AEV Brute Expedition Build in Dubai

[Oman4x4]

So I figure now is a good time to start the build thread on my Brute - the majority of the parts have finally arrived! Been quite quiet on Expedition Portal but now finally building the Jeep into a proper expedition vehicle rather than just a weekend toy.

First - an intro on what we have got planned - the whole goal is to make the Jeep much more user-friendly for longer trips. That means replacing the 4 jerry cans with an in-built second tank, more accessible cargo that can be better organised, and more comfortable cabin.

The build will take a 2001 Wrangler and do the Brute conversion, with custom long arm suspension using MetalCloak parts. I'm already starting with on board air, air locker in the front, Ected in the rear, SwayLoc etc etc... And the 6-pak shocks will be complimented with King 2" gas bump stops.

The refined part of the build - will be on two levels - firstly the interior is going to see quite a lot of leather and alcantara trimmings and a lot more noise insulation than it's ever had. Recaro seats may also be done too. The other refinements will be the expedition preparedness like the dual tanks with secondary pump, dual battery. The roof top tent. Also a swing-out tire carrier on a custom rear bumper. Taking the hard work out of it all.

The HiTech aspect - it's going to have Garmin in-dash GPS integrated to the OBD-II system. Park sensors. Camera systems front / rear / underneath. Power Sunroof. Power drop down rear window. Power normal windows. Add to that radar based blind spot monitoring system. Already has power retracting running boards. Also some of the technology that will be used to make the parts - using scanning equipment and CAD to do the suspension pieces, design the roll cage, and make the rear bumper and cargo rack (and perhaps re-do the front bumper).


And now some pictures!

This is the Jeep as it stands today:

Photoshop goal:

Unboxing some parts!

New Frame - 0 miles!:

Should take a while to wear these bushings out

 

[Oman4x4]

Going to copy and paste a few updates from the other forums and then will continue to keep this up to date Would definitely appreciate inputs from experienced expedition wheelers.




Frame is now cut! After the weekend it will be welded up again in its extended length, and then we worry about the tail section. After that, we throw axles and shocks under it and take measurements on where we will be placing the long-arm bracketry.

This is the cutting template - shows you where to section the frame. It's used on both sides, and you cut on the straight edge of the rear-most zig-zag holes.

This is the rear extension sub-frame - which includes the rear winch mount and the trailer hitch connector.

This is the alignment template for when it goes back together. It has the same holes as the cutting template and access holes for you to tack-weld it in place. This ensures the stretched frame is straight and correct.

This is the section of frame rail that will go in the extended part of the frame.

The cutting template clamped in place for the holes to be drilled.

 

[Oman4x4]

The frame is now cut - and repositioned on the jack stands using the extension templates. They will then come off again while the inner reinforcements are put on. Then the extension pieces are loosley put in place, re-attach the extension templates and begin welding!

Some of you may notice no pictures of the interesting bit - when it gets cut - but there IS video and I'm working on it

 

[Oman4x4]

Video of the Jeep frame being cut in half

 

[Oman4x4]

Been a slow week as the build-room gets AC and extractor fans installed to help combat the 120+F temperatures here - but now making progress again.

The main chassis extensions are done - although a bit more welding to be done on the reinforcement plates tomorrow, then the tail section, bed mounts and then we will throw the axles under the frame with the new shocks, and standard control arms, and then start taking measurements to design the long-travel suspension.

Frame with the extension done:

What join lines? Wish I had been able to stop by the shop and get some pictures before smoothing it out but was not able to...

External reinforcement plates. This will then be seam welded on the top and then the whole chassis will be flipped upside down and the same again for the lower side.

 

[Oman4x4]

Latest time-lapse update:


Although I did learn with this one that shooting at 12MP is overkill for this purpose so the memory card filled up way too quickly. Still learning

 

[xkid]

That's a different looking garage. What kind of tires are you going to run in that terrain?

 

[Oman4x4]

That's a different looking garage. What kind of tires are you going to run in that terrain?

It's an air-conditioned room within the garage for the more complicated builds. After my Brute is out there should be a friend's Jaguar E-type getting a Jag XF-R drivetrain

Tires - currently running my second set of 35x12.50-R15 Cooper STTs - will continue to use them after the Brute conversion too as they have plenty of life left in them. I like them, they're a tough tire and they do well when you deflate them a lot - at around 4-5 psi they have an almost tank-track-like ability to find grip and crawl up the sand dunes. Would like to add Hutchinson Rock Monster wheels though - and see what they can do at around 1-2 psi

Later - maybe 37 x 12.50 R15 - but with bigger axles.

 

[X-plorenow]

Great looking build, will be following with interest. Where did you get that rear winch mount?

 

[xkid]

Very cool and well thought out. Can't wait to see more.

 

[Oman4x4]

Great looking build, will be following with interest. Where did you get that rear winch mount?

It's part of the standard Brute frame kit - as the rear overhang gets extended...

 

[jscusmcvet]

Awesome. Will be following along for sure. Sitting here watching the video had me wondering if I could have actually made the first cut on the frame! Intestinal fortitude!

 

[redthies]

Great start! Can't wait to see it progress!

 

[locrwln]

Been watching over on JeepForum and as I said over there, I have Brute envy and can't wait to see your finished product.

Jack

 

[Oman4x4]

Tail Section extension almost done - a little more work on the passenger side and some more seam welding to finish up.

Here you can clearly see the winch mount and trailer hitch.

Reinforcement plates and bumper mounts.

Rear view - frame is looking quite long now!