Builds Stretched 1-Ton FJ40

[Mike Shull]

In addition to the welder, somebody needs to take the drill away from me! 16 bolts later…

The lower portion of the bumper is done and I am extremely satisfied with it. I am going to switch gears and move back to the cage next so that I can get it ready for the upholstery shop in a month. I’ll finish the carrier later.

 

[Ditcherman]

In addition to the welder, somebody needs to take the drill away from me! 16 bolts later…

The lower portion of the bumper is done and I am extremely satisfied with it. I am going to switch gears and move back to the cage next so that I can get it ready for the upholstery shop in a month. I’ll finish the carrier later.

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You gave credit to DJ for being behind the CAD design on your roll cage, how much easier did it make it to have it drawn up vs winging it? Did he have software to calculate angles and/or how and where to set the tube in the bender for the right length?

My bending projects so far have been ‘bend and cut off the extra later’ which seems like a bad idea right now…

 

[Mike Shull]

You gave credit to DJ for being behind the CAD design on your roll cage, how much easier did it make it to have it drawn up vs winging it? Did he have software to calculate angles and/or how and where to set the tube in the bender for the right length?

My bending projects so far have been ‘bend and cut off the extra later’ which seems like a bad idea right now…

He also came over and helped me with the bending. His setup was pretty amazing. His program and his experience told him exactly where to put the clamp blocks and the exact degree to bend with shrinkage factored in.

I was so impressed with his Rogue Fab bender that I had to get one myself. DJ actually found one used on Marketplace that I snatched up minutes after it was posted. I’ve used a few benders and this one is the most precise. It is normal and good practice to have extra length at the end that you cut to fit in place.

 

[bluehawk]

I’ve got a JD Squared bender and I bought the Bend Tech software but don’t even know where to start at to design the cage. I’ve watched several YouTube videos but still not sure how to get the A pillars started. I did measure and design the halo bar in Bend Tech.

 

[EWheeler]

I’ve got a JD Squared bender and I bought the Bend Tech software but don’t even know where to start at to design the cage. I’ve watched several YouTube videos but still not sure how to get the A pillars started. I did measure and design the halo bar in Bend Tech.

This guy's video series really helped me figure out bending, but I have not used Bend Tech....

 

[Mike Shull]

I’ve got a JD Squared bender and I bought the Bend Tech software but don’t even know where to start at to design the cage. I’ve watched several YouTube videos but still not sure how to get the A pillars started. I did measure and design the halo bar in Bend Tech.

I started on a napkin and gave that to DJ.

 

[Ditcherman]

This guy's video series really helped me figure out bending, but I have not used Bend Tech....

I’ve watched a bunch of his but it’s time for a refresher course. I cut the cheater things he talks about and they’ve been helpful.

I’ve got a JD Squared bender and I bought the Bend Tech software but don’t even know where to start at to design the cage. I’ve watched several YouTube videos but still not sure how to get the A pillars started. I did measure and design the halo bar in Bend Tech.

This is kinda how I see myself… I can buy some extra tube and just start in bending, but if I had to figure out a computer program I’d feel stuck…but I don’t know what don’t know, so…

I started on a napkin and gave that to DJ.

This is where my heart lies, on so many projects over the years. I might get the graph paper out to figure out exactly how a hydraulic cylinder needs to move or something like that, but it’s mostly a tape measure and a chop saw and whack that angle iron!

 

[Mike Shull]

I’ve watched a bunch of his but it’s time for a refresher course. I cut the cheater things he talks about and they’ve been helpful.

This is kinda how I see myself… I can buy some extra tube and just start in bending, but if I had to figure out a computer program I’d feel stuck…but I don’t know what don’t know, so…

This is where my heart lies, on so many projects over the years. I might get the graph paper out to figure out exactly how a hydraulic cylinder needs to move or something like that, but it’s mostly a tape measure and a chop saw and whack that angle iron!

This is version 2.0 converted from the napkin to paper. I also love building this way. I’ve never thought of myself as being strong with creating art but I have really enjoyed making a dream

 

[DangerNoodle]

He also came over and helped me with the bending. His setup was pretty amazing. His program and his experience told him exactly where to put the clamp blocks and the exact degree to bend with shrinkage factored in.

I was so impressed with his Rogue Fab bender that I had to get one myself. DJ actually found one used on Marketplace that I snatched up minutes after it was posted. I’ve used a few benders and this one is the most precise. It is normal and good practice to have extra length at the end that you cut to fit in place.

I usually leave about a half inch to inch extra, enough to make a notch then adjust if needed. I've screwed myself several times by messing up the notch and not having enough material extra to change the angle or clocking without a gnarly gap.

 

[DangerNoodle]

I’ve got a JD Squared bender and I bought the Bend Tech software but don’t even know where to start at to design the cage. I’ve watched several YouTube videos but still not sure how to get the A pillars started. I did measure and design the halo bar in Bend Tech.

I'm happy to help with some design if needed. Let me know.

 

[Mike Shull]

The soft top rails (the ones that have arrived) are in. The tailgate piece needs a little adjustment so that the weatherstripping will clear the tailgate as it shuts. When it is done I will be able to open the tailgate without having to unzip my back window.

 

[Ditcherman]

The soft top rails (the ones that have arrived) are in. The tailgate piece needs a little adjustment so the weatherstripping will clear the tailgate as it shuts. When it is done I will be able to open the tailgate without having to unzip my back window.

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Is that the same size tire on back? It looks so much bigger than the others.
Making me rethink spare and cooler/fuel…

 

[Mike Shull]

Is that the same size tire on back? It looks so much bigger than the others.
Making me rethink spare and cooler/fuel…

Yes, that is the same size spare. It’s a bit more aggressive than my other tires.

 

[Ditcherman]

Yes, that is the same size spare. It’s a bit more aggressive than my other tires.

I could tell the tread was different and thought maybe you were testing an extra-large.
How’s it feel on the new swing away?
It looks good.

 

[Mike Shull]

I could tell the tread was different and thought maybe you were testing an extra-large.
How’s it feel on the new swing away?
It looks good.

Thanks! I got that tire used a few years ago so that I could finish my suspension and body clearances. That tire has been on the road in the right-rear position for the past year while I was waiting for my final wheel to arrive and last week was the first time that I drove the Cruiser on the highway with all 4 Micky Thompson tires in the road. It’s amazing how much smoother it rides without the one Maxxis tire on the road, and three of my Mickey Thompson tires aren’t balanced yet.

The carrier is stout though there is a little flex coming from the spindle when I swing the tire open. I am going to run it this way and see what happens. Later on I may add one more gusset to the frame if I can fit something around the sway bar. My old carrier flexed a bit, too, though probably not as much. I added an extra tie in to my cage when the carrier is closed and it’s solid when it is latched. I’m pretty happy with the result! I will add an antenna mount, then paint.

 

[Broski]

I added an extra tie in to my cage when the carrier is closed and it’s solid when it is latched.

This is what I was thinking would make it solid.

 

[Mike Shull]

I also replaced the rear springs to handle the additional weight. I went from 150/150 to 225/180 lb per Accutune’s recommendation and it sits pretty nice.

 

[Mike Shull]

I am building rock sliders today!

 

[Mike Shull]

I got a little further with the right slider. I’m glad that I went with the 1-1/4” dimple die like @Ditcherman did on his truck. It looks beefy.

 

[Firemedic831]

I got a little further with the right slider. I’m glad that I went with the 1-1/4” dimple die like @Ditcherman did on his truck. It looks beefy.

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This pic looks like one of those clown house Mirror pics when you have a big head and little body