'04 TJ Rubicon clone by CFM

[CarterFab]

I don't have much time anymore to do build threads on all the builds we do and custom work but I had to share this one. This was a really cool build for us to take on, as we also built the 1:1 for the customer that this was based off of.
1:1 Specs
'04 TJ Rubicon
5.5" X Factor Stretch kit from Rock Krawler suspension (Magic 100" wb)
37" Cooper STT tires
17x9 Walker Evans black/chrome beadlocks
GenRight stubby bumper with CFM tube work
Quadratec 10,000lb winch
Poison Spyder hood louver kit
20" Rigid Industries light bar on custom CFM hood mounts
Custom CFM front tube fenders
GenRight rocker armor with CFM sliders/steps
GenRight rear quarter armor w/CFM tube fenders
Rear CFM swing out/drop down tire carrier and fuel carrier

Clone specs
Axial scx10 drivetrain and chassis
Walker Evans black/chrome wheels
Cloned front bumper
KK Poison Spyder hood louver kit
VP Rigid Industries 2" light bar
Cloned front tube fenders, rocker armor, sliders/steps, rear quarter armor, and spare tire carrier
Rc4wd Rock Krawler suspension links
Matching wheelbase at 10"
Tamiya YJ body converted to a TJ

 

[CarterFab]

We have built the 1:1 a couple times now. We originally did a Rubicon Express 4.5" LA kit back in '04 and ran the rig on 33" and 35" tires. In mid 2012 we stretched the wheelbase and did the body armor modifications and tire carrier. Then in mid 2013 we installed the 5.5" X Factor stretch kit from our friends at Rock Krawler and installed the 37" tires and Walker Evans bead locks.

 

[CarterFab]

We are now building a Zero G buggy for the customer and when we picked up the deposit for that build, 2 weeks ago, he asked if I could have a clone ready for Christmas to give to his son to carry back to California with him. Reluctantly I said sure.
Grabbed a SCX Honcho kit since it had the right tires, wheels, and light kit to get the ball rolling, along with the drivetrain and electronics needed for this particular rig. RPPHobby had a special that included a battery with the truck, picked up the Tamiya YJ body, and a winch from them also.
The hood louver kit and license plate are from Krawler Konceptz, and the licensed Rock Krawler links are from Rc4wd.
First thing to do was get the body modified. Trimmed off the factory fenders and running boards, filled the square head light holes, removed the body mold lines, and had to shave the entire his down to get rid of the hump so the hood louver kit would fit.

 

[CarterFab]

Next was body armor. Used 22ga steel and made the rocker armor and rear quarter armor all one piece.

Then I used 1/8" solid rod for all the tube work. Started by attaching the sliders/steps to the rocker armor. To get a clean attachment point, I drilled the armor then plug welded from the back side.

Also started the front tube fenders.

 

[CarterFab]

Next was the spare tire carrier.
Used our "shortie" Fab Tabs for hinge brackets and some 3/16" chromoly for the hinge. Carrier is 1/8" solid rod. Used one of our "90*" Fab Tabs and our body pin mounts to make the latch system. Super clean, no body clips or large hardware detracting from the scale appeal.

 

[CarterFab]

Then I added the rear tube fenders to the rear quarter armor, attaching the same way I did with the sliders and plug welding from the back side.

Wasn't taking a whole lot of pictures as I couldn't post them anywhere till the build was delivered and I was under a tight deadline already.
The front bumper was made from a machined piece of solid steel, added the winch plate with 22ga sheet and the tubing on it is 3/16" 4130 chromoly tube.

 

[CarterFab]

Next comes the "fun" part, paint and assembly. At this point, it's Christmas Eve morning and the first cost of paint is being applied to everything. Went back over the entire body with a fine grit sanding foam pad and thoroughly washed everything. Luckily weather was on my side and it was sunny and 55*

All the armor was painted flat black, the hood louver was shot satin black, and the body was shot with 4 coats of gloss black.

http://img.tapatalk.com/d/
13/12/26/amaveda3.jpg

 

[JatoTheRipper]

That's really cool. I've always thought about filling in the square headlights and making round openings in my Jeep CC01 body, but I don't have the patience for fab work. Can't wait to see the finished product.

 

[CarterFab]

Sorry I'm rushing through this and if I leave something out, just ask.
To set the wheel base correctly, I grabbed a set of the Rock Krawler links from Rc4wd. It comes with two different lengths, didn't measure, but the short versions were a direct match with the front lowers. For the rear, I had to take 2.5" out of the wheelbase I get it down to 10". I took the long set of links and machined them down to length for the lowers. I found a set of old Crawler InNovations Delrin links that were very short and happened to be a perfect match for the uppers. Relocated the shock hoops and cut off the back of the frame. I then used the cut off frame rails, welded to the bottom of the chassis frame resold on the rear, so the tail lights would clear the body underneath. Didn't get good pics of this mod I just realized but you can see the lights in the following pics.

All the body armor is secured with 0-80 hardware. Assembly took a while putting all the hood louver and armor screws in.

 

[Louisbaby]

Dude, those look great. Great metal work you've done there. "thumbsup"

 

[Szczerba]

Super clean rig , Clay. Proportions are perfect.

 

[fordsuperduty]

Looks really good man. The flat fender setup makes it really look like a crawler.

Sent from my iPhone in the shop

 

[cruuk]

This is the nicest work ive seen in a long time. If you ever want to build me one let me know

 

[ROWDY RACING]

Incredible, love it! "thumbsup"

 

[CarterFab]

This is the nicest work ive seen in a long time. If you ever want to build me one let me know

Works the other way around. If you want something built, email us at carterfab@ymail.com

 

[G-crawler]

Very nice metal work!