Build Schmutz FZJ80 build thread

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Nuce truck and excellent build thread. Subscribed!
 
It just dawned on me that while I've been doing a lot of reading on MUD, I have been neglecting to post...So here's an update. The only thing I have really accomplished on the 80 so far this year, is to mount my HID lights on the ARB.

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They are amazing to drive with at night! I don't even bother with the regular headlights half the time. Which becomes scary when I turn them off for oncoming traffic, and suddenly everything in front of me goes dark:doh:

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oh, and I did put 2 coats of Monstaliner on the plywood cargo deck. Helped a mate Monstaliner his uncles truck a few weeks ago, and we had some product leftover...I did this in my 4Runner, and it performed really well. This is not the perfect color, orange would have been better But it looks better than naked plywood IMO

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sometimes one has to step back briefly in order to see progress made.
I decided to blast all the bentonite off the underside of the 80 with a pressure washer today. Poor thing hasn't had a real wash since Moab last October. But the red Moab dust and mud is a bit of a status symbol...while Bentonite from our local foothills is just an ugly, clumpy and heavy curse!
Anyway, back to my original point. A clean rig deserves a photo. And in taking the photo I noticed how much progress I've actually made over the last year. In my OP I said this build would progress like a fine wine -slowly. While I'm far from complete, the results definitely please me...
How it looked in Nov 2014 compared to now
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versus:
May 2016 1

May 2016 1

  • Media owner Schmutz
  • Date added

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For the record, ordered my 4x4labs rear bumper today. Dual swing out with tire carrier. Ordered the kit, so I look forward to a little welding project this summer. After all my research and gathering feedback on this thread:
pros/cons of single v double swing out?
In the end I decided in favor of the dual swing out for the following reasons:
  • Lazy factor: A single would often be very cumbersome and heavy, therefore, especially difficult for the missus to open/close (so I would have to frequently do it for her).
  • Safety factor: there will be a LOT of weight on a single, and sometimes we just don't find level ground where we wheel. Add three small kids to that mix...
  • Daily practicality factor: in my garage a single would make accessing the cargo area extremely awkward, and I fear I would end up cursing it more.
  • Towing factor: I will regularly tow a trailer for work and recreational reasons, (although, not off-road). A single would not open fully with either of my trailers
And why the 4x4Labs bumper?
  • It's been around for over a decade, with excellent feedback from those who have used and abused it in the field.
  • Superior ground clearance over many other styles.
  • I like the styling and design.
  • Totally customizable.
  • Accessorizable at a later date.
  • Available in a kit, so I can have the satisfaction of welding it up Myself, and save money at the same time.
  • The 15% savings from the group buy!!!
That having been said, I'would like to acknowledge that there are many other excellent rear bumper options out there, so this was not an easy decision to make).

Looking forward to receiving it !!!
 
Wow! Has it really been so long since I did anything significant to my 80? Sadly so. The wheeling gods have not been kind to me this year...

Anyway, I have been looking forward immensely to my 4x4 Labs rear bumper build, which I ordered early this summer...
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Finally the time has come. I have blocked out some time this week and Hope to complete it!:)
 
Of all the days my father-in-law could have needed my air compressor -why today? This is not fair!!! Those factory bolts holding on the tow hitch have likely not been removed in 21 years and I have to do it by hand now!!! :bang: I hope this is not indicative of how this project will proceed...
 
Sorry about the holdup, I'm looking forward to seeing how the 4x4 labs bumper build goes. I have to do something with my daughter's ol' 96er stock bumper so I think she might inherit mine and my 80 will likely get the 4x4 labs diy kit. I can weld just fine (if I chill out and take my time!) and I do powder coating so the kit would be great.

I absolutely love your 80. She has perfect mods, color and style. Keep the thread coming!
 
All in all not a bad afternoon's work. Removed all the original items and made a stockpile (hee hee). All in all we shed 116 lbs (give or take a few pounds of Moab dirt);)
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All the major surgery complete, and trying on new bumper parts:
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Btw, you other mudders who have installed one of these bumpers, or similar: what are you all doing about the resonator that has to be cut out? Are you reusing it? If so where? Or are you simply terminating the exhaust pipe without it? If so, where are you terminating the pipe? Thanks for any input...
 
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Frustrating afternoon today. Luke's instructions do state: "some grinding will be needed to get the parts to fit together perfectly". OK, that's understandable. However this bumper just got rediculous... After fiddling with the shell and both sides for several hours, using clamps, pry bars and even a come-along, this was how my PS rear corner lined up:
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I couldn't grind off the lip, or the Hi-lift jack pocket would have only had 1/8" - 1/4" of material above it. So I tacked it flush:
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But now the bottom has a 5/16" gap :bang:
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And I haven't even begun to grind on it yet... :mad: Luke, this one might have slipped by QC...
 
I had to beat the hell out of my wings using a 6 pound sledge hammer and pieces of
2X4 screwed to a chunk plywood in various configurations to support the piece while I beat it into submission. In the end, It worked out well even though there were a few gaps to fill. These projects teach us the value of patients. BTW, it looks like you live in a very nice place.
 
baldilocks said:
I had to beat the hell out of my wings using a 6 pound sledge hammer and pieces of
2X4 screwed to a chunk plywood in various configurations to support the piece while I beat it into submission. In the end, It worked out well even though there were a few gaps to fill. These projects teach us the value of patients. BTW, it looks like you live in a very nice place.
Click to expand...
Thanks for the pep talk @baldilocks ! I needed to hear that. And yes, it's definitely one version of paradise out here:D
 
I was reading through my build thread this morning, and noticed my OP comment about enjoying the journey on this build. So, enough with the griping...My attitude is readjusted. All the primary components have been beaten and coerced into submission, and tacked. Time to pull it off and turn up the heat...
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They are a sweet looking bumper. I'm sure you will get it done nice. Is there any way to keep the mud flaps if you want to?
Thinking about one for my 80 but i like having the mud flaps day to day just to keep the truck clean, and maybe take them off to wheel
 
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