I've got to try out Send Cut Send at some point....
Building Homer (2005 TJ Build Thread)
- Thread starter FarFire70
- Start date
I've got to try out Send Cut Send at some point....
It's a great service! You need to have in-hand or create a CAD design of the part for them. From that — the imagined because a reality...
They keep adding services - I'm waiting for when I need something bent to try that service from them.
There's a lot of sponsored folks - the one above happens to be one I follow for his fun approach to (actual) engineering, (good enough) engineering, and funny antics. I always learn something from his posts — he's building a off-road Viper which has been fun to follow along. 15% discount from his link.
I used Fusion 360 to CAD. It's free and I've always been an Autodesk fan vs SolidWorks/others.
I'm hoping later this spring I can get time to learn my 3d scanner and bring in parts of the Jeep for some future projects...
This is where I'll run into issues since I have no real knowledge of how to use any of the CAD software. I'm sure I could learn but I haven't played with any of them in YEARS...
Breather-to-intake solution created.
Masked around the curved washer as a starting point and template.
From there, I locked the intake into a vise and used this Dremel attachment as a hand operated mill.
Initial test fit looked pretty good, but I think I needed to take down about another millimeter to get more thread exposure.
So I ran another milling effort and ended up with this:
Clean it up and finalized by adding RTV under the washer and putting blue loctite on the threads:
I'm happy with this setup. Thank you to so the suggestions and ideas to get me here!
Masked around the curved washer as a starting point and template.
From there, I locked the intake into a vise and used this Dremel attachment as a hand operated mill.
Initial test fit looked pretty good, but I think I needed to take down about another millimeter to get more thread exposure.
So I ran another milling effort and ended up with this:
Clean it up and finalized by adding RTV under the washer and putting blue loctite on the threads:
I'm happy with this setup. Thank you to so the suggestions and ideas to get me here!
I've used send cut send before to create patterns for my leatherwork and they did all the CAD for me. I provided them with sketches and measurements and they drew them up. I think I had to pay an extra $5 per pattern for them to do this.
Fusion360 could us used as a pseudo-AutoCAD where you can just create a 2D drawing and just export that as a .dxf for Send Cut Send. That's fairly straight forward with plenty of YT videos for advice.
That way you're not getting into full 3D modeling like I did for the fuses.
Food for thought.
A few updates over the past few weeks in the next couple post. Really need to get going if I want to hit my 'Driving' target of June...
Aluminum mounting panel received for electrical fuses. This this is beautiful - even if it is a pretty basic-function part...
I actually think that many of the wires going into the new hole in the firewall for interior accessories or switch are going to up and behind the panel - rather than around the battery and hugging the firewall - there's getting to be less space near the batter and this new route would be a straight shot from the new/second fuse block.
I'll run some longer bolts through to hang/ziptie the wire loom off to secure the wires going into the interior.
Aluminum mounting panel received for electrical fuses. This this is beautiful - even if it is a pretty basic-function part...
I actually think that many of the wires going into the new hole in the firewall for interior accessories or switch are going to up and behind the panel - rather than around the battery and hugging the firewall - there's getting to be less space near the batter and this new route would be a straight shot from the new/second fuse block.
I'll run some longer bolts through to hang/ziptie the wire loom off to secure the wires going into the interior.
The original clasps for my rethread kit (I freaking love this thing! One of my most go-to tools!) were breaking. One was completely gone and the second was breaking.
So I drew it up in Fusion360 and printed replacement in TPU on the X1C.
TPU is flexible so they work perfectly!
So I drew it up in Fusion360 and printed replacement in TPU on the X1C.
TPU is flexible so they work perfectly!
Throttle cable has been sticking. I've had to put my foot under the throttle and pull it up to get the Jeep from about 1500 idle back to a normal ~750.
I had previously replaced the throttle cable - that wasn't sticking.
After seeing this video, I wondered if the bearings were sticking, so I figured it was worth a try to replace them.
Ordered Koyo JTT-67 bearings: eBay
Broken down the throttle body - there is definite wear and rust...
I ran some 400 then 800 grit sand paper over those grooves to smooth them out for the next bearings...
Used mapp gas to heat up the bearings and a punch & mallet.
I figure the o-rings in the bearings will account for the oblonged holes caused by the punches.
One hit went a little wild - I used a dremel to sand this smooth.
I have install the new bearings. They went in smooth with a c-clamp and a washer and socket...
If this doesn't resolve it, I'll try an eBay throttle body - may grab a backup anyway because they're running around $90 and I can't find any reliable new source of throttle bodies...
I had previously replaced the throttle cable - that wasn't sticking.
After seeing this video, I wondered if the bearings were sticking, so I figured it was worth a try to replace them.
Ordered Koyo JTT-67 bearings: eBay
Broken down the throttle body - there is definite wear and rust...
I ran some 400 then 800 grit sand paper over those grooves to smooth them out for the next bearings...
Used mapp gas to heat up the bearings and a punch & mallet.
I figure the o-rings in the bearings will account for the oblonged holes caused by the punches.
One hit went a little wild - I used a dremel to sand this smooth.
I have install the new bearings. They went in smooth with a c-clamp and a washer and socket...
If this doesn't resolve it, I'll try an eBay throttle body - may grab a backup anyway because they're running around $90 and I can't find any reliable new source of throttle bodies...
Today I got a chance to spend some time painting the frame. Important steps forward to getting the bumpers installed.
Added a drain hole in the rear frame on both side before painting:
I pulled out pass seat in prep to install new foam & seat warmers.
Found the parking brake needed attention. ——- Every step forward is one more step backwards for rust resolution!!
So I pulled it out and I'm painting it...
Tomorrow I hope to hit the frame with another round of black and then clear coat... Inching progress. Hoping to make miles soon to get back on the road...
Added a drain hole in the rear frame on both side before painting:
I pulled out pass seat in prep to install new foam & seat warmers.
Found the parking brake needed attention. ——- Every step forward is one more step backwards for rust resolution!!
So I pulled it out and I'm painting it...
Tomorrow I hope to hit the frame with another round of black and then clear coat... Inching progress. Hoping to make miles soon to get back on the road...
Went and found reverse signal. I'll pull it from the C102 in the driver footwell for the rear camera trigger.
I'm likely eyeing a double-din instead of the OEM looking stereo I have on-hand... we'll see if Memorial Day throws me a convincing sale...
I'm likely eyeing a double-din instead of the OEM looking stereo I have on-hand... we'll see if Memorial Day throws me a convincing sale...
Been working on the Jeep a few minutes at a time in off hours. A few updates:
Throttle body new bushings installed. I also picked up a used one off eBay for $70, cheaper than the going rate, so I have a backup if the new bushings don't work out...
Cleaned off the intake gasket. Started with plastic scraper blades but eventually I had to move to a steel razor (I know - very dangerous on aluminum) but used it at a 90* angle, much like scrapping crack filler off a windshield to reduce gouges.
Hopefully this solves the sticky throttle causing high throttle...
Throttle body new bushings installed. I also picked up a used one off eBay for $70, cheaper than the going rate, so I have a backup if the new bushings don't work out...
Cleaned off the intake gasket. Started with plastic scraper blades but eventually I had to move to a steel razor (I know - very dangerous on aluminum) but used it at a 90* angle, much like scrapping crack filler off a windshield to reduce gouges.
Hopefully this solves the sticky throttle causing high throttle...
Been getting after the electrical more. Ran a lot of the wires into the dash for all the switches to the 'new' aux fuse panel (used OEM PDC).
All the wires crimped and run into the dash. Use bare couplers and heat shrink. SOO much better and quicker than soldering....
I added heat shrink, pinched with needle nose, to wires I don't have a use for now. Most are to an empty fuse but I still didn't want open wires flopping around.
Zip-tied un-used relay wires together to help clean things up some.
While this looks messy - I see an end to dozens of wire runs... Organized chaos.
Final install in the engine bay and all buttoned up.
Only blue wire there is for my future ARB twin compressor. I'm not ready to run it into the firewall so I'll tie it off if I don't get the compressor installed before I drive it again.
Used OEM PDC I got off eBay has broken most it's mounting clips. Luckily the mount design lets a zip-tie work...
New dash switch panel is going to look freaking sweet!!!!
Panel is from here: https://www.custom3dfab.com/
Picked up seat heater switches off eBay. I only plan to run them on high from the switch.
All the wires crimped and run into the dash. Use bare couplers and heat shrink. SOO much better and quicker than soldering....
I added heat shrink, pinched with needle nose, to wires I don't have a use for now. Most are to an empty fuse but I still didn't want open wires flopping around.
Zip-tied un-used relay wires together to help clean things up some.
While this looks messy - I see an end to dozens of wire runs... Organized chaos.
Final install in the engine bay and all buttoned up.
Only blue wire there is for my future ARB twin compressor. I'm not ready to run it into the firewall so I'll tie it off if I don't get the compressor installed before I drive it again.
Used OEM PDC I got off eBay has broken most it's mounting clips. Luckily the mount design lets a zip-tie work...
New dash switch panel is going to look freaking sweet!!!!
Panel is from here: https://www.custom3dfab.com/
Picked up seat heater switches off eBay. I only plan to run them on high from the switch.
Started tearing down the passenger seat for new foam and seat heater pads install.
I figured, since I'd be this far into the project, I'd strip off the back fabric and run it all through the wash...
Base has terrible rust.
Torn it down more:
I'll hit these parts with a wire wheel and then some self-etching primer and flat black.
I figured, since I'd be this far into the project, I'd strip off the back fabric and run it all through the wash...
Base has terrible rust.
Torn it down more:
I'll hit these parts with a wire wheel and then some self-etching primer and flat black.
I wanted to pull off the radiator cap for a quick check inside - this is the original OEM cap. I kept it even after the engine swap because it was in decent shape still. Newer radiator though...
This time when I went to get it open off a very cold/unpressured (hasn't run in months) engine - I had to use pliers to grip it and put my full body weight on it to get it to open.
So a new OEM Mopar is on the way...
https://www.amazon.com/dp/B0049EFN2I?tag=wranglerorg-20
This time when I went to get it open off a very cold/unpressured (hasn't run in months) engine - I had to use pliers to grip it and put my full body weight on it to get it to open.
So a new OEM Mopar is on the way...
https://www.amazon.com/dp/B0049EFN2I?tag=wranglerorg-20
I need new jumper cables. My old ones have done well but they're hand-me-downs and the clamps are gnarled and only one side of the jaws per clamp connects.
So I started looking and I think next month I'll pick up a set from these folks:
https://spartanpower.com/product/jumper-cables/
So I started looking and I think next month I'll pick up a set from these folks:
https://spartanpower.com/product/jumper-cables/
- Made in USA
- 100% copper wires
- Braided wire connects both jaws per clamps
It's really been finding small pockets of time. Not expecting a lot of 'full day' garage moments on weekends with the twins about to turn 3 yrs old - so I'm finding a new 'dad power' to squirrel away time to get after inches rather than miles at a time.
Electrical has no joke 15-20+ hours of work completed but spread out over the past many weeks - it's been the only way it would have ever gotten done...
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