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Norcal69's Common Sense Build.

Discussion in 'Builds and Fabricators Forum' started by Norcal69, Sep 11, 2014.

  1. May 19, 2020
    Norcal69

    Norcal69 Out of the box thinker 2020 Sponsor 2019 Sponsor

    Northern California
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    This is as far as I got last night before being pulled away. All holes opened up to 1/2".
    The vertical rows of 4 holes will get opened up to 1-1/2" and the 3 hole rows will get opened up to 1".

    [​IMG]
     
    Muzikp, Rich M., homersdog and 2 others like this.
  2. May 21, 2020
    Norcal69

    Norcal69 Out of the box thinker 2020 Sponsor 2019 Sponsor

    Northern California
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    Here is as far as I got last night before getting pulled away. The 1" holes for the 1" dimple die are all drilled. The smaller holes in the bottom of the shelf are waiting to get enlarged to 1.5" for the 1.5" dimple die. The rim of the shelf is circled with 1/2" holes which will be hit with the 1/2" dimple die.
    I'm really starting to regret telling Steve that I would build one of these for him....... after mine was done..... :banghead:

    [​IMG]
     
    Muzikp and ITLKSEZ like this.
  3. May 21, 2020
    FinoCJ

    FinoCJ 1970 CJ5 Staff Member 2020 Sponsor

    Denver, CO
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    aluminum next time?
     
  4. May 21, 2020
    Norcal69

    Norcal69 Out of the box thinker 2020 Sponsor 2019 Sponsor

    Northern California
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    My only problem with aluminum is welding the corners... Aluminum would certainly be easier to put all these holes in..... :confused:
    I will weigh this one when I get the 1.5" holes hogged out. I would be interested in knowing what your shelf weighs?
     
  5. May 21, 2020
    FinoCJ

    FinoCJ 1970 CJ5 Staff Member 2020 Sponsor

    Denver, CO
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    According to HF, the shipping weight is just under 27lbs (300 lb. Capacity ATV Cargo Carrier)
    Of course, I cut-off the extended hitch which I just weighed at about 4lbs - so lets say after removing packaging and hitch its about 20 lbs for just the shelf, but then with the bracketry to mount to the roll bar is a few pounds (shaft collars mostly)...So still under 25lbs all total. When moving it around and test fitting it...it seemed even lighter than that, like under 20lbs.
     
    Last edited: May 21, 2020
  6. May 21, 2020
    Buildflycrash

    Buildflycrash Member 2020 Sponsor

    Gulf Breeze FL...
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    Can you show us the photo of what that looked like installed again?
     
  7. May 21, 2020
    Norcal69

    Norcal69 Out of the box thinker 2020 Sponsor 2019 Sponsor

    Northern California
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    Muzikp and FinoCJ like this.
  8. May 21, 2020
    FinoCJ

    FinoCJ 1970 CJ5 Staff Member 2020 Sponsor

    Denver, CO
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    If I were to do it again...I would change the mounting and probably have used 4 exhaust clamps instead of the 2 shaft collars....maybe my welds just make me nervous, but when things twist and flex i worry all the stress gets put on my poor short welds....I had planned to take it out when not in use, but its never left the jeep since I put it in...
    Here it is loaded....[​IMG]

    Here it is loaded with 3 waterproof duffels - 1 bag each for my wife and my personal clothes, and a 3rd, larger one for the 2 sleeping bags and tent etc....and i think there is one of those solar heating water bag/shower thingy....Great place to put bulky but not heavy items and makes cargo room for the heavy stuff like cooler, food, cook stuff, parts and tools, and maybe some whiskey/beer....

    FWIW - I really like that mine only has the rail/edging along 3 sides, and has no lip on the rear so its very easy to load things from the rear....I used nylon webbing cam straps (loop style) that we use for rigging gear in the oar boat.
     
  9. May 22, 2020
    Norcal69

    Norcal69 Out of the box thinker 2020 Sponsor 2019 Sponsor

    Northern California
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    After what felt like hours of drilling holes. I was able to do something satisfying.

    [​IMG]

    [​IMG]


    Here is the end result. After dimpling the 1.5" holes I decided to hog out all the 1" holes to 1.5" The 1/2" dimples around the outside are hard to see.

    [​IMG]

    [​IMG]
     
  10. May 22, 2020
    FinoCJ

    FinoCJ 1970 CJ5 Staff Member 2020 Sponsor

    Denver, CO
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    Final product is looking good. Was thinking about the aluminum option some more...I would probably go hack and just use some 90degree corner brackets on the sides and drill and bolt the corners together...of course, that would assume I had a brake to bend the sides up to begin with....
     
  11. May 22, 2020
    Norcal69

    Norcal69 Out of the box thinker 2020 Sponsor 2019 Sponsor

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    If choose to gift this one to Steve..... in exchange for a case or two of premium beer..... I will build the next one out of aluminum and farm out the corner welding.
    I used to have my brother weld aluminum, after hours at his old job, but he got a new job that doesn't allow that kinda stuff....... :rolleyes:
    The final product in steel weighs 15 lbs with mounting brackets.
     
  12. May 22, 2020
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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    *Steel is quieter than aluminum. (y)
     
  13. May 22, 2020
    FinoCJ

    FinoCJ 1970 CJ5 Staff Member 2020 Sponsor

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    that is pretty good
     
  14. May 22, 2020
    Norcal69

    Norcal69 Out of the box thinker 2020 Sponsor 2019 Sponsor

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    This is true.
    My old roof basket and cross bars weighed like 39lbs. I think lowering the weight to 15... and getting it nearly 2' lower on the jeep... will really help when the swaybar is unhooked.
     
    FinoCJ likes this.
  15. May 22, 2020
    FinoCJ

    FinoCJ 1970 CJ5 Staff Member 2020 Sponsor

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    and then don't put too much stuff on it...camping out of ecj5 is more akin to backpacking than to car camping, but you travel slower, get dirtier, and can carry just a bit more beer and whiskey.
     
  16. May 22, 2020
    Norcal69

    Norcal69 Out of the box thinker 2020 Sponsor 2019 Sponsor

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    This is exactly what I told my wife! We needed to free up space and weight without sacrificing our beer/whiskey supply!
    I came into some old barn wood that I was able to sell for $$$ so we put the whole jeep camping kit on a diet!
    Old Cabelas camp chairs were 14lbs each x2..... New Helinox chairs..... 2lbs. 2oz each x2.
    Old Cabelas camp table was 4.5 lbs..... New Helinox table..... 1lb. 8oz.
    Old Coleman tent was 13lbs..... New alps tent..... 6lbs. 6oz.
    We shaved 32 or so lbs off of the camp furniture and the new items take up only half as much space.
    Backpacking sleeping bags are next on the list!
    32 lbs doesn't seem like much, but when it's on the roof it is!
     
  17. May 22, 2020
    Steve's 70-5

    Steve's 70-5 Member 2020 Sponsor

    Louisville, Ky
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    I will say, you do have some pretty dimples. :bananatool::bananatool::bananatool:
     
    Muzikp likes this.
  18. May 22, 2020
    Norcal69

    Norcal69 Out of the box thinker 2020 Sponsor 2019 Sponsor

    Northern California
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    Mock up time.

    [​IMG]


    [​IMG]
     
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  19. May 22, 2020
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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    Is that a HF jack stand? Careful you don’t get under that shelf until it’s securely mounted. :sneak:
     
    Snoops, Focker, Fireball and 2 others like this.
  20. May 22, 2020
    Rich M.

    Rich M. Shoe pusher

    Maryland
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    Bookmarked under " ideas to shamelessly rip off"
     
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