How Do You Remove The Underseat Toolbox?

It looks like it will take a lot of cutoff wheel type removal?

 

find the spot welds and drill them out.

 

There are spot welds around it's perimeter. If you want to save it, drill out the spots. If not, cut away!

 

Thx

 

Ok that's a crappy job, not as easy as it sounds. Making some progress... Maybe by next week some time I'll get it out.

 

If the floor underneath is still good don't drill all the way through..if you are replacing the floor underneath then it doesn't matter. A spot weld cutter with lots of oil works well for me

 

Pretty sure the floor underneath is good. Just want to remove it because the space will become a gas tank.

Are there supposed to be this many? GAH!!!

 

For sure use a spot weld cutter. they are available at most auto body and paint supply shops. Just a fyi in case you don't already have some. Will save a lot of work and time.

 

Getting my Google on...

 

Are you trying to save the tool box?

 

Not particularly, but if I can save it might as well. I'm sorta tearing up the edge pretty good tho.

 

if you don't want to save it do yourself a favor and take your cut off wheel and cut out the tool box as close to your spot welds as you can and remove the bulk of the tool box. Then starting on an edge take your grinder and grind the small portion of metal left with the spot weld. Take your pliers and peel up the strip until you get to the next spot weld and repeat. You will be less likely to damage the underlying metal this way

 

Not only that, there are probably twice as many as you are seeing.

 

If you do not want to get in the outside side of the body, do what is explained above. A spot weld cutter will penetrate the outside of the body. Watch when grinding, so yo do not over heat the sheet metal and bubble the paint.

 

Drilling spot welds... not so much fun. Sawzall, at least it's more fun.

 

A rear gas tank would give more capacity and you'd still have the storage under the seat...

 

I would normally agree and I even picked up this rear tank for that reason but I decided not to use it.



Instead I designed an aluminum tank that spans nearly the entire width of the tub and holds 24.3 gallons and uses the stock fuel filler location with no transfer pumps and has a sump to allow the Jeep to run while at angles for probably 1/2 hour. Here's all the aluminum I've already started cutting up into the shape. That's the next step I'll document in my build thread.



I have a Muncie SM420 trans and I have plenty of room to make a flat spot in the floor where the trans tunnel hump sticks up. This new tank will have baffles in it to keep the gas from sloshing side to side. I've spent about 3 months thinking about it and designing it. I don't want to cut a new filler location into the body for a second tank and I like the extra capacity this will provide. The only thing I don't like is that it would have been nice to have the weight over the rear tires like a rear tank would provide.

The storage space I lose will be reclaimed behind the rear wheels in the rear fenders. I'm planning on making aluminum storage inside the rear fenders, might even make one of them into an aluminum double wall ice chest (well see). I had also considered for a long time making two aluminum tanks inside the fenders but it was just more complicated than the 24 gallon under seats tank.

 

Sounds like a great plan.

So... your daughter welds aluminum too?