Lexan JKU, hacked into J8/brute style rig

[summerof95]

The JK Unlimited (four-door Wrangler) may have something of a minivan reputation among many Jeep drivers, but since my LHS doesn't sell the G6, and I wanted something I could see in person before buying, I ended up owning a JKU.

But hey, it's still a Jeep. If you don't like something, you change it!


I've seen this done (with much better results) on hardbody builds, but I already have a body that I don't particularly care for, so why not hack it into something little more "unique?"


Before:



First, remove the back seats and the fuel cell.


Then, cut a piece of styrene to fit inside the tub rails.


Drill holes for roll cage, and test fit.


Cut the hole for my tool box, and painted with "Truck bed coating."
Also removed some of the cross-members of the roll-cage.


Mark and cut the rear of the cab out of styrene, paint silver and black.


Assemble!


Good visibility for the rear-view


I still need to make corners for the rear of the cab.
Then I'll be painting the whole thing a khaki-tan.

[T I N Y]

These are the kind of builds I like...
If you don't like something....fool around with it till ya do....lol

[summerof95]

Started working on the cab corners.



Once I get it sanded and painted, I'll be putting a clear styrene window in there, too.

Also, with all the extra cargo space, I figured I'd need some bungees. Not too shabby.


Future plans include some 1.9 beadlocks and Dirt Grabbers.

After that, I think all I'll need is a wider front bumper, and it'll be class-1 legal.
I think I'll try to make an ARB styled one out of styrene (with plenty of gussets). I'll stick to the stock one for random trail runs and messing around.


Few questions:
Cutting out the back seats doesn't count as excessive body trimming as far as C1 goes, right?

Also, Does any one know if Lexan-specific paint will stick to styrene, too? I really don't want to have to color-match between various types of paint.

[Ty@Tekin]

I like it! I would hope JKU drivers don't really have a bad reputation, it's still a Jeep and some of us need more space than a shoe box.

[summerof95]

Maybe "bad" isn't the right word...
When it's the size of a minivan, has the engine of a minivan, and all the luxuries of a minivan, it doesn't seem like much of a Wrangler anymore.
They have kind of a soccer-mom reputation.
Not bad, just different, I suppose.


Any way...
Started working on the bumper. This is what it's based on:



Instead of the rubber pads, mine will have shackles. I haven't decided if I want to do a grill guard yet. I think, being made of styrene, it would just snap off if it ever hit something. I may do one anyways, just for looks.



The beginning:


I'm gluing with plastic cement first (the kind that melts/welds), then covering the joints in E6000 for added measure.

Here I've got the main shape cut, and started on the front.




I added the front of the "wings," and closed the ends.
The front tabs will cut down, reinforced, then drill for the shackles.




I figured the only way this will hold up to even the slightest abuse is to gusset the hell outtav' it.


Over kill, maybe.
Not enough, maybe.
Time will tell.

Needs a lot of sanding, then some paint.


At 16cm wide, this should qualify for C1. All that would be left is to get my smaller tires.


Question:
Does anyone have a link to a desert-sand colored Lexan paint?
I couldn't find it on Amazon, nor at my LHS.

[summerof95]

Sanded.

Of course, the camera seems to bring out every imperfection... It looks really nice in person, and the seams all feel smooth. I cleaned up the end-cap a little more after taking this photo, too.

Painting is probably tomorrow or Wednesday. Maybe.




PS. I put a tow-chain through one of the shackles and picked the rig up off the ground. Scary as hell, but it held.

[summerof95]

Got the C1 bumper painted and mounted. I used the same "truck bed coating" that I used on the rear deck. I like the texture it has.

Some quick shots:



How the whole thing sits, currently:


Sorry that none of the photos are real great, I need to take it out again, so I can get some good ones in the sunlight. Makes everything look better.

Anyone have a set of used 1.9 Dirt Grabbers they want to part with?