Build Rough 470 aka Lunch Mobile aka Lunch Box Build Thread (condensed)

[KiPod]

May-July 2026:
While waiting on other parts to arrive and in between other steps, I worked on a custom headlight setup. First cardboard, then wood, then metal, and then powder coat and wiring. Baja Design DOT LP6’s for driving/low/high and LP4’s for “fog” or off road high’s.

 

[KiPod]

And now with the lights mounted.

 

[KiPod]

IFS w/ 35’s and SAS w/ 37’s
(and my old hood/grill setup)

 

[KiPod]

I used an oil cooler for the power steering return line from box to reservoir. I had a local hydraulics shop make a custom pressure line with 100 series pump side fitting and 80 series box side fitting. That’s the blue hose you see in some pics. I’ll secure it more once I make a little skid to go under radiator.

 

[KiPod]

July-August 2026:

While normal driving around town is fine, when you start to flex some issues become apparent. With the front panhard bar already being at a sloped angle and the 100 series frame being wider than an 80, when you drop the axle it swings driver side. That’s when I noticed the passenger shock hitting the frame rail and completely limiting the down travel of the shock. Here you can see the gap between frame rail and shock on driver side and passenger side, where it hits.

The axle would drop level and then when the passenger shock hit the frame, it would stop on that side and the driver would keep going without interference.

 

[KiPod]

It’s not as severe of an angle as the rear shocks but I thought I could get away with a little spacing for the lower shock mount. Later on I might move the upper out as well, but for now here’s what I did to gain some extra clearance:

Made a plate with factory and secondary location.

Trimmed the factory mount to make space for the repositioned lower bushing.

Added vertical support

And then welded and painted it all.

I can still revert back to factory location, but by moving the shock out (and slightly back) I gained way more needed clearance between the shock and frame rail.

 

[David310]

Nice build! Talk to us about the hood vents. I’m thinking of doing something similar to reduce heat soak in the 100 degree Texas weather.

 

[KiPod]

Nice build! Talk to us about the hood vents. I’m thinking of doing something similar to reduce heat soak in the 100 degree Texas weather.

Yeah, was starting to have overheating issues when hauling family and trailer up mountains in higher elevation. Used a few different companies to get the look I was after:

Louvered Panels, Escondido, CA

At RodLouvers® and Sheet Metal Design in Escondido, CA, our products ensure that your vehicle is in great condition. Our louvered panels will keep your Jeep automobiles and modern hot rods cool regardless of the weather. For additional information about what we offer, get in touch with our team.

rodlouvers.com

Jeep Hood Vents | Hood Louvers for Wrangler JK/TJ/YJ & More | GenRight Off Road

Improve engine cooling with GenRight Jeep hood louvers. Designed for Wrangler JK, TJ, YJ and more, these aluminum vents reduce heat and add trail-ready style.

genright.com

It’s been a few years but from peak temps under load, it dropped like 15-20 degrees Celsius, if I remember correctly. App I use to monitor battery temps is in Celsius.

 

[jaewastooshort]

I'm entirely unexperienced with the solid front axle world, but Watts Link setups are supposed to be far superior in terms of lateral movement compared to panhard bars on rear ends, is there any reason that shouldn't work on a front axle as well? I realize that it is a bulky setup and that alone might make it entirely impractical...

 

[KiPod]

I'm entirely unexperienced with the solid front axle world, but Watts Link setups are supposed to be far superior in terms of lateral movement compared to panhard bars on rear ends, is there any reason that shouldn't work on a front axle as well? I realize that it is a bulky setup and that alone might make it entirely impractical...

My guess would be steering, but I’m new to front solid axle as well. I figured I would get it front and rear solid and then play with 3/4 link setups.

 

[hoser]

I'm entirely unexperienced with the solid front axle world, but Watts Link setups are supposed to be far superior in terms of lateral movement compared to panhard bars on rear ends, is there any reason that shouldn't work on a front axle as well? I realize that it is a bulky setup and that alone might make it entirely impractical...

Yes, packaging for one. Panhard does have lateral movement but the drag link (steering) is near parallel to the panhard and so the steering and panhard move together and the steering stays relatively straight through the suspension cycle.

Watts and drag link would not be compatible because the difference in lateral movement. Would need hydraulic ram steering where the ram is fastened to the center of the axle, not to the frame. But full hydraulic steering is not street legal. An electric power ram steering could work but I don’t see it much.

 

[KiPod]

Next up was a bit more protection. Using scrap metal for rear arm sliders (another idea from Alex):

 

[squidmotion]

When people say ‘Built, Not Bought’ …. this is the kind of rig I think of.

 

[KiPod]

When people say ‘Built, Not Bought’ …. this is the kind of rig I think of.

Appreciate the kind words.

I’ve been working on modifying a set of Slee skids to fit. Like 90-95% happy with how they turned out. First was the transfer case skid with trans crossmember. I had to notch a section out of each side for the radius arm mounts.

 

[KiPod]

Then I trimmed, bent, drilled, and welded the trans skid to make it clear the driveshaft. I used longer bolts at the bottom of the trans to extend out the front end and mount to that. Not 100% on this idea for multiple reasons, but for now it’s okay.

 

[excessive]

incredible fab skills !

 

[KiPod]

incredible fab skills !

Thank you.

Went back and widened the bolt holes on the front of the skid and added a rubber insulator to help with vibration transfer. Still working to get the skid acceptable for me.

Went ahead and hacked the front skid to protect the radiator and give some support and coverage for the PS lines.

Then worked on some limit straps since the shocks can drop more than the current springs.

Also used a combination of @Delta VS and EimKeith axle side to get the rear panhard bar closer to level

 

[KiPod]

September 2026:

Finally got the chance to take it out on some mild trails this past weekend. Not many obstacles to really test it, but enough for a shake down and see what rubs.

I hope to get back out in another few weeks for a more serious test on some familiar trails.

 

[TRDdrew]

I've seen this truck in person but not since the SAS, impressive is the understatement of the year

 

[KiPod]

I've seen this truck in person but not since the SAS, impressive is the understatement of the year

Dude, it’s been a project and a half up to this point, and I still have more to get done. I’m just super happy to have it mostly “trailable”. You need to drive it next time, though. It’s (as my oldest son calls it) “a lot”.