www.PNWJeep.com

Finished up the brake setup this weekend.
Cable brake works great...
Need to pick up some RV Jacks and weld the jack receivers on.
After that the frame should be ready to go to the Powder Coater.
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MY ALMOST COMPLETED 5.7 HEMI TJ BUILD

http://www.pirate4x4.com/forum/jeep-har ... 2-5-l.html

Is that brake lever from the original trailer or aftermarket?

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'04 LJ on 35's
'11 Jeep Extreme Trail Edition Camper on 35's
'97 ZJ TSi with lots of cutting

It's the original one but if you google it you can find replicas/replacements on sites like etrailer.com,
Example: https://www.etrailer.com/Accessories-an ... BUQAvD_BwE
These replicas don't look as beefy as the old WWII stuff...
This particular one was rusted to heck and took a lot of soaking and such to free it up and clean it.
Tried to keep as many original parts as possible but the more I push forward the more the original parts go by the wayside for improvements.

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MY ALMOST COMPLETED 5.7 HEMI TJ BUILD

http://www.pirate4x4.com/forum/jeep-har ... 2-5-l.html

Ended up putting a round trailer jack receiver on each corner, made two from some 2inch tube I had. Now I can choose which corner(s) to put jack(s) on. I still have only 2 jacks, but pending on how it goes I may pick up two more.
Also bolted up the brackets I made for the Wrangler taillights. I am going to use some 97 Wrangler taillights I had laying around for now. If the lights end up getting destroyed down the road I may go with recessing LED's in the rear frame.
Now to set up some type of anti-sway bar that can be quick disconnected, there are several ideas I am thinking of, I'll see what happens. That will be the last step before the frame goes to the powder coater....
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MY ALMOST COMPLETED 5.7 HEMI TJ BUILD

http://www.pirate4x4.com/forum/jeep-har ... 2-5-l.html

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_______________________________________________
http://www.auburncarrepair.com
http://www.jeepglass.com
http://www.masterpull.com

Finished welding on the mounts for the trailer jacks and friction sway control.
Clocked the pivot bracket (made a new one) for the brake cable a little more and bulked up the bracket (Original on left, New on Right in pic below).
Sprayed some rubberized coated on the bracket for good measure.
The frame is now officially ready for the powder coater.
Now a day off work without rain would make it much easier to throw the frame in the back of the truck and get it to the powder coater.
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MY ALMOST COMPLETED 5.7 HEMI TJ BUILD

http://www.pirate4x4.com/forum/jeep-har ... 2-5-l.html

Dropped the frame off at the powder coater for a semigloss black coating. Should have it back in a week or three....
I have been looking for an internal frame coater so I don't have to worry about rusting from the inside out.
Found this stuff below... It's supposed to be pretty good and adheres and incapsulates everything, rust-grease-etc....
Comes with a 12inch hose fitted with a 360 degree spray nozzle at the end to be able to fully cover the inside of the frame.
I drilled drain holes about every 24 inches on the frame so I should be able to coat the entire interior of the frame with this stuff.
Should work well?
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MY ALMOST COMPLETED 5.7 HEMI TJ BUILD

http://www.pirate4x4.com/forum/jeep-har ... 2-5-l.html

I bought something similar off amazon to coat the inside of my jeeps frame after the stretch. It sprayed out as a light oil, crept into all the lap joints and then turned into a wax. Any effort to protect inside the frame is better than no effort.

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My CJ6 Build

"Any effort to protect inside the frame is better than no effort"
Exactly what I was thinking.......

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MY ALMOST COMPLETED 5.7 HEMI TJ BUILD

http://www.pirate4x4.com/forum/jeep-har ... 2-5-l.html

I got the frame back from the powder coater and set up in the garage.
I started off running the wires for the Brake Lights and electric brakes, pretty straight forward.
Hung the axle and put the bump stops on - spring pad worked great to mount the bump stops onto.
I hooked up the parking brake cable to the old M416 parking brake handle and it works perfectly.
I then sprayed that internal frame coater by Eastwood, seemed to coat well. It runs out the holes like water so be very careful if you use this stuff. When it dries it reminds me of thick black nail polish, almost like a black marble..
Installed the brake light brackets and brake lights..
Picked up new toy - tube bender, waiting on die so I can make tube fenders for the trailer... * Any suggestions on how to mount to the garage floor temporarily, that way I can set it in a corner when not using it, any good ideas?
Bottom line the frame is all together.
Next - Make Tube Fenders, install on tub.
Weld 1 inch flat steel around upper lip inside tub to prevent water from blowing in to trailer.
Paint the M416 tub & lid.
Weld base mounts for telescoping rack
Touch up paint
Rhino line inside tub and lid.
Weld together rack to fit into base mounts attached to trailer.
Rooftop tent install
Batwing Canopy install
Solar Panel and battery setup
and a few more doodads..
Really want to be ready for snow wheeling and camping this coming winter.....

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MY ALMOST COMPLETED 5.7 HEMI TJ BUILD

http://www.pirate4x4.com/forum/jeep-har ... 2-5-l.html

few more pics..
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MY ALMOST COMPLETED 5.7 HEMI TJ BUILD

http://www.pirate4x4.com/forum/jeep-har ... 2-5-l.html

DUDE!!! That is looking great!!

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http://www.auburncarrepair.com
http://www.jeepglass.com
http://www.masterpull.com

So I pulled the trigger and bought the ProTools 105 HD manual bender.
I got the 1 ½ 180 degree die for it to make tube fenders for the trailer.

Question:
I put the bender together and when I cycle the die arm the degree pointer lifts upward away from the bender degree plate.
at 0 degree the degree pointer is almost flat with the degree plate.
at 180 degrees the point is about ⅛ further away from the degree plate. See the pics.

I had a bigger gap at one point but I went back and ensured the top arms and bottom arms were aligned directly on top of each other which took away some of the gap.
I also took a breaker bar and tightened the heck out of the bolts. AND I made sure the degree plate is flat. And the die is sitting flat on the lightly greased bearing.
Any ideas on how to get it dead-on, or does ⅛ not matter and I will not notice it in the bends?

Thank you for any help ahead of time...
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MY ALMOST COMPLETED 5.7 HEMI TJ BUILD

http://www.pirate4x4.com/forum/jeep-har ... 2-5-l.html

Degree plate bent slightly?

EDIT: nevermind, I see you checked for that already. Hmmm don't know then.

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My CJ6 Build

That was my first thought but No, I took it off and set it on a table (perfectly flat).

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MY ALMOST COMPLETED 5.7 HEMI TJ BUILD

http://www.pirate4x4.com/forum/jeep-har ... 2-5-l.html

A little more headway made today, added a lip to the rim of the tub.
This should help prevent water/dirt/crud from entering the tub.
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MY ALMOST COMPLETED 5.7 HEMI TJ BUILD

http://www.pirate4x4.com/forum/jeep-har ... 2-5-l.html

Looks awesome!

Little more headway, put up some plastic and positioned some fans to do a little spraying today.
I had the paint from the Jeep color matched at my local auto paint supply shop.
Sprayed the base then 3 coats of clear, sure makes all the WWII/Vietnam dents and dings stand out.
It's just a trailer, i'm moving on, 24 hours to dry now.....
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MY ALMOST COMPLETED 5.7 HEMI TJ BUILD

http://www.pirate4x4.com/forum/jeep-har ... 2-5-l.html

The original red paint job ended up really orange pealed due to low pressure. Turns out my water separator was clogged.
So I had to sand it down and paint it again. I did 3 coats of base and 3 coats of clear. I did not paint the very top since it will be Rhino lined.
I was able to get it mounted onto the frame. I am hoping to get a chance to make the tube fenders this weekend.
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MY ALMOST COMPLETED 5.7 HEMI TJ BUILD

http://www.pirate4x4.com/forum/jeep-har ... 2-5-l.html

Made some good headway this past weekend on the tube fenders.
I used 1 1/2 120 wall DOM tube and bent the top corners to 60 degrees and the bottom corners to 90 degrees.
Need to make two cross braces/supports from 5/16 flat bar and then skirt them 1/8 thick plate.
I won't have any time to make much more headway for a while...
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MY ALMOST COMPLETED 5.7 HEMI TJ BUILD

http://www.pirate4x4.com/forum/jeep-har ... 2-5-l.html

I went to Metal SuperMarket in Kent to determine what size steel I was going to use for the telescoping rack.
The trailer frame is 2 inches wide so that limits me to 2x2 for the base the rack will slide into.
The guy at MSM said 2x2 ¼ wall as the base with 1½ ⅛ wall is the best they have for making a telescoping rack.
There seems to be a lot of wiggle room which means a noisy rack down the trail.
Any better ideas using 2x2 as a base, what would fit inside of it better? Any special tubing I could order online?
I drew it out on CAD earlier today. see below...
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MY ALMOST COMPLETED 5.7 HEMI TJ BUILD

http://www.pirate4x4.com/forum/jeep-har ... 2-5-l.html

I got one fender/tube mounted after work today.
The bump stop seems to be set just right for the clearance, will find out at some point, easily adjustable if I need more clearance.
I need to mount the other one this weekend, add some supports and then cut out a template for the sheetmetal...
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MY ALMOST COMPLETED 5.7 HEMI TJ BUILD

http://www.pirate4x4.com/forum/jeep-har ... 2-5-l.html

I added the cross bracing to the tube fenders and had them both mounted up today.
I cut out a cardboard template to use to trace the pattern onto ⅛ plate (need to pick up some plate).
Also picked up some latches, trying to decide which ones to use. Not really crazy about any of them at this point..
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MY ALMOST COMPLETED 5.7 HEMI TJ BUILD

http://www.pirate4x4.com/forum/jeep-har ... 2-5-l.html

6th time is a charm.... After purchasing 5 latches I could not decide on I pulled the trigger on some JK aftermarket hood latches.
They fit pretty snug and seem to look pretty good...
I ordered up the steel sheathing for the tube fenders, pick it up Friday and work on it this weekend.
Just another baby step completed..
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MY ALMOST COMPLETED 5.7 HEMI TJ BUILD

http://www.pirate4x4.com/forum/jeep-har ... 2-5-l.html

Picked up the ⅛ plate, cut out the shape using the template, bent the plate around the tube (not easy). Tacked the plate to the tubing.
Bolted up tube fenders, and boom, fenders done.
Next up rhino lining.
Having them spray the fenders, complete inside of tub and the very top of the lid.
Should be able to get this done in the next 3-4 weeks.
Might start working on the telescoping rack till then.
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MY ALMOST COMPLETED 5.7 HEMI TJ BUILD

http://www.pirate4x4.com/forum/jeep-har ... 2-5-l.html