1985 BJ70 CND refubishing and modifications

[crushers]

there was a need to be able to disconnect the snow blower quickly and easily.
also the winch won't be on during the summer so a quick disconnect made sense.
mount the relay in a place where it will be safe and out of the way. next to the rad mount and tucked behind the batteries.
measure and cut the wires, install the quick disconnects, silicone the back and a rubber boot for the front ... nice and dry.
the other switch is for front control of the winch for attaching and removing the blower.

 

[crushers]

the blower has power turn shoot, remote start and stop so these 6 wires needed a quick connect.
a typical trailer attachment will work fine, he will be able to still wear gloves while hooking up in a snow storm.
heavy duty with a spring to help prevent kinking ...

 

[crushers]

kind of nice to have the colors stamped right next to the attaching hole.
once all attached then silicone the inlet, don't "shove" the silicone inside but use a decent amount, this way IF you need to get back inside you can peel the silicone away and out comes the wire.
once the silicone dries then screw the big spring back on ...

 

[crushers]

i had to relocate the factory relay to under the upper rad support lip.
someone mentioned the sharp edges of the ties as a concern, i looked at the actual tie tool but didn't like the bulky design of the ones i found so i bought this snip. not sharp now. thanks for the warning.
where the wires to the winch and the plow lights will be secured. reusable ties so easy on and off at the beginning and the end of the season.

 

[crushers]

time to start on the roof rack.
i wanted to keep the weight down so aluminum is being used.
it was Mitch's idea to cut the corners and to step the top inward.
hard at work... if you can call doing what you like "work"

 

[crushers]

the main beam is 1.5" and the upper wrap and spacers and cross bars are 1" ...

it is pretty tight in there when the rack is laying down.

 

[crushers]

test fitting front
clears the snorkel
allows for the "work" lights

 

[crushers]

test fitting the rear
clears the rear "work" light and allows them to tilt

 

[crushers]

meanwhile i found some interior flood lamps to illuminate the driver and passenger areas. very close to flush mount and doesn't take up much room inside the console.

 

[crushers]

then it was on to the rear bumper
the rear winch arrived and the control pack was removed and will be relocated off the winch to minimize the size of the rear bumper.
the twin spindles showed up
and the scetching began ...

 

[crushers]

the cross bars tacked in place and set on the roof again to see how it looks ...

 

[crushers]

plastic board to test fit and see how it looks ...

that winch makes it look big but it still has tons of clearence to the ground.
it will have the winch, twin swing outs (spare tire and basket), 2 X 5" back up lights, ladder, steps, fairlead, plug for winch controller, clevis attachment points, side markers, trailer hitch and plug.

 

[crushers]

then you open the plastic template and lay it out on the new sheet with all the measurment, bend angles etc
and off to the water jetters.
they will cut it out, bend it up and we can weld it. a few short welds and the cover is completed ...

 

[crushers]

making the winch basket, the cover will slide over this basket.

 

[crushers]

some more pics...

 

[crushers]

prepping for the inverter install into the rear door.
originally we were going to install one of my small door storage cabinets but this unit will be hidden out of site in that door.
you flip down the unit as you would any of the pocket doors and plug in and start grinding, sanding, cutting away. once done, unplug, fold back up and out of site and protected from damage...

 

[Gun Runner 5]

Does the rear "work light" have it's own on-off switch or is is activated somewhere else?
Thanks.....

 

[crushers]

it will be activated by its own switch on the dash...

 

[1985bj70]

Coming along nicely. Good call on the flush cutters, these are the type I usually use at work:

Save yourself from shredding your hands later, it is surprising how sharp those untrimmed zap straps can be.

 

[Horgey]

Ok so, that rear bumper is awesome. Far more awesome than the rear bumper I currently have. Seems like your plan is to make pretty much my ideal bumper. Swingouts for tire and jerry can bin, winch, hitch, etc. Two questions for you, what do you intend to do to maintain taillight visibility and also allow for swingouts? Secondly, any interest in making a second identical bumper?

Moar pictures please!!