Gone Postal : Mail Jeep Build
- Thread starter 95yjjeep
- Start date
Nissanwheeler
Active Member
- Joined
- Sep 4, 2010
- Location
- kannapolis NC
sounds good man! cant wait to see this thing in actionInterior cage for sure. it'll be a simple 8 point cage. I'm going to start accumulating tubing in the next few days.The seats will be mounted directly to the cage and I will tie in the cage to the frame at 6 of the 8 points. I want to build the cage before I add the sheet metal to the floor so I can drop the cage down through the floor to weld the top of the cage bars. I thought that would make it easier and cleaner than drilling a bunch of 1.75" holes in the floor to drop the cage down to weld them up.
Thanks! I'm starting to like it more. I'm never satisfied. Now I won't rest until the cage and seats are in. These things are an addiction!
Trust me....me too!
Short update: I ordered 30ft of 1.75" .120 wall DOM tubing from Barnes 4wd. I'm hoping it comes in today so I can get started on the roll cage this weekend. 
If not, I'll plate the inside of the framerails at the rear spring perches and add bracing at the rear of the frame using some 1.75" tubing I have laying around.
If not, I'll plate the inside of the framerails at the rear spring perches and add bracing at the rear of the frame using some 1.75" tubing I have laying around.
Barnes 4wd
Well-Known Member
- Joined
- Aug 6, 2007
- Location
- Etowah NC
Short update: I ordered 30ft of 1.75" .120 wall DOM tubing from Barnes 4wd. I'm hoping it comes in today so I can get started on the roll cage this weekend.
Chad,
FedEx says that it is on the truck for delivery!
Thanks for your business
Brad
Brad, you're the man! Thanks for the help. You've got great service and are always super quick!
TJcrawler97
Joe
- Joined
- Oct 12, 2006
- Location
- Charlotte
Ive got to stop by and check this out someday....since you live in my neighborhood! looks great! 
BERTIE RENEGADE
Active Member
- Joined
- Jul 25, 2009
Good job , I like all the oroginal work . One of a kind.
Ive got to stop by and check this out someday....since you live in my neighborhood! looks great!
for sure! come on by. i'll be out there again tomorrow.
Good job , I like all the oroginal work . One of a kind.
thanks man! much appreciated! i don't have to worry about getting any "bolt on" items for this thing to say the least.
I added the frame / rear bumper cross supports. I figured it would stiffen up the rear frame to prevent twisting.
this image is looking from the back bumper forward if that makes sense.
another picture. welding upside down in a tight space sucks!!! all i had was some nasty looking gloss paint so i'll get some satin paint tomorrow and hit them again. i hate shiny black!
this image is looking from the back bumper forward if that makes sense.
another picture. welding upside down in a tight space sucks!!! all i had was some nasty looking gloss paint so i'll get some satin paint tomorrow and hit them again. i hate shiny black!
1980CJ7
If it don't go, chrome it
- Joined
- Dec 10, 2006
- Location
- Leesville, NC
Congrats on the JP magazine coverage. Just went through the whole thread playboy style(pics) ....looks like you have your welder all figured out. Keep up the good work.
Thanks man! I'm very very happy with my welder. I'll take that as a compliment! I wouldn't trade it for anything. I would LOVE to try one of the new 252 or DVI Millers to see how they run but I'm very happy with mine. This build is a friggin' blast for me! Glad you like...
I had a little tube bending party today...and enjoyed the hell out of it! I have to go back to work so I can get some rest.
I got the b-pillar finished up with the floor plates and everything. building a cage in this thing is tough since you can't take the top off. I'll be adding a angled down c-pillar and a typical a-pillar that follows the windshield and dash. This was just all I could get done today.
bend and welds of the b-pillar.
I put the b-piller on the wheel well and welded a tube that travels down to the floor so I would have more seat room. I want the seats as far back as they can possibly go so I can actually sit in the jeep comfortably. The tube that goes to the floor will have a tube that goes up and attaches to the a-pillar down bar and a cross bar that goes across and holds the rear tabs of the corbeau seats.
again, this down bar will have a bar that attaches the passenger and driver side.
I got the b-pillar finished up with the floor plates and everything. building a cage in this thing is tough since you can't take the top off. I'll be adding a angled down c-pillar and a typical a-pillar that follows the windshield and dash. This was just all I could get done today.
bend and welds of the b-pillar.
I put the b-piller on the wheel well and welded a tube that travels down to the floor so I would have more seat room. I want the seats as far back as they can possibly go so I can actually sit in the jeep comfortably. The tube that goes to the floor will have a tube that goes up and attaches to the a-pillar down bar and a cross bar that goes across and holds the rear tabs of the corbeau seats.
again, this down bar will have a bar that attaches the passenger and driver side.
Copasetic
Active Member
- Joined
- Jun 22, 2008
- Location
- Grovetown, GA
Been following this since page one and it's coming together awesome. That looks like the same fuel cell I'm looking at putting into the back of my Samurai. 30"x9"x12" right? Do you like how it's built? I may go with the 17" high, 7" deep one. Depends on how much 2" is going to affect how my back seat is going to fit. Keep up the good work!
Been following this since page one and it's coming together awesome. That looks like the same fuel cell I'm looking at putting into the back of my Samurai. 30"x9"x12" right? Do you like how it's built? I may go with the 17" high, 7" deep one. Depends on how much 2" is going to affect how my back seat is going to fit. Keep up the good work!
Thanks man! Your sami is looking sweet too! It's the RCI 2161A (I think that's the model #). It's the 15 gallon model. I like it so far. It's fits nicely in the back. I picked it up 2nd hand but this one or the bigger model you are referencing are the 2 models I considered initially. I only got this one because I was able to pick it up for a great price.
had a long day in the garage.
i got the rear most angled b-c pillar tubes bent, notched and welded in place.
initial mockup stage.
outside shot showing the angle of the rear tubework.
i also taped off the front dash and primed it. I'm going to leave it gray primed to match the interior of the factory DJ-5s.
i notched everything and got it as precise at possible so i could make everything look as good and be as strong as possible. Notching without a tube notcher TAKES FOREVER!!
Rear floor plate. These will bolt to tubing that connects to the frame.
another shot of the dash. It looks so much better than rust.
Upclose of B-Pillar weld.
A-pillar / windshield downtubes.
i got the rear most angled b-c pillar tubes bent, notched and welded in place.
initial mockup stage.
outside shot showing the angle of the rear tubework.
i also taped off the front dash and primed it. I'm going to leave it gray primed to match the interior of the factory DJ-5s.
i notched everything and got it as precise at possible so i could make everything look as good and be as strong as possible. Notching without a tube notcher TAKES FOREVER!!
Rear floor plate. These will bolt to tubing that connects to the frame.
another shot of the dash. It looks so much better than rust.
Upclose of B-Pillar weld.
A-pillar / windshield downtubes.
Then I cut, notched, and welded in the cross bar for the seats.
another shot.
the whole rear portion completely welded.
Lower cross bar. The rear seat mounts will be attached similar to how it's shown but I'm going to cut those mounts in half and re-drill the holes so I can get the seats a little lower.
rear welded in.
Just getting an idea on how the seats will look. They'll sit a good 1 1/2" lower than what is shown.
rear. You can see my pretty primered upper dash and windshield frame.
another shot.
the whole rear portion completely welded.
Lower cross bar. The rear seat mounts will be attached similar to how it's shown but I'm going to cut those mounts in half and re-drill the holes so I can get the seats a little lower.
rear welded in.
Just getting an idea on how the seats will look. They'll sit a good 1 1/2" lower than what is shown.
rear. You can see my pretty primered upper dash and windshield frame.
Nissanwheeler
Active Member
- Joined
- Sep 4, 2010
- Location
- kannapolis NC
This thing is coming together quick, when is it going to be wheel-able, or when are you shootin for it to be wheel-able?
Haha! Yeah I'm prone to working like a mad man on something until it's done. I'm really taking my time so it all turns out how I want it to and so I don't get burnt out. I hope to have it wheel-able by mid-summer 2012. That's my goal. We'll see.
Nothing major but I did pick up some Garage Sale Tube Fender Inserts from Genright Offroad. I'm planning on putting the inserts behind the air vents on the postal. They're Stainless steel so they should look good behind the door air flap things.
got to work in the garage again today. gota love work vacation.
my steering wheel came in. i picked it up off of amazon.com since i had a gift card to use. i like it. it's different than most that you see in jeeps.
you can see my high tech tubing holder. haha!
passenger side.
I also picked up a tubing notcher from northern tool today so notching the a-b pillar connecting piece was a breeze.
upclose of one of the notches.
more.
upclose of the spliced tubing for the a-pillar. i welded a plug in that is 1.5" .250 wall so it should be plenty strong.
my steering wheel came in. i picked it up off of amazon.com since i had a gift card to use. i like it. it's different than most that you see in jeeps.
you can see my high tech tubing holder. haha!
passenger side.
I also picked up a tubing notcher from northern tool today so notching the a-b pillar connecting piece was a breeze.
upclose of one of the notches.
more.
upclose of the spliced tubing for the a-pillar. i welded a plug in that is 1.5" .250 wall so it should be plenty strong.
- Joined
- Mar 10, 2005
- Location
- Hooterville (24171)
Mount the door bars flat/straight and adjust the seats with the mounting tabs/brackets...
Okay. I'll see what i can do to make them straight.
I got to work on my jeep today.
Got all the tubing bent, welded up and I'm only lacking welding top side of the B-pillar. I'll have to cut the roof out to get to that so I'll do that when I get some more garage time.
Upclose of center windshield bar.
I made some custom little seat tabs to keep the rear seats low.
I cut, notched and welded in the windshield dash bars and the center bar is bent to match the angle of the side bars.
another.
From the front.
Rear.
Got all the tubing bent, welded up and I'm only lacking welding top side of the B-pillar. I'll have to cut the roof out to get to that so I'll do that when I get some more garage time.
Upclose of center windshield bar.
I made some custom little seat tabs to keep the rear seats low.
I cut, notched and welded in the windshield dash bars and the center bar is bent to match the angle of the side bars.
another.
From the front.
Rear.