending conduit mostly by eye for 40 years, I was skeptical, especially since I couldn't use my Mac for the program, which pissed me off from the start. But I eventually warmed up to it.
To get started, there is a lot of checking, angle-finding, measuring. I feel pretty good about the program, but it's only as good as the dummy feeding it information. So things that need to be right: windshield angle, side bars parallel to the body, A-bar to C-bar dims...it goes on. That's why I need the jeep present while we bend. Those values entered, and we're getting close to bending.
Making sure we have a 90 here on the template. We also used digital angle finders, protractors, digital levels, and the old eyeball a lot.
Then, the bend program gets calibrated to the bender, so we make a test bend and record the stretch, shrink, centerline radius etc. Enter that into the program, and we are finally ready to bend. On the test bend, (seen on the table), I was surprised at how much effort was required. One pull, all I could do, with my boots slipping on the floor, nets 5 degrees of bend. Now I have 15 more to go to get a 90.
The program gives you the cut length, and after some math we figured if we were careful we could end up with not too much 8-bucks-a-foot waste. So the cut is within 2 inches of what it tells us. Then it tells us where the 4 bend starts are, so we make 4 marks, double-triple check, and load it up for the first 4 bends.
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