Gear's Baja JK Thread

[Gear]

Well it has been two months since I brought the new JK home(May 14, 2007) and it is now time to start the transformation-- Baja JK

http://i298.photobucket.com/albums/mm251/justinpitcairn/P1010566.jpg
Here is the Baja JK at Gorman OHV park a couple of hours after purchase.

Lets skip ahead - I hate looking at stock vehicle photographs. Here it is today!

http://i298.photobucket.com/albums/mm251/justinpitcairn/P1020177.jpg
So far I have added the following to the Baja JK -

Shrockworks front bumper with grill hoop, winch mount, and skid plate.
Warn 9.5Ti winch with synthetic line
Baja Designs Sol Tek HID driving lights
HID headlights
sPOD and Source - 6 switch panel and relay source.
Optima yellow top battery.
Side marker lights changed to turn signals mod.
AEV Bridger 16" wheels
Goodyear MTR 315/75/16
Removed the Jeep badges.


Here is what is on order for the Baja JK -

Jeeperman rear bumper with swingout tire carrier
Nth Degree Mobility's 4+ lift kit
Custom built roof rack
Paint those AEV Bridgers Black:yikes:

[calamaridog]

Looking better already:)

You going to paint the wheels or powdercoat them?

[cshontz]

I love it, Justin. I was just messing with the "build your own" feature on Jeep's web site, and ended up with an ExPo white Rubimited just like yours.

[Gear]

Yes, it is a great Jeep and a family wagon to boot. Love the fact that I can take the freedom top off of the front two seats and leave the kids covered in the back with the rear portion of the hard top. I have a lot more photographs of the installs and will post as time permits.

Calamaridog wrote-
You going to paint the wheels or powdercoat them?
I am just going to rattle can them flat black at first and see if I like the look if not I will add some semi gloss. As long as I do not scratch up the clear coat to much the flat black primer should be fine.

[Gear]

Here is the HID headlight install-

http://im1.shutterfly.com/procserv/47b7d932b3127cce87032819aac700000045108EatWzFu0cO
I 3M adhesived the ballast to the bottom of the cowl.

http://im1.shutterfly.com/procserv/47b7d932b3127cce87030a00aacf00000036108EatWzFu0cO
Here they are all wired up.

http://im1.shutterfly.com/procserv/47b7d932b3127cce87030accaa0300000036108EatWzFu0cO
The wires from the ballast making there way to the relay.

http://im1.shutterfly.com/procserv/47b7d932b3127cce87030ad0aa1f00000035108EatWzFu0cO
I placed the relay to the right of the battery. You can trace the red positive lead back to the relay from the battery in the photograph.

http://im1.shutterfly.com/procserv/47b7d932b3127cce87030afcaa3300000045108EatWzFu0cO
Here is the driverside light hooked up. Inside you can see the silver box(ignitor) has been 3M adhesived to the Jeep frame.

http://im1.shutterfly.com/procserv/47b7d932b3127cce87032823aafd00000036108EatWzFu0cO
Headlights low beam before HID.

http://im1.shutterfly.com/procserv/47b7d901b3127cce879e014e7aae00000026108EatWzFu0cO
Headlights low beam after HID.

http://im1.shutterfly.com/procserv/47b7d901b3127cce879e0113fbc300000026108EatWzFu0cO
One more on the road(low beam). Let there be light. :victory:

[Grim Reaper]

Jeep is going ot get me yet! I really like the new JK. Its a size I can live with and that multi part hard top fits my needs quite well!!
I like that front bumper. Looks very clean and looks part of the vehicle instead of something just bolted on where it sort of fit.

I haven't talked my Buddy into letting me drive his yet. Actually I am worried I would like it enough to go get one on Mom's employee discount. LOL Now if it could handle our Airstream...

[jeffryscott]

Looks great ... I too really like the JK. Being able to take the top off is a big plus, I have missed that on every vehicle I've owned since my trusty little Samurai of old.

[LUISJG]

stock on 35' :smileeek:

[Gear]

LUISJG wrote
stock on 35'

Yes, I know kind of scarry. Your comment made my laugh. Hopefully Nth Degree comes thru with there lift kit on time. Should be released any day now.

[Gear]

Baja JK has the first customer installed sPOD and Source and I could not be more pleased with this product. This is worth every penny. This is my third Jeep build and this product has turned the difficult decisions of were to put all the relays and switches into one easy answer, sPOD and the Source. I have photographed the install and below you can see for yourself how easy it is to install.

http://im1.shutterfly.com/procserv/47b7d932b3127cce87036f6d6b3800000036108EatWzFu0cO
A quick photograph of the Source which includes 6 relays and 6 fuse locations. Simple add your positive and negative wires for any switch to work aux. lights, CB, 2M, Engle refrigerator, etc.

http://im1.shutterfly.com/procserv/47b7d932b3127cce87036f596b0c00000046108EatWzFu0cO
The sPOD with 6 illuminated rocker switches. I chose all red but other colors are available.

http://im1.shutterfly.com/procserv/47b7d932b3127cce87036f016b5400000046108EatWzFu0cO
The Source attaches to the computer using two existing 8mm bolts. Then simply attach the Pos. & Neg. leads to the battery.

http://im1.shutterfly.com/procserv/47b7d932b3127cce8703717a6b2000000046108EatWzFu0cO
Here is the access hole thru the firewall. Either disconnect the rear windshield washer hose and drill a larger whole for the sPOD wire or simple cut a slit.

http://im1.shutterfly.com/procserv/47b7d939b3127cce87f3d9a687e900000046108EatWzFu0cO
The sPOD bracket is installed behind the stock footmans loop. Drill out the rivets and screw in the supplied screws.

http://im1.shutterfly.com/procserv/47b7d932b3127cce87036fe16bb400000046108EatWzFu0cO
Simply run the wire bundle down the A pilar thru the firewall and attach the termals as marked. Simple as that.

http://im1.shutterfly.com/procserv/47b7d932b3127cce87036fb4ead100000046108EatWzFu0cO
Finished sPOD!

You can find this product at www.4x4spod.com

[durango_60]

What a great solution, looks like I'm ordering an sPOD.

[RunninRubicon]

I like your front bumper. It manages to keep the wench out of the air flow to he radiator. I live in the SW desert and it's a challenge to keep things cool as you would like.

[FourByLand]

Nice build!

[Boston Mangler]

Awesome!

Your attention to detail on your installs is great! :safari-rig:

[Willman]

Love your Jeep!

Keep the mods coming!!!

:chowtime:

[XJxplorer]

Where do i get one of these sPOD's???

[Gear]

Here is the link www.4x4spod.com

[XJxplorer]

hmmm..I see its only for wranglers...

Is there any way to hook it up to an xj???

[Gear]

XJxplorer
Is there any way to hook it up to an xj???

Not really sure. My suggestion is to give a quick email to John the sPOD guy at sales@4x4s-pod.com. He checks his emails regularly and should be able to give you an answer. Let me know how it turns out!

[Gear]

Well I scuffed up the new AEV Bridger wheels today and sprayed a nice coat of black on them. Here are the photographs. Now I just want to sit outside and :drool: over my cool rims and tires.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/P1020323.jpg
Semi Gloss Black

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/P1020327.jpg
On the Jeep.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/P1020320.jpg
Also tried Flat Black

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/P1020331.jpg
Flat Black on the Jeep.

Looks like I will be going with Semi Gloss Black. I just need to go pick up a few more cans of paint.:victory:

[articulate]

Well I scuffed up the new AEV Bridger wheels today and sprayed a nice coat of black on them. Here are the photographs. Now I just want to sit outside and :drool: over my cool rims and tires.

http://im1.shutterfly.com/procserv/47b7d906b3127cceb863e8eda05b00000025108EatWzFu0cO
Semi Gloss Black

I love it.

I just noticed the switch pod - OMG those are cool. There are more switches than I need, but what the heck. I can always add accessories.

[Gear]

I added a small but significant mod for my youngest son. He has always disliked driving at night in the dark. So I found this little Petzl headlamp the other day which has a 360 degree swivel LED light source( white as well as red.) It can be clipped to the brim of your hat or worn with the supplied headband. I simple 3M adhesived it to the center roll bar. I can use it to read maps or change a flat. Best of all I can place the one red LED on for driving at night and all is well with my youngest.:)

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Headlamp/P1020303.jpg
Petzl E+lite
http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Headlamp/P1020306.jpg
What's inside, headband, storage case, batteries. Shown cliped to my hat.
http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Headlamp/P1020314.jpg
3 white LED's or 1 red LED.
http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Headlamp/P1000402.jpg
E+lite shown in the upper left corner
http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Headlamp/P1000403.jpg
1 red LED -- Works great!

[4Rescue]

http://im1.shutterfly.com/procserv/47b7d938b3127cce87960b473eb000000036108EatWzFu0cO



Holy No Up Travel Batman!!! Looks tough tho.

[LUISJG]

LUISJG wrote

Yes, I know kind of scarry. Your comment made my laugh. Hopefully Nth Degree comes thru with there lift kit on time. Should be released any day now.


35 look lot better on the jk ,,I been debating into getting 35 and selling my 33's but then I gonna have to change gears,,or maybe not how does yours behave with stock gears?

[Gear]

So far the stock gears have been just fine. Yes there are times when you have to step on the gas to make the Jeep down shift but for the most part I don't feel a need to run out and get them. With this said I would like a little more power out of the Jeep and know that gears should be first on the list. I need to contact Off-road Evolution and see if they are still doing front and rear gears for $1000. This would be worth it. Will just have to give them a call on Monday. Oh and your JK looks great on 33". We all want the next size up. 37" would be nice but not really practical.

[LUISJG]

So far the stock gears have been just fine. Yes there are times when you have to step on the gas to make the Jeep down shift but for the most part I don't feel a need to run out and get them. With this said I would like a little more power out of the Jeep and know that gears should be first on the list. I need to contact Off-road Evolution and see if they are still doing front and rear gears for $1000. This would be worth it. Will just have to give them a call on Monday. Oh and your JK looks great on 33". We all want the next size up. 37" would be nice but not really practical.

yeah,,, I rather use the 1000 for gears for something else. like bumpers.
maybe in 3 years I might change ..

just finish my cb install look at my jk thread will upload pics tonight.

[Gear]

The other day I started work on installing my Jeeperman bumper.

http://im1.shutterfly.com/procserv/47b7d609b3127cceba0d0366c83900000026108EatWzFu0cO
First off, remove the 14 lbs. plastic brick that Jeep calls a bumper.

http://im1.shutterfly.com/procserv/47b7d633b3127cceb96a74af340800000026108EatWzFu0cO
Here is the back of the Jeep without the brick. In the photo I still need to remove the receiver hitch, 2 metal tabs on top of the crossmember and the metal side wings. The last two items are what you unbolt to take the brick off your Jeep. You will then bolt up the new bumper to the 4 bolt holes at the receiver hitch as well as 3 bolts on each side of the frame members.

http://im1.shutterfly.com/procserv/47b7d609b3127cceba01e88f090e00000026108EatWzFu0cO
Here is the parts bag with the expanded view of how the bumper goes together. No instructions were supplied. The overall build is pretty self explanatory but I will give some of my thought on where things go just to help you get over some of the hurdles. The photographs show the order of the build. Oh and by the way when I called Jeeperman about the instructions they said they were on there website at www.Jeeperman.com. You just need to adapt the TJ instructions to you JK.

http://im1.shutterfly.com/procserv/47b7d609b3127cceba01e976c85f00000026108EatWzFu0cO
Install the latch pin and delron spacer. The hole in the picture is where you attach the bump stop.

http://im1.shutterfly.com/procserv/47b7d609b3127cceba01e971496800000026108EatWzFu0cO
Important use the two supplied nuts on the backside of the bumper to space the bump stop off the bumper. This will align the swingout with the latch pin.

http://im1.shutterfly.com/procserv/47b7d609b3127cceba01e965497c00000026108EatWzFu0cO
Here is the latch that attaches to the lower portion of the swingout.


http://im1.shutterfly.com/procserv/47b7d609b3127cceba01e96b497200000026108EatWzFu0cO
Here is the layout for the swingout carrier. Goes like this bolt, aluminum top spacer, inner spacer, seal, bearing. This goes in the top portion of the swingout. The bottom will have bearing, seal, inner spacer, thick washer, 2 thin washers. Also in the photograph is the swingout catch bar and a zerk fitting to grease the bearings.

http://im1.shutterfly.com/procserv/47b7d609b3127cceba01e95ac87300000025108EatWzFu0cO
Lower section greased and ready for the swingout.

http://im1.shutterfly.com/procserv/47b7d609b3127cceba01e947495e00000025108EatWzFu0cO
Here is everything in place except the top aluminum cover with bolt. I had to modify this part. See next photograph.

http://im1.shutterfly.com/procserv/47b7d609b3127cceba01fe6188db00000025108EatWzFu0cO
Must be black.

To be continued --

[Gear]

http://im1.shutterfly.com/procserv/47b7d609b3127cceba01fe7b88c100000025108EatWzFu0cO
Install zerk fitting.

http://im1.shutterfly.com/procserv/47b7d609b3127cceba0114c6880900000035108EatWzFu0cO
Install the latch catch. You will need a snap ring tool to make this happen. You can see in this photograph that I am missing some powdercoat. If you do not install the bump stop on the bumper correctly as stated above the swingout will extended to far and scratch the powdercoat.

http://im1.shutterfly.com/procserv/47b7d609b3127cceba01fe6988d300000025108EatWzFu0cO
This picture shows the correct bolt pattern for 5 on 5. This is the new Jeep JK wheel pattern. I used a washer and a spare nut to press the wheel studs into the metal.

http://im1.shutterfly.com/procserv/47b7d609b3127cceba01fe6c09e600000025108EatWzFu0cO
Completed hinge.

http://im1.shutterfly.com/procserv/47b7d627b3127cceb88f6f562ef400000026108EatWzFu0cO
Finished install.

[RunninRubicon]

Wow! Nice bumper and tire carrier. Great job on detailing it for us.:wings:

[Gear]

Thanks for the compliments. More mods to come.

[Gear]

Once the Jeeperman bumper was installed I started in on the 7 way trailer harness for my Chaser #15. I went ahead and purchased the harness from the Jeep dealership and although it was expensive(just under $80.00) I think I got my moneys worth. Now that Jeep is using a CAN-BUS system the harness has relays back at the tail light complicating the harness.

http://i298.photobucket.com/albums/mm251/justinpitcairn/7%20way%20harness/P1020338.jpg
First off remove the two inner screws from the driverside tail light. This removes the whole tail light.

http://i298.photobucket.com/albums/mm251/justinpitcairn/7%20way%20harness/P1020344.jpg
Use a pair of wire cutters and snip all the zip ties holding the existing flat 4 way plug. Disconnect the plug at the light and unclip it from the bumper mount.

http://i298.photobucket.com/albums/mm251/justinpitcairn/7%20way%20harness/P1020346.jpg
This zip tie at the bottom was the most difficult to get to.

http://i298.photobucket.com/albums/mm251/justinpitcairn/7%20way%20harness/P1020353.jpg
Here is the removed flat 4 way plug.

http://i298.photobucket.com/albums/mm251/justinpitcairn/7%20way%20harness/P1020341.jpg
Now simple clip the new harness to the tail light and feed the wires down to the frame, across the rear cross member and up the passangerside frame rail. Connect the positive and negative wires at the battery. Feed the blue and red(see below) wires into the cab. I went thru the firewall at the same spot I used for my sPOD install. Zip tie the harness along the way.

http://im1.shutterfly.com/procserv/47b7d609b3127cceba0114b3094c00000026108EatWzFu0cO
I decided to flush mount the plug into the rear bumper. Here is where I made the cut.

http://i298.photobucket.com/albums/mm251/justinpitcairn/7%20way%20harness/P1000048.jpg
I used a 2" whole saw to drill the bumper.

http://i298.photobucket.com/albums/mm251/justinpitcairn/7%20way%20harness/P1000541.jpg
Painted the raw metal and installed the new 7 way connector.


Important -- A note about the factory wire harness. It comes with the supplied blue wire for hooking up the trailer brakes. Unfortunately there is not a wire in the harness for a brake trigger. Jeep has one under the dash for this but it does not provide enough of a load to trigger the Prodigy brake controller that I have. So with this said I had to add a red wire(brake trigger) to the harness. Not difficult but time consuming.

http://i298.photobucket.com/albums/mm251/justinpitcairn/7%20way%20harness/P1000623.jpg
Here is the red wire(brake trigger) connected to the white/yellow wire at the tail light.

http://i298.photobucket.com/albums/mm251/justinpitcairn/7%20way%20harness/P1000626.jpg
And one more wide shot.

[Gear]

Decided it was time to mount up my 10# PowerTank. Since I had the tank, bracket and hose fittings already I called up PowerTank and ordered there roll bar clamps and a hose for the back bumper.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/P1000650.jpg
Here are the goodies

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/P1000657.jpg
10# tank installed with 2 roll bar clamps and bracket. Very secure.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/P1000673.jpg
5 1/2' of Superflexy hose is run thru the gromet at the top of the wheel well down to the bumper.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/P1000652-1.jpg
Drill another hole into the bumper and connect the hose fittings.

[Gear]

Went ahead and installed my Painless wire 7 fuse power center under the driverside dash. Pulled this from my 03 Rubicon so all I had to do was fabricate a small bracket. Used a sheet of thick steel and a piece of C channel.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Painless%207%20way%20harness/P1000550.jpg
Made the sheet oversized just in case I decide to add a couple of relays.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Painless%207%20way%20harness/P1000555.jpg
Here is the back side.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Painless%207%20way%20harness/P1000556.jpg
The C channel gives me clearance for the nut that secures the bolt in place. This makes it so I do not need to put two wrenches underneth the dash to take it out. I notched the C channel to fit over the ridges where it will be mounted. From past experience this bracket needs to be mounted securely while still being easy to take in and out.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Painless%207%20way%20harness/P1000726.jpg
Simple install the bracket and secure the one nut using one ratcheting 7/16 wrench.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Painless%207%20way%20harness/P1000727.jpg
Wiring the 7 fuses. One positive wire goes to the battery positive terminal. One of the bolt holes on the plastic case has a negative ground wire. I extended a second wire to the above bolt(center). Also you will need to give what ever you are powering up a ground(negative) wire. I simple took four 16 gauge wires approxiametly 16" long and wrapped them in one plastic sleeve. This was attached to the same bolt. Now all I have to do is quickly connect the ground wire to these easily accessible wires. I left the wires long so I can pull the whole panel down to work on it if necessary.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Painless%207%20way%20harness/P1000572.jpg
Now 4 of these fuses are ignition hot. So with Jeeps new CAN-BUS it is a little difficult to find an ignition hot wire. The only one I know of is the 12 volt power in the dash(left side of gear shift). Take the wire from the Painless box(very well marked) and run it under the steering column and using a coat hanger pull it up behind the 12 volt power source.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Painless%207%20way%20harness/P1000581.jpg
Now connect the ignition hot to the blue/pink wire using a scotch lock.

I am now ready to install my CB, 2M, flashlight, etc.

[Gear]

Mounted my Streamlight SL-20XP flashlight to the driverside seat bracket.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Streamlight%20Flashlight/P1000631.jpg
First off I made a small backing plate to hang the flashlight holder on.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Streamlight%20Flashlight/P1000693.jpg
Next I drilled two small holes into the seat bracket(none sliding side). Mounted the flashlight and ran the positive and negative wires under the seat up to the Painless wire 7 fuse holder. Attached the two wires and I now have a rechargeable flashlight in the Jeep.

[RunninRubicon]

Decided it was time to mount up my 10# PowerTank. Since I had the tank, bracket and hose fittings already I called up PowerTank and ordered there roll bar clamps and a hose for the back bumper.

http://im1.shutterfly.com/procserv/47b7d609b3127cceba01523188dd00000025108EatWzFu0cO
Here are the goodies

http://im1.shutterfly.com/procserv/47b7d609b3127cceba0d9c6d88e500000025108EatWzFu0cO
10# tank installed with 2 roll bar clamps and bracket. Very secure.

http://im1.shutterfly.com/procserv/47b7d609b3127cceba01522809f400000025108EatWzFu0cO
5 1/2' of Superflexy hose is run thru the gromet at the top of the wheel well down to the bumper.

http://im1.shutterfly.com/procserv/47b7d609b3127cceba01522388cf00000026108EatWzFu0cO
Drill another hole into the bumper and connect the hose fittings.

I truely like this idea. I still use a hose and have to open-up the back window when the vinyl window is dusty and hard to unzip. This is a much smarter idea having it plumped into the rear bumper. This will cut down on abuse my zippers take at the end of the trail when I'm ready to head home and blow off the dust....not carry it home! I am sure others will as well.

[LUISJG]

CO2 tank !! yeah! great idea...
stop it!! my pocket is already empty....

[Gear]

Spent 6 hours this morning bending pipe for the roof rack. Just thought I would share some photographs.

http://im1.shutterfly.com/procserv/47b7d722b3127ccebafc929bd95500000025108EatWzFu0cO
Rear will be bolted to the Jeeperman bumper. The front will be welded to a second set of A pilar brackets that I purchased.

http://im1.shutterfly.com/procserv/47b7d722b3127ccebafc928c587200000026108EatWzFu0cO
Nothing like bending 14' of 1 1/2" pipe.

http://im1.shutterfly.com/procserv/47b7d722b3127ccebafc93e999bf00000026108EatWzFu0cO
Side shot of the Baja JK. That's Joe on the left.

http://im1.shutterfly.com/procserv/47b7d722b3127ccebafc93ca18ac00000025108EatWzFu0cO
Rear compound bend.

Many Thanks to Joe at Joehauler.com. He is the one working the machines.

[Mlachica]

Oh man, mighty fine job Justin! Everything is coming together so nicely. Can't wait to see the next update...

[Gray Matter]

Hey Justin:

Long time no see. The new Rubicon is looking great. I was wondering whether you were going to bring the Jeep back to Hunter to have a new rack made or procure one in Calif. Looking forward to the finished product.

Brian L.

[Gear]

Hello Brian
Good to see you found the Portal. Here is your friendly :wavey:. Now how about posting up some photographs of your Jeeps. Yes, John at Hunter Off-road does some nice work. I just needed to have it done a lot closer to home.

[MtnMan]

Gear,
Any more pictures of the roof rack? Looks great so far.

[Gear]

Here are two more shots with the side bars welded up. We are working on the cross members as we speak.

http://im1.shutterfly.com/procserv/47b7d732b3127ccebbc9d6c3e15b00000026108EatWzFu0cO

http://im1.shutterfly.com/procserv/47b7d732b3127ccebbc9d6c8606000000025108EatWzFu0cO

[LUISJG]

Looking great !!!

[JChatary]

One word.

WOW. :Wow1:

[ujoint]

That spare tire looks HUGE on the back of that JK!

[MtnMan]

That looks great so far, :clapsmile What do you think your load capacity will be?

[Gear]

MtnMan wrote -
What do you think your load capacity will be?

I am not sure on the new JK rack. My tollerances to the hard top will be very close. I hope to be able to use it for the following. Transporting Sea Kayaks atleast 2 (100 pounds). I want to be able to use it as a viewing plateform for the Baja races. This means my brother and I standing and sitting on top(375 pounds). Then there is the possibility of moving the RTT to the JK. I also built it to take on my shopping chores at Home Depot. The rack on the TJ held 12 bags of wet bark up there. I think that was about the max. Here is a shot of that rack.

http://im1.shutterfly.com/procserv/47b6da36b3127cce8821d18faac500000026108EatWzFu0cO
2003 Jeep Wrangler Rubicon

http://im1.shutterfly.com/procserv/47b7d739b3127ccebbaf9f560d8e00000025108EatWzFu0cO
Baja Jk Rack close to A pilar 1/2" clearance at the top.

[kcowyo]

Very unique. Your JK is going to be something to see when it's all said and done.



12 bags of wet bark.....? :confused:

[Gear]

Kcowyo wrote -
12 bags of wet bark.....?

12 bags of mulch(bark) for the front yard, 2 cubic feet each. I don't know the weight off hand but I sure could feel it up top.

[Gear]

Here are the cross members tacked in place. The rack is very close to the roof but I think it is going to work. By the way I can still remove the front hard top panels.

http://im1.shutterfly.com/procserv/47b7d739b3127ccebc5121ffbc1d00000026108EatWzFu0cO
Front view.

http://im1.shutterfly.com/procserv/47b7d739b3127ccebc5121e43d3600000026108EatWzFu0cO
Back view.

http://im1.shutterfly.com/procserv/47b7d739b3127ccebc5121e83d3a00000026108EatWzFu0cO
Here is how the cross members will be disconnected. Mainly used at the rear for easy removal of the hard top.

http://im1.shutterfly.com/procserv/47b7d739b3127ccebc5121dfbc3d00000026108EatWzFu0cO
Cross bar clearance. Hard top panels just squeeze out.

http://im1.shutterfly.com/procserv/47b7d739b3127ccebc5121c3bc2100000026108EatWzFu0cO
This photograph shows a side profile of the front bar. I located it further back on this rack so that I can make a fairing. I am going to try a rack pad at first. This should take up the space between the hardtop and the rack. Eliminating the small amount of wind noise that is present. This could make it hard to get the front hard top panels off. If so I will look at some sort of plastic fairing similar to Yakima's.

[Willman]

Looks good Gear!:)


Are you going to be done before the Trophy?


Are you doing this Fab yourself?.....Clean bends by the way!......You must have a nice shop!


I have been thinking of making a rack like that for my Tacoma.

:jumping:

[Gear]

Willman wrote -
Are you going to be done before the Trophy?

Are you doing this Fab yourself?.....Clean bends by the way!......You must have a nice shop!


I hope to have it done by the Trophy. Along with alot of other things(Radio's).

The Fab work is being done by Joe and www.joehauler.com. Joe is a great guy with alot of baja experience. We are working together to build this rack.

Looking forward to seeing your nice Tacoma at the Trophy.

[Willman]

Willman wrote -

I hope to have it done by the Trophy. Along with alot of other things(Radio's).

The Fab work is being done by Joe and www.joehauler.com. Joe is a great guy with alot of baja experience. We are working together to build this rack.

Looking forward to seeing your nice Tacoma at the Trophy.

Very nice!

Ditto on taking a look at your sweet rig as well!

:chowtime:

Good luck with the project!

:)

[crossbones]

Here are two more shots with the side bars welded up. We are working on the cross members as we speak.

http://im1.shutterfly.com/procserv/47b7d732b3127ccebbc9d6c3e15b00000026108EatWzFu0cO

http://im1.shutterfly.com/procserv/47b7d732b3127ccebbc9d6c8606000000025108EatWzFu0cO

Love your JK And the painted black bridgers are awesome! I noticed that your tires do not stick out past your flares, and they are 12.5 wide MTR correct? with 4.6" backspacing on the AEV... weird because some tires stick out with this combo and urs don't.. any thoughts?

[Gear]

Crossbones wrote -
I noticed that your tires do not stick out past your flares

The tires are Goodyear MTR's 315-75-16. You are correct they do not stick out. This is the reason I went with AEV. They make wheels specifically for the JK. I love the Black too. Thanks for the comments.

[LUISJG]

Man ,that rack has inspired me to get on the bench,,,
specialy that ladder !!! or gas tank holder ??

very cool.

[Gear]

Baja 1000 - just thought I would post up a few photographs of our adventure.

http://im1.shutterfly.com/procserv/47b7cf34b3127cceb0479f53256e00000026108EatWzFu0cO

http://im1.shutterfly.com/procserv/47b7cf34b3127cceb0479f5aa45700000026108EatWzFu0cO

http://im1.shutterfly.com/procserv/47b7cf34b3127cceb0586ca0849f00000036108EatWzFu0cO

http://im1.shutterfly.com/procserv/47b7cf37b3127cceb077e1320ce000000026108EatWzFu0cO

http://im1.shutterfly.com/procserv/47b7cf34b3127cceb0479f46a44b00000036108EatWzFu0cO

http://im1.shutterfly.com/procserv/47b7cf34b3127cceb0479f43257e00000036108EatWzFu0cO

[kcowyo]

Nice!

:lurk:

[CaliCruiser]

I might have missed it but what are you using for rock lights?

Dylan

[ventura911]

That rack looks great! If you don't mind, what's it costing you to build it?

Kevin
'07 JK Unlimited Rubicon

[Gear]

CaliCruiser wrote "I might have missed it but what are you using for rock lights?"

On the Jeep I am using lights purchased from Walmart. They are called Burners and cost $15.00 for a pair. On the trailer I am using two lights on the driver side facing the passenger side. These are some cheep rectangular 55 watt lights that I picked up at the local AutoZone.

http://im1.shutterfly.com/procserv/47b7cf34b3127cceb0479f53256e00000026108EatWzFu0cO
Rock lights on the BajaJK and the Chaser #15

http://im1.shutterfly.com/procserv/47b7cf08b3127cceb0a1425e1b4000000025108EatWzFu0cO
Light tucked inside bumper

http://im1.shutterfly.com/procserv/47b7cf08b3127cceb0a158631b7000000005108EatWzFu0cO
Close up of the light

[jwhutch]

Cool Jeep. Do you have any closeups of the antennas you have on the back? I would be interested. Thanks

[gprubicon]

Nice rig how do you like the trailer after a few days out

[Gear]

Ventura911 wrote "That rack looks great! If you don't mind, what's it costing you to build it?"

So far the rack has cost me $1000.00 to build and another $300.00 for the powdercoat. I still need to do the center cross bars and add a piece of Aluminum tread plate on top. Not bad considering the pricing for off the self racks.

[Gear]

jwhutch wrote "Do you have any closeups of the antennas you have on the back?"

http://im1.shutterfly.com/procserv/47b7cf09b3127cceb0a56a8a820500000026108EatWzFu0cO
The back of the Jeep has a Firestick on the passenger side for my CB. The driver side has a Diamond 2 meter antenna. Both work well in the open terrain, but to be honest I have already bent the Diamond on some branches. I think I will be moving them forward and down to the hood.

[jwhutch]

I saw the coolest JK at one of the dealerships here. Jeep Green, lifted with the new BFG MT's. I was wondering how to mount my antennas. Teraflex makes a JK mount which bolts to the spare tire carrier. You might want to check it out. Thanks for the update.

[Gear]

My problem with antennas is the garage. I just hate having to pull them on and off. Very troublesome with two sleeping boys in the back seat. I either need to keep them below the 7' garage or put them on some sort of 90 degree pivot point. Diamond Antenna makes a motorized unit that I am looking at trying.

[Gear]

gprubicon wrote "Nice rig how do you like the trailer after a few days out"

My trailer is one of the best purchases I have made. It use to take me days to get ready for a trip with just the Rubicon. Removing the rear seats, installing the false floor, adding the Engle and gear. Now I just keep the trailer ready to go. I add my clothing and food. Hook it up and down the road I go. Just for reference I have had this trailer for over a year now. I use to tow it behind a 2003 Rubicon. Kids grow, Jeep got two more doors!

http://im1.shutterfly.com/procserv/47b7d604b3127cceba43accbf62500000036108EatWzFu0cO

[TACODOC]

:lurk:

Simply awesome Justin, Nori and I both love your new ride! :bigbossHL:

Thing is... since she saw the JK... I think she likes Jeeps better than Toyotas :exclaim:

[goodtimes]

I think she likes Jeeps better than Toyotas :exclaim:

Smart girl. You aught to hold on to that one. ;)

[Willman]

Looking good Justin!

Rock lights are on my list to do.....LEDs mostly.

:)

[Redline]

Just found your build thread here Justin, great installs and fab work. Obviously I didn't look closely enough at your fine Jeep at the ExPo Trophy (actually needed more time for lots of things ☺. I look forward to checking out some details in Death Valley.

[Bayou Boy]

This is the mount that I use on my JK.
http://www.cooltechllc.com/servlet/Detail?no=1

It mounts in the license plate bracket extremely securely. You can bend the antenna lower than the roof line and it just bounces back.
Comes with the antenna and cable.

[Scott Brady]

What is the wheel lug pattern on the JK?

[1leg]

5x5

[Redline]

A crazy change wasn't it... they couldn't have used 5 on 5.5?

[The Swiss]

A crazy change wasn't it... they couldn't have used 5 on 5.5?It's the same they used on the WJ since 1999

[Gear]

Bayou Boy wrote "This is the mount that I use on my JK.
http://www.cooltechllc.com/servlet/Detail?no=1

It mounts in the license plate bracket extremely securely. You can bend the antenna lower than the roof line and it just bounces back.
Comes with the antenna and cable."

--- Cooltech makes great products. I actually have several areas to mount antennas to the rear bumper made by Jeeperman. I was just trying to get better reception by placing it up high. Looks like I should just move it down. Thanks for the idea.

[Redline]

I'm sure that's correct, but 5 on 5.5 offers many more wheel choices.


It's the same they used on the WJ since 1999

[Gear]

Yes it is 5 on 5. There is not a lot of choices at the moment. AEV had the best buy for the buck. They were also built for this JK which helps a lot with keeping the tire inside the fender.

http://im1.shutterfly.com/procserv/47b7cf34b3127cceb04666bf452a00000025108EatWzFu0cO

[Hunter]

Wow, good looking JK. Knowing what you did with the TJ Rubi, I am not surprised at how well your latest project is going. Looks great man. Nice looking rack too! One of these days we will need to catch up. :campfire::friday:

[articulate]

Justin, I was just slobbering over your gorgeous tire carrier bumper by Jeeperman, so I looked up the website. It appears they, too, are closing down.
http://www.jeeperman.com/. Total shame.

[Redline]

That is too bad. I had their sliders on my Rubicon and they were pretty nice, liked the bolt-on design.



Justin, I was just slobbering over your gorgeous tire carrier bumper by Jeeperman, so I looked up the website. It appears they, too, are closing down.
http://www.jeeperman.com/. Total shame.

[Grim Reaper]

5x5
I think that is the size on full size Chevy trucks 4x2 till 2 years ago. Now I think all full size Chevy's run 6x5.5 reguardless of 2 or 4wd.

[ExpoMike]

I think that is the size on full size Chevy trucks 4x2 till 2 years ago. Now I think all full size Chevy's run 6x5.5 reguardless of 2 or 4wd.

Actually, the Chevy truck 5 on 5 starts in '71 and runs until '98. The '99 have 6 on 5.5 (1/2 ton & LD 3/4 ton), which is the same as '70 and earlier. Funny what's old is new again. Go figure. :REOutArchery02:

[Fifthpro]

I also have the SPod w/Source in my 99TJ. Excellent bit of kit and easy to install itself. Adding additional items is a snap!

Keep the build up going!

[Gear]

Straight forward install. I mounted these 8" lights straight onto the Shrockworks bumper. The light has an outer housing with 3 mounting bolts. I used grade 8 hardware and made a 3/4 spacer out of a couple of pieces of delron plastic. The spacer allows the winch handle to move freely between free spool and locked. Using the 3 bolts per light also keeps thief down since you would have to remove the hole bumper in order to remove the lights. The side of the lights are held on with keyed Allen bolts that also have the center punched out meaning you need a special key to unbolt them. The top of the light has an aluminum adjuster to do quick light adjustments on the trail. Here are the photographs.

http://im1.shutterfly.com/procserv/47b8dc23b3127cceb4eca432f41700000026108EatWzFu0cO
Outer housing with the 3/4 custom Delron spacer.

http://im1.shutterfly.com/procserv/47b8dc23b3127cceb4eca429753c00000025108EatWzFu0cO
3 bolts mounted to the bumper. Removal requires the bumper to be removed.

http://im1.shutterfly.com/procserv/47b8dc23b3127cceb4eca421753400000025108EatWzFu0cO
Delron spacer helps clear the Warn winch handle.

http://im1.shutterfly.com/procserv/47b8dc23b3127cceb4eca438f41d00000025108EatWzFu0cO
Keyed side allen bolts deter thief.

http://im1.shutterfly.com/procserv/47b8dc23b3127cceb4eca44b755e00000026108EatWzFu0cO
Finished install. The wiring goes directly to the sPod and Source(Post #10).

[xcmountain80]

Yes it is 5 on 5. There is not a lot of choices at the moment. AEV had the best buy for the buck. They were also built for this JK which helps a lot with keeping the tire inside the fender.

http://im1.shutterfly.com/procserv/47b7cf34b3127cceb04666bf452a00000025108EatWzFu0cO


Dang those are some sexy rims, this was my approach
http://i36.photobucket.com/albums/e31/xcmountain/P4201868.jpg

Aaron

[Gear]

Aaron, looks great!! I wish the stock Jeep rims would have worked, but with 35" you need to add wheel spacers. So I opted for the AEV's.

[Gear]

Quick teaser -- The lift has arrived. Unfortunately it might be a couple of weeks before it gets installed. So on with the photographs.

http://im1.shutterfly.com/procserv/47b8dc23b3127cceb4e0939f350a00000025108EatWzFu0cO
The product.

http://im1.shutterfly.com/procserv/47b8dc23b3127cceb4e09384b42100000026108EatWzFu0cO

Oh, I guess you might just want to know what is in the boxes. It is a 3" Poly Performance Synergy Stage III lift kit and 4 Fox Racing shocks(Piggy Back Reservoir w/ Compression Adj.) :yikes:

[MuddyMudskipper]

You have a very nice Jeep Justin and I have really enjoyed reading this thread. I couldn't help but admire it at the DV trip.

[Willman]

Way to go Justin!!!!

Can't wait to see the new digs!

How much taller will this system put ya?

07' ET overland route......

http://i51.photobucket.com/albums/f374/nicwillman/DSC03618.jpg

Sand course.....

http://i51.photobucket.com/albums/f374/nicwillman/DSC03550.jpg


Can't wait for 08' ET!!!!!....I'll be pulling my trailer through the course too!!!

:roost:

Oh ya..........love the OJ center fold shot!

[Redline]

I have not heard of that lift/company (thought I knew most of the major payers).

What does it offer over what you have now (what do you have now?)?

Nice looking tool box!

[24HOURSOFNEVADA]

Very cool Justin. Every time my other half sees your jeep she says "Oh, I like that one." She never said that about my Unlimited....


Redline Polyperformance is in San Lois Obispo. He's pretty popular on pirate4x4. Just a guy that owns a shop and keeps expanding his line. Living the dream.

[Gear]

Redline wrote "I have not heard of that lift/company (thought I knew most of the major players)."

Currently my JK is sitting on a 2.5" Teraflex budget boost. I was waiting for Nth Degree's kit to come out. Changed wheels and tires and then got stuck without a lift for the new tires and wheels. The Teraflex kit was just meant to get me thru until I decide on Poly Performance.

"What does it offer over what you have now (what do you have now?)? "

From there website www.polyperformance.com - Poly Performance Stage III key features are a front track bar relocation bracket, drag link flip kit, rear track bar relocation bracket, and all adjustable upper & lower control arms. Here is the link to the kit. http://www.polyperformance.com/shop/Poly-Performance-Jeep-JK-Stage-3-Synergy-Suspension-System-p-16428.html


Nice looking tool box!
Thanks - lista www.listaintl.com

[Gear]

Willman wrote "How much taller will this system put ya?"

Should only raise the Jeep an inch. I am going to pull the Teraflex budget lift (2.5" pucks) and install the new 3" coil lift kit. I need to keep the overall height down for the garage. Also a low center of gravity is nice. The Poly Performance kit should be a dramatic improvement in ride quality. :wings: Thanks for the shots. Good times, looking forward to this years Expedition Trophy.

[Gear]

Thought I would post up some nice photographs of the Baja JK with my Chaser #15 in tow. These were all taken on the Expo Death Valley Trip.

http://im1.shutterfly.com/procserv/47b8df03b3127cceb47bb17fd0f100000026108EatWzFu0cO
Trona Pinnacles

http://im1.shutterfly.com/procserv/47b8df03b3127cceb47bb177d0f900000026108EatWzFu0cO

http://im1.shutterfly.com/procserv/47b8df03b3127cceb47bb16451da00000025108EatWzFu0cO
Panamint Springs

http://im1.shutterfly.com/procserv/47b8df03b3127cceb47bb16fd0e100000026108EatWzFu0cO
Rob's Mog.

http://im1.shutterfly.com/procserv/47b8df03b3127cceb47bb13bd0b500000025108EatWzFu0cO
Miles(brother) enjoying the canyon views.

http://im1.shutterfly.com/procserv/47b8df03b3127cceb47bf80a110800000026108EatWzFu0cO
A well traveled road.

http://im1.shutterfly.com/procserv/47b8df02b3127cceb468a465e81d00000076108EatWzFu0cO
South Pass leaving Saline Valley.

For those that would like to read about the trip report. http://expeditionportal.com/forum/showthread.php?t=11107

[1leg]

Justin.
Are you going to install yourself? If so give me a call.

I'm Interested in your suspension parts. All of them.

Jerry

[HMR]

Just when I thought it was impossible for your rig to get any cooler...

Can't wait to see it with the new lift!

:Mechanic:

[Willman]

Got the new lift on yet????

:camping:

[1leg]

yes he does, and he has a bunch of pics too. Come on Justin post up. :lurk: :lurk: :lurk: :lurk:

[HMR]

yes he does, and he has a bunch of pics too. Come on Justin post up. :lurk: :lurk: :lurk: :lurk:
Maybe Justin is still trying to figure out how to thank me for what an incredible resource/wealth of Jeep knowledge I offered during the install. :xxrotflma

[1leg]

Maybe Justin is still trying to figure out how to thank me for what an incredible resource/wealth of Jeep knowledge I offered during the install. :xxrotflma
Some has to bring the burritos. :chowtime: :sombrero: :steak:

[Gear]

Well my new Poly Performance Synergy III lift kit is installed. A big thanks to Jerry(1leg), Ryan and Jeremy(HMR)(lunch boy). :clapsmile Without the help of these guys I would of just passed it off to a local shop. Here are a few photographs of the install. Unfortunately it has been raining in San Diego so I do not have any good outdoor shots.

http://im1.shutterfly.com/procserv/47b8dc04b3127cceb5f5e522dff900000026108EatWzFu0cO
Jerry and Ryan working on the rear end.:shakin: :oops:

http://im1.shutterfly.com/procserv/47b8dc04b3127cceb5f5e556df8d00000025108EatWzFu0cO

http://im1.shutterfly.com/procserv/47b8dc04b3127cceb5f5e51f5ef400000026108EatWzFu0cO

[LUISJG]

............................:bowdown: :bowdown:

[FourByLand]

Very nice Justin!

But a little rain won't hurt it!

;)

[Gear]

Ok, here are a couple of photographs of the lift installed. Enjoy, I know I am. The ride quality is 100% better. :smiley_drive:

http://im1.shutterfly.com/procserv/47b8dc07b3127cceb5ffb244775a00000026108EatWzFu0cO

http://im1.shutterfly.com/procserv/47b8dc07b3127cceb5ffc59b372600000026108EatWzFu0cO

[Mlachica]

Wow, that looks really good Justin :bowdown:

Hopefully we'll get to wheel again soon :friday:

[XXXpedition]

that's one nice build, congrats justin!
now i'm gettn really jelous
sven

[Gear]

Hope to see you on the trails soon Mark. Thanks for the compliments. Oh and Sven I have no reason to believe with a little time your JK will be just as nice. It is just amazing how much time it really takes to build one up.

[FourByLand]

Jerry and Ryan working on the rear end.:shakin: :oops:



Aww, I just caught that.

Have you had a chance to test the flex at all? Glad that you didn't compromise any ride quality.

:)

[XXXpedition]

Oh and Sven I have no reason to believe with a little time your JK will be just as nice.
well, the problem is that i cannot do everything i want due to tech. inspection here in germany. and i don't know anybody. i'd like to develop a roof rack but i can't pay to have it done by somebody. and here are very few people who have shops...

It is just amazing how much time it really takes to build one up.you can say that loud....

[Gear]

FourByLand wrote "Have you had a chance to test the flex at all? Glad that you didn't compromise any ride quality. "

Not exactly. I am having some difficulties with the rear swaybar and the very deep backspacing of the AEV Bridger wheels. Poly Performance has designed a very nice shock relocation bracket that moves the shocks up 2". Unfortunately with the wheels so far inboard the rear swaybars need to be moved to the inside of the swaybar to clear the tire. See photographs. For now I have crossed up the driverside so the bottom is on the outside and the top is on the inside. It is working but does not look very good. Poly Performance is suggesting I get wheel spacers. Not really interested in doing this. My thoughts are to remove the shock relocation bracket and reweld new shock tabs on but move them up and out of the way. This if done right would allow me to move the swaybar to the inside on the bottom.

http://im1.shutterfly.com/procserv/47b8dc23b3127cceb4e0938f351a00000025108EatWzFu0cO
Poly Performance Rear Shock Relocation Brackets.

http://im1.shutterfly.com/procserv/47b8dc01b3127cceb538c6bb44c200000025108EatWzFu0cO
This photograph shows the rear swaybar link crossed up. The top is on the inside and the bottom is on the outside. You will also see that the new shock bracket is braced off of the swaybar tab. This is why I think I need to reweld new tabs on. So that I can make room for the swaybars to be moved to the inside. This is really only necessary for the driverside.

http://im1.shutterfly.com/procserv/47b8dc01b3127cceb538c6a744de00000025108EatWzFu0cO
This is a close up of the bracket with the swaybar crossed up. Eventually if all was good you would be able to cut off the section below the relocation bracket. Effectively gaining 2" of ground clearance.

Well any thoughts!!!!!!!!!!

[Gear]

On a lighter note: I was able to get my sea kayak out in the water today. Temp. in the high 70's. The rack worked great!

http://im1.shutterfly.com/procserv/47b8dc06b3127cceb5e7f1daaeff00000026108EatWzFu0cO

http://im1.shutterfly.com/procserv/47b8dc06b3127cceb5e7f1c6aee300000026108EatWzFu0cO

http://im1.shutterfly.com/procserv/47b8dc06b3127cceb5e7f1c12fd400000025108EatWzFu0cO
Oh and the boys had fun with the kayak as well.

[Ursidae69]

Cool pics. :costumed-smiley-007

[1leg]

:bowdown: :bowdown: :bowdown: :bowdown: :bowdown: :bowdown:

[XXXpedition]

Temp. in the high 70's. we had that too (VERY unusual for here...) and i went topless a couple of days ago:wings:

The rack worked great!what tube size did you use? what wall width? any movement with the kayak onboard? do you happen to know the rough weight of your rack?
so many questions...sorry!
thx
sven

[Gear]

XXXpedition wrote "what tube size did you use? what wall width? any movement with the kayak onboard? do you happen to know the rough weight of your rack?"

Tube size is 1.5" on the side bars that go from the A pillar to the rear bumper. The cross bars are 1.25". We were trying to save a little weight plus the span is not as long. We used these disconnects on all of the cross members.(see photograph). I think the thickness on the tube was 1.25 cold rolled tube does that sound right. I'll ask Joe the fabricator when I talk to him. The rack is solid with the kayak. I get a little side to side movement in the back when I shake it with my hand. I wanted the cross members to be removable so the hard top could easily be taken on and off. This presented a little problem when trying to triangulate the corners to make the rack ridged. I am hopping that once I install the top plate(flat piece of aluminum or King Starlite XL) this will anchor all the corners and tighten up the rack. Weight I did not get, but it is lighter than you would think.

http://im1.shutterfly.com/procserv/47b7d739b3127ccebc5121e83d3a00000026108EatWzFu0cO
Here are the quick disconnects for the cross members.

http://im1.shutterfly.com/procserv/47b7d739b3127ccebc5121ffbc1d00000026108EatWzFu0cO
Quick front shot.

http://im1.shutterfly.com/procserv/47b7d732b3127ccebbc9d6c3e15b00000026108EatWzFu0cO
Here is a shot of the 1.5" tube that runs from the A pillar to the rear bumper. Notice there are no cross members installed.

http://im1.shutterfly.com/procserv/47b7cf09b3127cceb0a56b07432000000035138EatWzFu0cO
Ladder and at the top you will see a pipe with a bend. This pipe has one removable bolt that goes to the side bar. This was used to triangulate the corner. The problem again was I need to be able to remove it for the hard top.

http://im1.shutterfly.com/procserv/47b7cf09b3127cceb0a56a8a820500000026108EatWzFu0cO
Another shot of the triangulated corner.

http://im1.shutterfly.com/procserv/47b7dc26b3127cce813bc0149d9500000016108EatWzFu0cO
Here is my old rack with the aluminum on top. Makes for a great platform to stand, sleep, and store things. The new rack I am looking at using King Starlite XL(Plastic foam core sheet)

[HMR]

:bowdown: :bowdown: :bowdown: :bowdown: :bowdown: :bowdown:+1

[XXXpedition]

thanks for the detailed answer!

Here is my old rack with the aluminum on topjust for interest: why didn't you take a perforated aluminum?seems to me it would have several advantages: lighter, easier to hook stuff to, etc.

[Gear]

XXXpedition wrote "why didn't you take a perforated aluminum?seems to me it would have several advantages: lighter, easier to hook stuff to, etc."

I use to live in Sunny Arizona. The solid top gave me great protection from the heat. Actually I was often able to run the AC on the 1st or 2nd dial with the outside temp. in the high 100's. I think if I had gone with perforated aluminum I would not have had the rigidity up top to stand, sit and sleep. On this rack I used 1 1/8" cross members to copy Yakima. I used there quick clips(5) to attach the aluminum to the rack. Weight of the aluminum was approximately 60 pounds.

http://im1.shutterfly.com/procserv/47b6da36b3127cce8821062cea9500000016108EatWzFu0cO
Baja 500 race. My brother and I like to watch from the roof top.

http://im1.shutterfly.com/procserv/47b6da36b3127cce882102c6ea7d00000016108EatWzFu0cO
Brother would sleep in the tent. I would lay my Thermarest next to the Thule box on top of the rack. Baja 1000 Trip 2005.

http://im1.shutterfly.com/procserv/47b7dd25b3127cce825386ea098e00000026108EatWzFu0cO
Yakima quick clip attachment for the aluminum.

http://im1.shutterfly.com/procserv/47b7dc30b3127cce812b5daf865700000026108EatWzFu0cO
The purple bag on top has my soft upper doors. I use basic straps with a cam lock. The Aluminum bends enough that I can just slip the strap under the aluminum around the rack bar and back over the bag to the other side.

http://im1.shutterfly.com/procserv/47b6d633b3127cce8b98b8b652b400000026108EatWzFu0cO
Parting shot. Baja, good memories!

[805gregg]

Where did you get those disconnects for your rack, and who makes them?

[TACODOC]

FourByLand wrote "Have you had a chance to test the flex at all? Glad that you didn't compromise any ride quality. "

Not exactly. I am having some difficulties with the rear swaybar and the very deep backspacing of the AEV Bridger wheels.

Justin, I would consider ditching the rear swaybar. I see a possibility for carnage there in the right situation if left as is...

Lots of people do this on the front of IFS trucks (I did) with good results.

That would be an easy fix for your issue, no cost and you would lose a few pounds :)

[Redline]

Are there no issues fitting 16-inch wheels to a JK? I believe the JKs come with 17s but do most or all 16-inch wheels fit? I see you put 16-in 315s on so I assume it is cool.

The prospect of a diesel JK has got me hoping & planning :-)

[durango_60]

Are there no issues fitting 16-inch wheels to a JK? I believe the JKs come with 17s but do most or all 16-inch wheels fit? I see you put 16-in 315s on so I assume it is cool.

The prospect of a diesel JK has got me hoping & planning :-)

No problem at all with 16's, you can actually use 15's with the correct bs.

[Redline]

Cool/Thanks!


No problem at all with 16's, you can actually use 15's with the correct bs.

[Gear]

805gregg wrote "Where did you get those disconnects for your rack, and who makes them?"

Which one. If you are asking about this photograph. It is a Yakima Universal Snap around.

http://im1.shutterfly.com/procserv/47b7dd25b3127cce825386ea098e00000026108EatWzFu0cO

Here is a link to the product.

http://www.yakima.com/Product.aspx?Number=8810135

Now if you are talking about the mount to the rear bumper as shown in this photograph.

http://im1.shutterfly.com/procserv/47b7cf09b3127cceb0a56b07432000000035138EatWzFu0cO
I am not sure the technical name but I think it is just a body mount. You can pick them up at your local 4 wheel shop. You just need to source one that will fit your application.

http://im1.shutterfly.com/procserv/47b8dd27b3127cceb5aeb8a4caab00000025108EatWzFu0cO
Here is a close up from the other day. The plate that holds the bushing was custom fabricated. Nothing more that some metal tabs welded to some flat stock.

Hope this helps.

[viatierra]

Don't you also have some of these disconnects?

http://www.ballisticfabrication.com/ID-Tube-Clamp_p_21-1467.html

http://farm3.static.flickr.com/2279/2100051618_d7970e9b21.jpg

[p1michaud]

Justin,
First time reading through your entire build up thread. Very clean build.
Well done! :clapsmile

[korisu56]

Glued to your thread and I check it daily. Keep it coming.

[Gear]

Hi Greg,
Yes I have those disconnects on all of the cross members. My reasons for using them are: one easier to powder coat and two the rear ones I remove in order to slide the hardtop out. Here is my shot of the disconnect. I guess I should get the camera out and take one that is completely welded up.

http://im1.shutterfly.com/procserv/47b7d739b3127ccebc5121e83d3a00000026108EatWzFu0cO

[Gear]

Here is a quick review of my TeraFlex Aluminum Rocker Guards that I installed a while back. To date this is the only product that I have actually lost weight when installing an aftermarket product.

http://im1.shutterfly.com/procserv/47b7d628b3127cceb9445533d0e100000026108EatWzFu0cO
Assorted hardware and the one page instructions.

http://im1.shutterfly.com/procserv/47b7d628b3127cceb944551451f600000025108EatWzFu0cO
Using my seat as a jack I test fit and mark the holes to be drilled.

http://im1.shutterfly.com/procserv/47b7d628b3127cceb944550851ea00000026108EatWzFu0cO
A quick mark with the pen and a punch and I am ready to drill.

http://im1.shutterfly.com/procserv/47b7d628b3127cceb94455b0515200000025108EatWzFu0cO
A quick reminder before drilling, locate the wire bundle on the inside of the Jeep. This is from the passenger side. I just slide a screw driver under the bundle to lift it up and out of harms way. I was installing the 3 large bolts that come up from the bottom of the rocker panel.

http://im1.shutterfly.com/procserv/47b7d610b3127cceba2904635da800000026108EatWzFu0cO
Nutserts installed. Nothing like drilling 7 holes into the side of your brand new Jeep.

http://im1.shutterfly.com/procserv/47b7d628b3127cceb94455f8511a00000025108EatWzFu0cO
TeraFlex supplies a rubber gasket so I installed it with the bolts to hold it in place.

http://im1.shutterfly.com/procserv/47b7d628b3127cceb94455ee510c00000025108EatWzFu0cO
Used the seat as a jack again for the final install.

http://im1.shutterfly.com/procserv/47b8dd29b3127cceb659bba64caa00000025108EatWzFu0cO
Completed. The TeraFlex Aluminum Rocker Guards make for a great step. This will be a great asset when placing things on the roof rack.

[Gear]

Now for my review of the Rocker Guards. They have been fantastic for there intended purpose. My two boys can easily get in and out of the lifted Jeep. I have used them as steps for loading the roof rack. They have also kept my doors clean of dents while in shopping.

Now for the problems. On the first test drive with the rocker panels installed I noticed a very loud creaking sound. On further inspection I noticed that TeraFlex forgot to make cut outs for the body mounts. I was forced to remove the rocker panels and do some modifications. A little time consuming but noting I could not handle. Then the next problem creaped up. Several nutserts began to spin on me as I was removing the rocker panels. Needless to say I am a little upset about Teraflex not doing there homework on this product. I had them installed and they were perfect then when I removed them the problems started.

http://im1.shutterfly.com/procserv/47b7d610b3127cceba290464dc9f00000026108EatWzFu0cO
Rocker panel hitting the body mount.

http://im1.shutterfly.com/procserv/47b7d610b3127cceba29046adc9100000026108EatWzFu0cO
The white dot is where it was rubbing.

http://im1.shutterfly.com/procserv/47b7d610b3127cceba29046cdc9700000026108EatWzFu0cO
My solution.

Oh and my last complaint. The powder coat is coming off all over the place.

http://im1.shutterfly.com/procserv/47b8dd29b3127cceb659b85f0cca00000026108EatWzFu0cO

http://im1.shutterfly.com/procserv/47b8dd29b3127cceb659bbb24cbe00000026108EatWzFu0cO


And on last thought. If you run into problems with a spinning nutsert try tighting it with light use of an impact gun. I have not attempted this but I wish I had known about this technique during my problems. At this point I am not sure if I want to remove them again to fix the problem nutserts.

[RunninRubicon]

Very cool. It appears that the step is deep enough to hold your foot as you move along the side of the vehicle. Nice stuff Teraflex.:p

[Willman]

Looking good Justin!

;)

[Gear]

I installed my Uniden CB under my front seat. When I use it I preset the channel before starting my trip. From the drivers position I can reach down and adjust the volume and the squelch. I use an external speaker to help with the volume. Here are the photographs.

http://im1.shutterfly.com/procserv/47b8da33b3127cceb7d0dc12e5a100000026108EatWzFu0cO
The CB radio with a 15.5" piece of 1/2" C channel to mount it on.

http://im1.shutterfly.com/procserv/47b8da33b3127cceb7d0db67a54f00000025108EatWzFu0cO
The C channel simple extends between two factory bolts.

http://im1.shutterfly.com/procserv/47b8da33b3127cceb7d0d9d8a5f100000025108EatWzFu0cO
Here is a close up.

http://im1.shutterfly.com/procserv/47b8da33b3127cceb7d32414850f00000025108EatWzFu0cO
Mock up. Just need to paint it black and get it into the Jeep.

http://im1.shutterfly.com/procserv/47b8da33b3127cceb7d0c4bb643400000026108EatWzFu0cO
The CB located under the seat. I ran the power and ground wire up to my Painless wire 7 way fuse box. Works great!

[FourByLand]

Very impressive as always Justin, Let us know when you are heading back out this way.

:clapsmile

[jerdog53]

I installed my Uniden CB under my front seat.

http://im1.shutterfly.com/procserv/47b8da33b3127cceb7d0c4bb643400000026108EatWzFu0cO
The CB located under the seat. Works great!



Thats a really good idea! :wavey:

[Jake5326]

Brother,
Saw your JK and rack at SM Sports Chalet tonight....what a beautiful job you did.

Question: Would you entertain building another one w/dual ladders (Rear/Side on both sides)?

Still entertaining the Gobi but loved your work Justin.

R/

Mike

[Jake5326]

Justin,
Just saw that Joe Hauler built it. Will give him a call, but have you had any issues or things you would change?

[Gear]

Saw your JK and rack at SM Sports Chalet tonight....

You should have come in and got me. I was enjoying some peace and quiet without the kids. No changes for the rack. I just need to finish it. I still want to put the center cross members in and then add the flooring.

[Steve Curren]

Justin,
I see, a little late, that you attached the Power Tank to the roll bar. I also have the tank, roll bar brackets and the platform that the tank rests in. I just bought a new JK and I don't want to be cutting and drilling just yet so tell me how you managed to fit the clamps on the roll bar? I tried and they were a bit small, I guess I could find clamps someplace but I was wanting to use the Power Tank ones.
I too love your Jeep, you have outdone yourself and have a great looking vehicle.
Steve

[Gear]

Hello Steve,
My quick guess is that I have a larger diameter PowerTank clamp. Also I am not sure but I think you have less room behind your roll bar in the 2 dr. You should start a quick tread on your build. Also take a look at Jerry's(1leg) Jeep. It is identical to yours. He has my old Teraflex budget boost on it and his Jeep looks great. I would also recommend the Poly Performance lift. Are you going to the AT event(Hurricane Lake) next week?

[Steve Curren]

Justin,
Thanks, I have been out there in the garage, 95+ degrees already, and figured a way to squeeze the bracket on without doing damage to the cover. I have to revert to using the 10 pound tank and maybe later figure out how to put the 20 pounder in.
2" budget boost from TeraFlex or one from Poly, I have looked at the TeraFlex and I like it. I had the 3" on my LJ and it was good, I did have the 4" rear springs from Nth and it helped with the trailer, also had the ACOS on. Any thoughts about the Pro Comp 2.5 with the adjustable shocks? I could throw some pictures on as soon as I get some of the badly needed "stuff".
No I am not able to get to Hurricane but am missing it already. It is getting really hot here and I need a cool down, maybe soon I can slip away.
Thanks,
Steve

[Jake5326]

You should have come in and got me. I was enjoying some peace and quiet without the kids. No changes for the rack. I just need to finish it. I still want to put the center cross members in and then add the flooring.


Yeah, should have. Thought you were w/family so didn't want to intrude. I am in Carlsbad/SM. Still waiting for my '09 to get in (they said July EOM). Would love to get w/you when it gets in. Great rack again. Are you still going w/solid aluminum or expanded?

[Gear]

Great rack again. Are you still going w/solid aluminum or expanded?
Currently I am looking at other options. The aluminum is really expensive. I am thinking about trying king starlite XL. Google it!

[Gear]

Here are a couple of photographs from a recent trip to the Eastern Sierra's.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Coyote%20Flats%208-16-08/P1020517.jpg
Miles bird watching!

http://i298.photobucket.com/albums/mm251/justinpitcairn/Coyote%20Flats%208-16-08/P1020583.jpg
Expo members enjoying the views!

http://i298.photobucket.com/albums/mm251/justinpitcairn/Coyote%20Flats%208-16-08/P1020561.jpg
Night shot!

[JRhetts]

Gear
I have an '08 Rubicon Unlimited - hardtop, and I have been wanting to put my 10# PowerTank on the slanted roll bar tube in the rear.

I previously found the larger PowerTank clamps, but... when I hand held one of my tanks into the space, there is NOT enough room for the tank to sit on top of the roll bar tube. Even without the clamps and bracket the tank is too long, and once they are mounted tight on top of the roll bar there would not be enough room to get the tank into the bracket.

How did you fit yours into the available space? Is yours mounted so that it is angled in toward the inside of the vehicle to get more clearance? If so, have you driven enough rough mileage to tell if it might just rotate around the side of the bar and/or put too much stress on the clamps and bracket?

Appreciate any help, as I want to do this but I haven't figured out how to do it.

thanks, John

[Gear]

How did you fit yours into the available space? Is yours mounted so that it is angled in toward the inside of the vehicle to get more clearance? If so, have you driven enough rough mileage to tell if it might just rotate around the side of the bar and/or put too much stress on the clamps and bracket?


Hello John,
My 10 pound Power Tank sits almost straight up. It has been in the Jeep now for about a year. Several trips and no movement from the clamps. Here is a photograph of the tank bracket. I might have a different one than yours. Also I had to take the handle off of the Power Tank to make it fit.


http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/P1000650.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/P1000657.jpg

[02TahoeMD]

SPLENDID photographs. I love the ghosting effect on the night shot. What kind of camera and lens did you use for the vista shot? And how much time did you set on the night pic?

[Gear]

02TahoeMD wrote
What kind of camera and lens did you use for the vista shot? And how much time did you set on the night pic?

I was using a Panasonic Lumix DMC-FX33 from Costco. Costs around $200. The night shot is a scene setting on the camera called starry sky. The exposure was 60 seconds. Not bad for the price. Thanks for the compliments!

[MC4X4]

great build up.
Could you post some more pics of your rack, all the one I an see are just thumbnail size
cheers mark

[Gear]

Sorry about that Mark. Shutterfly resized all my photographs and I just have not taken the time to transfer them over to photobucket. I went ahead and grabbed a few for you to see the rack. Let me know if you need any specific shots.
http://i298.photobucket.com/albums/mm251/justinpitcairn/JK%20Roof%20Rack/P1010325.jpg
Rack under construction.

http://i298.photobucket.com/albums/mm251/justinpitcairn/JK%20Roof%20Rack/P1010339.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/JK%20Roof%20Rack/P1010338.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/JK%20Roof%20Rack/P1010350.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/JK%20Roof%20Rack/DSCF0008.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/JK%20Roof%20Rack/DSCF0007.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/JK%20Roof%20Rack/P1010683.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/JK%20Roof%20Rack/P1020984.jpg
Last photograph shows the center section that I have been working on. I also removed the front bar just to see how I liked the look/wind resistance.

[MC4X4]

thanks for the pics. the rear legs look like they were fun to bend.
cheersmc

[jeepmedic46]

Looks great:smiley_drive:

[nwoods]

I think this is brilliant!

http://i298.photobucket.com/albums/mm251/justinpitcairn/JK%20Roof%20Rack/DSCF0008.jpg

[Gear]

Thanks everyone! The rack is one of those thinks that sets my Jeep apart from the rest. Plus I find it very useful as well as my boys. Can you say "Jungle Gym".

[The Swiss]

I also removed the front bar just to see how I liked the look/wind resistance.Did the removal of the front bar make any difference to fuel consumption and noise?

Looking good, white Rubies are the best :elkgrin:

[Gear]

The Swiss
Did the removal of the front bar make any difference to fuel consumption and noise?


It made a difference with the noise. Although I now can hear the noise behind me where it hits the rear bars(just a little bit). I actually use the rack pad to eliminate the air going under the front bar. This helps a lot. I also like the front bar removed when I have the T-tops down. The bar is not obstructing my view. As far as fuel economy - I do not see a significant change.

[keithro]

Do you have any pictures with the hard top off? I would be interested in seeing what it looks like. I'm getting ready to do a very similar roof rack, but I was going to follow the contours of the rear roll bar in the back (the rack will not be full length).

I'd also be interested in seeing what you end up with for a fairing or pad to cut the wind noise.
Thanks.

[Gear]

Keithro wrote
Do you have any pictures with the hard top off? I would be interested in seeing what it looks like. I'm getting ready to do a very similar roof rack, but I was going to follow the contours of the rear roll bar in the back (the rack will not be full length).

I'd also be interested in seeing what you end up with for a fairing or pad to cut the wind noise.

As sad as it might sound I have never had the hard top off. The easy removal of the T-tops has kept me from removing the whole top. My rack is set up for the hard top to be removed. Below are some photographs of how the cross bars come off. This will allow the hard top to slide out the back.

http://i298.photobucket.com/albums/mm251/justinpitcairn/JK%20Roof%20Rack/P1030535.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/JK%20Roof%20Rack/DSCF0007.jpg
The 45 degree tube has a simple bolt in it that needs to be removed before detaching the rear section. All lights have a disconnect plug.

As for the front fairing. I have always used a front rack pad to take up the space between the bar and the top of the Jeep. On this rack I moved the front bar as far back as possible so if I decide to make a fairing at least it will be at an angle and not straight up and down. With this said I could only go so far back and still be able to remove the T-tops.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Coyote%20Flats%208-16-08/P1020431.jpg

On my last rack the front bar was in front of the windshield and although I wanted to try a fairing it would have been coming forward up from the windshield. Hope this makes sense.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon/P1000244.jpg

I have been thinking about trying to make a fairing out of .063 aluminum. Simple take a sheet the width of the Jeep and about 8" tall and work it with a hammer to get the right look. I have yet to try this but would like to give it a go.

[viatierra]

Are those stainless allen screws for your detachable portion? I want those!
Did you get them seperately??




http://i298.photobucket.com/albums/mm251/justinpitcairn/JK%20Roof%20Rack/P1030535.jpg

[Gear]

Viaterria wrote
Are those stainless allen screws for your detachable portion? I want those!

Hello Greg,
Yes they are and you know I was thinking of you when I purchased them. Why you ask!!! They would only sell my the complete bag of 50. They are Hex Socket Cap Screws size 5/16 - 18 x 3/4. Check your size, let me know how many you need and PM your address.

[viatierra]

You are a man of the people...
A true nobleman...
And a really cool dude!

PM sent


Hello Greg,
Yes they are and you know I was thinking of you when I purchased them. Why you ask!!! They would only sell my the complete bag of 50. They are Hex Socket Cap Screws size 5/16 - 18 x 3/4. Check your size, let me know how many you need and PM your address.

[keithro]

Have you checked the wind noise with out the front horizontal cross bar (the one with the padding on it)?

[JPFreek1]

Justin, your rig continues to impress. :victory:

[Gear]

Keithro wrote
Have you checked the wind noise with out the front horizontal cross bar (the one with the padding on it)?

Yes if I remove the front bar the wind noise is significantly less. The noise actually moves back to the next bar in line. I would still like to make a fairing out of aluminum to see if it would completely eliminate the noise all together.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Expedition%20Trophy%2008/P1030011.jpg

[Gear]

JPFreek1 wrote
Justin, your rig continues to impress.


Thanks Frank, I need to step it up a bit and finish a few things. Oh and your latest issue looks very impressive. Nice Job!!!

[Gear]

Keithro wrote
Do you have any pictures with the hard top off? I would be interested in seeing what it looks like. I'm getting ready to do a very similar roof rack, but I was going to follow the contours of the rear roll bar in the back (the rack will not be full length).

Well I finally got around to removing the hardtop. Here are some photographs.
http://i298.photobucket.com/albums/mm251/justinpitcairn/JK%20Roof%20Rack/P1030602.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/JK%20Roof%20Rack/P1030605.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/JK%20Roof%20Rack/P1030619.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/JK%20Roof%20Rack/P1030618.jpg

[Willman]

looking great Justin!

That is one nice rack you have! Nice protection from the sun!

:drool:

[keithro]

It looks great, what did you do the deck out of?

[Gear]

The Deck material is King Starlite XL. This particular piece is 1/2" thick and was 60" wide by 96" long. I like the product but unfortunately it has a large expansion in the sun. If you look closely at the photograph below you will see it bowing in the middle. There is a gap between the crossbar and the King Starlite. This bow is mild in the photograph because the Jeep is in the shade. If I pull it out into the sun the middle section will go up almost 3". I am still looking for ideas to fix this. If I expand the attachment holes I will have to use a washer and a bolt that does not sit flush with the King Starlite.

http://i298.photobucket.com/albums/mm251/justinpitcairn/JK%20Roof%20Rack/P1030618.jpg

[keithro]

Can you countersink it from the top down and use a flat head screw the the support bar with a lock nut underneath?

I can't see your hardware attachments from the picture.

Are you still happy with the pad for the fairing to cut wind noise down? I need to do something at least temp...mine is too noisy.

[Gear]

Keithro
Can you countersink it from the top down and use a flat head screw the the support bar with a lock nut underneath?

Actually that is how it is attached I have several (19) to be exact. I am using steal flat head cap screws. When the rack was built we installed the threaded inserts all over the place. My problem is if I expand the slots to allow for the expansion of the King Starlite XL I am afraid that the cap screws might pull out. There for I would need to use a large fender washer and a regular bolt that would not be flush with the surface.

Expanding on this further because you asked about the rack. My first two racks I used 1 1/8 tubing for the cross members. This allowed me to use Yakima Quick clips which just snapped onto the bar. I used 5 of them to attach the aluminum piece on my 03 Rubicon. This worked Great!! Well when I started building this rack I thought 1 1/8 was going to look to small with the overall length of the rack. So I incorporated the weld in nuts. Now I wish I had just add a few tabs so I could thru bolt anything I wanted to put on top. I am actually contemplating welding a few tabs on to the top to try this out.

Well a long reply but hopefully this helps.

Also -- Try out the rack pad it works well. You just need to take up the air space between the rack and the vehicle. If you are coming to OvExpo my Jeep will be there. You are more than welcome to check it out in person.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon/P1010427.jpg
03 Rubicon with the Aluminum top panel.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon/AnteniamountTJ.jpg
Here is a shot of the Yakima Quick Clip that I used to attach the aluminum.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon/Rubiconwithwindshielddownatoverlook.jpg
Man I miss this Jeep. Here is one more out in Anza Borrego.

[keithro]

Nice TJ, I just sold my 06 rubicon a couple weeks ago now that I have the JK Unlimited.

I wouldn't be too concerned about the decking pulling through the hardware. Countersunk hardware distributes loads very well. There is a lot of surface area that the head contacts.

The other thing that comes to mind is maybe trying to put some wide Tee Nuts into the starlite and bringing the bolt up through the tube first and then into the nutsert.

I used to live in Murrieta just up the road from you.

[Gear]

Quick update -- The Hannibal Awning 2.4m is on! With Temperatures rising this will be a nice addition for the desert.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Awning/DSC_1189.jpg

[1leg]

How does it fit in the gerage?

[FourByLand]

That looks great!

Did it bolt right up?

[HMR]

How does it fit in the gerage?LOL!

Justin, if you put one on the other side you could have a modern day version of this:

http://www.showclix.com/event_pictures/Chitty_Chitty_Bang_Bang.jpg

The kids will love it! :sombrero:

The awning looks great! Any pics of it stowed?
I look forward to eating ice cream from your Engle while basking in its shade on a hot day. :sunflower

[Gear]

Yes it goes into the garage. Did it bolt right up. Not exactly but it was very close. When it is completely done I will post up how I did it.
Jeremy here it is folded up.
http://i298.photobucket.com/albums/mm251/justinpitcairn/Awning/DSC_1187.jpg

[HMR]

Jeremy here it is folded up.
Nice work Justin.
Perfect addition to my favorite Rubicon.

[Gear]

Well I worked on the awning a little today. This time I mounted it on the driver side. I painted the 12 gauge 1"x2" mounting bar. Added a few bolts and a couple end caps. The awning is now interchangeable between both sides of the Jeep.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Awning/DSC_1868.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Awning/DSC_1879.jpg

[flyingwil]

Looks great. now you need a matching one on the other side, then you can just drive with them open and fly over obstacles!

J/K Looks great Justin!

[1leg]

I love that awning. I can't wait to sit under it my friend. Now you just need a engal 45....

[Gear]

I started on the Fairing today. Picked up a long piece of Aluminum and started to form it to the roof rack and the Jeep. I think I am going to use a piece of door edge trim to protect the Jeep paint from the fairing. Oh and I need to paint it.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/DSC_1891.jpg

[HMR]

Justin- You shaped that piece of aluminum yourself?!

That looks like a perfect fit. Excellent work!

[Gear]

Yes, I did the lower edge by sliding the aluminum sheet in between my tool box drawers and applying downward pressure. Worked pretty well. The upper bend that goes to the two bolts I had done at a local shop.

Thanks

[tdesanto]

The awning looks superb. That looks like it will provide a lot of shade. Can you educate a non-Jeep owner on the utility of the fairing? Those are nice, clean modifications for sure. Nice work.

[Gear]

tdesanto wrote
Can you educate a non-Jeep owner on the utility of the fairing?

Hi Tony,

The short answer is to control the wind noise going thru the rack.

The long answer is I built the roof rack with a fairing in mind. I purposely moved the front cross bar as far back as possible so that the fairing would have a good angle to the wind. On my last rack the front bar was located in front of the windshield. This caused my a lot of head aches when I tried to control the wind noise coming off this front bar. I ended up using a large diameter rack pad to minimized the air flow below the bar and above the Jeep.

On the JK the noise from this bar comes on at anything over 40 mph. So my quick fix was again another rack pad. This works well when the front T-tops are in place(hardtop). But if I remove the T-tops there is a 1" gap below the rack pad. The wind comes thru this opening.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon/PB185494.jpg
Here is my old rack on an 03 Rubicon. You can see the bar is in front of the windshield. A fairing here would be concave to the windshield.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Death%20Valley%202008/P1020773.jpg
The JK with the T-tops removed. The air flows across the velcro seam of the rack pad makes a lot of noise.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Coyote%20Flats%208-16-08/P1020431.jpg
The JK with the rack pad in place. This shows the improved angle of the cross bar compared to my 03 Rubicon.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/DSC_1891.jpg
Here is the new fairing built out of Aluminum. With any luck I might increase my fuel economy.

[Gear]

Painted the fairing. Installed some weather stripping. Here is the finished product.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/DSC_1907.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/DSC_1905.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/DSC_1911.jpg

[tdesanto]

Justin, that's excellent. Thanks for clarifying. I can see it better in the pictures you just added. That looks very clean and purposeful.

Have you had a chance to test it out? Any noise from drag behind it, like in a typical sunroof?

[keithro]

Nice work on the fairing, interested in hearing how it's working for you...I need to do the same thing.

[Gear]

I got the Jeep out on the freeway yesterday. The new fairing works well. I had the T-tops off of the Jeep. I can still hear the wind coming over the fairing but at least it is not whistling thru the roof rack. Some of the wind noise is coming from the awning now that it is mounted on the driver side. So far I like it a lot. The T-tops go one easier now that I don't have the roof rack pad taking up the space under the cross bar. This is a plus. I am going to play around with the noise areas and see if I can't tame them. I will post up when I get some more feedback.

[FourByLand]

Painted the fairing. Installed some weather stripping. Here is the finished product.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/DSC_1911.jpg

Just beautiful!

[Gear]

I did a quick trip up to Adventure Trailers this weekend. Picked up my new Eezi Awn 2200. Then I took off to Joshua Tree for the night.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Joshua%20Tree%202009/DSC_2068.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Joshua%20Tree%202009/DSC_2139.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Joshua%20Tree%202009/DSC_2128.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Joshua%20Tree%202009/DSC_2201.jpg
On my way home I stopped off at the Salton Sea.
http://i298.photobucket.com/albums/mm251/justinpitcairn/Joshua%20Tree%202009/DSC_2204.jpg

[RunninRubicon]

Very nice combo! You'll love the RRT on the Horizon. Much wiser to place it there then on your vehicle...but not all can have an off-road trailer.
:victory:

[xcmountain80]

Very nice combo! You'll love the RRT on the Horizon. Much wiser to place it there then on your vehicle...but not all can have an off-road trailer.
:victory:

Have? Heck afford is more like it. I'm squeezing rocks to come up with something.

Aaron

[24HOURSOFNEVADA]

Justin that tent looks huge...I love it. Did you sell your old rtt?

[Gear]

24HOURSOFNEVADA Justin that tent looks huge...I love it. Did you sell your old rtt?

Yes, I sold the Overland on the Portal about a month ago. The Eezi Awn is huge when set up but compacts well when closed.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Joshua%20Tree%202009/DSC_2109.jpg

[Willman]

Justin,

Love the new RTT!

I bet your kids are going to love it! Tons of room!

Love the color too!

:sombrero:

[MC4X4]

do you notice much drag with the rtt on the trailer

[Gear]

MC4X4 do you notice much drag with the rtt on the trailer

I can feel the trailer back there on any hill. This is probably due to the weight of the trailer and not the drag of the RTT. The RTT sits lower than the Jeep. So this helps out.

[syke]

RTT looks great Justin. Glad I could help buy half of that RTT for ya. :wings:

Did you end up centering the RTT on the trailer? Did you add a third cross bar?

[MC4X4]

is there anything you would do differently with your rack, I am about to start mine.
cheers mc

[Gear]

syke RTT looks great Justin. Glad I could help buy half of that RTT for ya.

Did you end up centering the RTT on the trailer? Did you add a third cross bar?
Thanks Ryan, Yes, I centered the tent on the trailer and added a third cross member. I let the back end of the tent hang over the trailer by about 4". This keeps the front of the tent from looking awkward. It probably sticks out the front about 10"

[Gear]

MC4X4 is there anything you would do differently with your rack, I am about to start mine.
cheers mc

Yes, there are a couple of thinks I would change. First off the rack sits to close to the hard top. I wish it was 1" higher. This would have saved me a lot of trouble trying to figure out how I was going to make the cross bars work. The hard top has a rake to it. Second, instead of installing threaded inserts into the rack for add ons I should have just welded some flat stock in the areas I thought I would be using. This would of made attaching the King Starlite XL(top sheet, black) much easier. Don't get me wrong I love my roof rack. I just think a few changes would have made for a much easier finished product.

[Gear]

I worked on the BajaJK today. Finally got rid of the stock subwoofer enclosure. I built a little box to fit under the rear seat. Here are some shots. I think I am going to have the box line-X. I will see how much they quote me on the price.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/DSC_3935.jpg
The build.
http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/DSC_3937.jpg
The box.
http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/DSC_3938.jpg
The stock enclosure.
http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/DSC_3940.jpg
More space! Nice.

[Joaquin Suave]

Looken good Justin!

Let me guess???? your new speaker boxes are moveable? Possibly able to be set outside the Jeep?

just a wild guess.

Mostly, just posting to say howdy.

[Gear]

Hi Jack :wavey:, went for a great paddle the other day. I wish the speaker was set up like yours but it is only the subwoofer. The stock subwoofer will be movable just so I can lower the rear seats if need be. The main reason was to open up more space in the rear. I am contemplating a drawer/ Engel/ false floor for the rear.

[Gokracer1]

Well I finally read through the whole thread and got to say you have a SWEET set up there Justin. Many great ideas you brought to life on your rig. Very nice.

[Gear]

Thanks!!

[Gear]

Well I have been looking for a plug for the rear tailgate for several years now. I finally found the answer on another forum. So off to Lowes I went. Turns out they have a large selection of nylon hole plugs. The 9/16" works perfect for two of the holes on the tailgate.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/DSC_3967.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/DSC_3969.jpg
It is the oblong hole in the upper right corner.
http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/DSC_3970.jpg
Although the plug is circular it fits fine.

[Gear]

Line-X - $30 and the speaker box is done.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rubicon%20JK/DSC_3974.jpg

[BIGdaddy]

that looks nice!

[Gear]

I had a few days to play in Sedona, AZ. I will let the photo's do the talking.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Sedona%202009/DSC_4577_2.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Sedona%202009/DSC_4638.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Sedona%202009/DSC_4640.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Sedona%202009/DSC_4642.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Sedona%202009/DSC_4643.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Sedona%202009/DSC_4658.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Sedona%202009/DSC_4630.jpg

[Gear]

http://i298.photobucket.com/albums/mm251/justinpitcairn/Sedona%202009/DSC_4506.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Sedona%202009/DSC_4523_2.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Sedona%202009/DSC_4470.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Sedona%202009/DSC_4699.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Sedona%202009/DSC_4668.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Sedona%202009/DSC_4533.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Sedona%202009/DSC_4519_2.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Sedona%202009/DSC_4550_2.jpg

[Redline]

Very Nice Gear!

Love the awning.

[toyrunner95]

Line-X - $30 and the speaker box is done.

Wow nice Jeep! How did you ever get line x to do something for less than $400?! Every place I try gives me this line of BS about how they only can mix up a whole batch for a truck bed. I even asked if they could just spray mine after they do a bed job with any excess. Nope cant do it. $400 is the lowest we can go.

[Gear]

Redline Very Nice Gear!

Love the awning.

Thanks, James


toyrunner95
Quote:
Originally Posted by Gear
Line-X - $30 and the speaker box is done.
Wow nice Jeep! How did you ever get line x to do something for less than $400?! Every place I try gives me this line of BS about how they only can mix up a whole batch for a truck bed. I even asked if they could just spray mine after they do a bed job with any excess. Nope cant do it. $400 is the lowest we can go.

I guess I got lucky. They were going to shoot a bed and just added it to the job. Maybe with the down turn in the economy they are willing to add on these little projects. Maybe worth another try. The kicker was they did it before I could get home. I was not expecting a 2 hour turn around. Thanks for the compliments on the Jeep.

[JKDetonator]

Nice rig! Can you give me some info on the awning? I'd love to have that for my rig, thanks.

[mrbishi]

wow that is a fantastic looking Jeep and that awning is awesome!

[XXXpedition]

i love that awning!!!
man, i'm getting so jealous when i see that landscape. i really do miss the US!

[Gear]

JKDetonator
!?
Nice rig! Can you give me some info on the awning? I'd love to have that for my rig, thanks.

The awning is made by Hannibal. Here is a link. http://www.hannibal.co.za/Default.asp?pageid=543

This is the 2.4M version. I was able to get this thru Atlantic British. You might try contacting them to see if they have any more.(800-533-2210) They were on close out!

Thanks for the compliments on the Jeep.

[JKDetonator]

Thanks for the info, I'm going to give them a call! :victory:

[whitecon]

Nice Jeep. I have seen it around town and I think at the beach last week. I have that white LJ Rubicon with the Nth LA kit and AEV Pintlers you may have seen around town. I'll have to say "Hi" next time I see you. BTW I was admiring your rack at the beach the other day. Good job on that.

[Gear]

whitecon Nice Jeep. I have seen it around town and I think at the beach last week. I have that white LJ Rubicon with the Nth LA kit and AEV Pintlers you may have seen around town. I'll have to say "Hi" next time I see you. BTW I was admiring your rack at the beach the other day. Good job on that.
We were both parked at Cardiff. How do you like the Baja Design lights on the A-pilar?

[whitecon]

I like em except for the regular fog-up I seem to get when it rains. It dries quickly though. I'm looking into getting one of thoes Gobi racks and will eventually be moving them up there. If you don't mind me asking, who fabbed your rack? I havn't read your entire thread so you may have already mentioned it, forgive me if you have.

[Gear]

whitecon
If you don't mind me asking, who fabbed your rack? I havn't read your entire thread so you may have already mentioned it, forgive me if you have.
I believe the rack build starts on the bottom of page 4, but I will cut to the chase and say www.joehauler.com. Joe built the rack under my close supervision. He is located off of San Marcos Blvd. Price $1300.00 powdercoated.

[Gear]

Here is my latest project. I built a false floor with fender well storage. I wanted a secure tie down location for my Engel. Which will be located on the driver side. I hope to have this off to Line X next week. I will be picking up a VersaTie Track kit from MAC's Custom Tie Down to secure other items.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rear%20Deck/DSC_5328.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rear%20Deck/DSC_5306.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rear%20Deck/DSC_5304.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rear%20Deck/DSC_5331.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rear%20Deck/DSC_5316.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rear%20Deck/DSC_5336.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rear%20Deck/DSC_5311.jpg

[HMR]

Nice work J. That looks GREAT!

[Willman]

Very cool Justin!

I have had the same tinkerings with my truck.....

Nice mod!

:)

[TACODOC]

:Wow1:

Great work Justin!!!

[nwoods]

Looks really nice...but what about weight? Is that a concern?

[The Swiss]

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rear%20Deck/DSC_5336.jpgOutstanding work, Justin. Let me know when you start accepting orders for your kit, I will immediately place an order. :D

[Joaquin Suave]

Bravo Justin.

Excellent work!

Just by off chance...Have you tested how your router (with carbide cutter) worked with aluminum plate (.125 to .187 6061-t6)???? I bet you'd be plesantly surprised. Then find yourself a local talented TIG welder.

[Gear]

Thanks everyone for the praise.


nwoods Looks really nice...but what about weight? Is that a concern?
Yes, weight is a concern. Here are some of my thoughts. I normally tow a trailer when I am loaded down for a trip. This keeps the Jeep fairly empty/light(did I just say that, OK probably BS). During day trips I want my fridge, recovery gear, etc to be secured properly in the back of the Jeep. So yes the weight is there but I feel for my application the safety of a secure load out weighs the weight of the wood. Oh and here is what it weighs at the present moment 25 lbs. for the floor and 9 lbs. for each side(fender well).


On a side note I picked up my Mac's Custom Tie down rails at the Off-Road Expo yesterday. So the project is getting closer to completion.

[Gear]

Current photographs of the false floor and fender well storage. I am glad I went ahead with the Line-X. The finished product turned out Great!

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rear%20Deck/DSC_5366.jpg
False floor with SlideLock and Mac's Custom Tie Downs.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rear%20Deck/DSC_5477.jpg

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rear%20Deck/DSC_5483.jpg
With the Engel removed. Six allen head bolts and the Slidelock can be removed from the top. I used T nuts under the plywood. The center tie down strip can be removed as well.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rear%20Deck/DSC_5481.jpg
Fender well storage. Currently I am storing my 25' air hose and tire inflator.

[AZUnlimited]

Justin, Absolutely fantastic!!! How does the floor and sides secure to the rear of the Jeep?

[Scott Brady]

most impressive Justin.

We are having fun with the storage configuration on the Overland JK. Think 74L National Luna ;)

[Gear]

AZUnlimited How does the floor and sides secure to the rear of the Jeep?


http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rear%20Deck/DSC_5344.jpg
The front of the false floor mounts on both sides to existing rear seat brackets.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rear%20Deck/DSC_5334.jpg
Here is a photograph of the test fit.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rear%20Deck/DSC_5477.jpg
The rear of the false floor has a bolt on both sides going down into the stock jack storage area.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rear%20Deck/DSC_5479.jpg
The sides are sandwiched together around the roll bar. The two lower bolts on the vertical fender are drilled thru the tube behind the tail lights.

http://i298.photobucket.com/albums/mm251/justinpitcairn/Jeep%20Rear%20Deck/DSC_5346.jpg
The front of the fender well storage box is attached to an upside down L bracket that goes to the two drilled holes up by the wiring harness.

Thats it!

[Redline]

Clean

[nwoods]

Justin, that's simply awesome. The Line-X makes it look like a molded poly formed insert. Looks great.

I have a suggestion for you, to make the storage cubby more useful, there is a company that makes a deeper tub that replaces the factory tray.
http://www.jeepswag.com/#Jeep_JK_Storage_Tub_Enlargement_Kit

http://www.jeepswag.com/Jeep%20JK%20Storage%20Tub%20Enlargement%20Kit%20Wr angler%204xfix.jpg

[tdesanto]

Justin, that's a fine example of excellent work.

[XXXpedition]

that looks awesome!!!
now i'm jelous :-( - yours looks so much nicer than mine...

[Gear]

expeditionswest We are having fun with the storage configuration on the Overland JK. Think 74L National Luna

I am looking forward to seeing your storage solutions and that National Luna.


nwoods I have a suggestion for you, to make the storage cubby more useful, there is a company that makes a deeper tub that replaces the factory tray.
http://www.jeepswag.com/#Jeep_JK_Sto...nlargement_Kit

Looks like a great product but I currently have the stock exhaust. I believe you need to relocate it in order for the new tub to fit. Thanks for the idea!

[taco2go]

So yes the weight is there but I feel for my application the safety of a secure load out weighs the weight of the wood. Oh and here is what it weighs at the present moment 25 lbs. for the floor and 9 lbs. for each side(fender well).


What type of plywood did you use ? I am now considering a similar floor for the back of the 80 series, and possibly the tailgate as well. Thanks for sharing such detailed pictures of your projects.

[Gear]

taco2go
What type of plywood did you use ?

I used 5'x5' Baltic Birch. Cost was $29 and change out the door per sheet. I built the whole project with 2 sheets.

I believe the reason it looks so good is the Line-X. There is no way I would get this same result with a do it yourself application.

[taco2go]

Thanks. and a true testament to your abilities. i was looking at some MDF at our local Gemmens.

[durango_60]

Wow, that looks fantastic, the AT guys should buy the pattern from you and produce it from the same composite they are using for the drawers.

[nwoods]

Wow, that looks fantastic, the AT guys should buy the pattern from you and produce it from the same composite they are using for the drawers.

Wow that's a pretty good idea, and much lighter as well! The JK industry is certainly booming. That would make a lot of sense.