Building Homer (2005 TJ Build Thread)

[FarFire70]

Got ride of all the OEM clips for the brake lines to get them tucked away. Used the 1/4" rubberized clamps with self-tapping screws. You can see them in the images above.

Stupid me, I went lazy to drill one of the holes into the cross-tube and tried to sit in front of the frame and drill 'towards me'... Welp, I broke a bit off in the tube when the bit finished the hole and friction dropped.

I could have left the bit there and drilled a new hole nearby but that wasn't the right way. So had to remove the Anti-Rock and push the bit into the tube and fish it out.

Tried to weld a nut on the bit but there was so little outside the tube to get a good weld onto that the nut just twisted off.

Didn't grab any pics. Added another few min to the project for R&R of the Anti-Rock. Should have done it right and laid under the Jeep to better control the drill... Another reminder to myself to do it right the first time.

 

[FarFire70]

I've found drillhog on eBay has been a decent source for bits to re-fill my broken bits.

Unfortunately, I've broken too many small bits. Picked up a few of those from drill hog to replenish my kit from Drill America.

This was my most recent drill bit set I picked up 3 years ago to fill in the sizes I needed beyond the clamshell kits I had from Dewalt/Ryobi. The clamshell kits didn't include enough fidelity between bits...

https://www.amazon.com/gp/product/B00B0327QQ/?tag=wranglerorg-20

 

[FarFire70]

Clearance of the brake line to the bumper now.

 

[FarFire70]

Taped off the stainless steel lines on the front end in prep for painting the frame.

Hit the frame with the first round of mineral spirits to clean it off. It's still a little wet so a little more shine than it will have.

Will hit it a second time with monster spirits for anything missed on the first pass.

Trying to hit paint projects now before the weather really turns cold. Enjoying this warmer fall right now...

 

[FarFire70]

Because I like the OEM styling and the MorRyde requires trimming to install these tai lights so I didn't want to do the install twice...

Need a way to mount a front license plate mount too, so I'll use the @Fluxor bracket until I pick up a winch. Black Friday??

 

[FarFire70]

Enjoying the life with kids — colds...

Twins picked up a cold late last week, passed it to my wife, and I caught it yesterday.... So my hopes to use the long weekend were all about taking care of each other.

So no updates...

I do have the BMB tail lights in hand that I planned so show pic of putting them together....

Instead, I'm building a build list instead. Rather than just hitting what makes me happy, I'm trying to lay out a plan...

 

[FarFire70]

My priority is the paint because I stripped of all protection when I washed it with dish soap to remove wax and haven't finished detailing...

So that's my focus before I start painting frame and hitting other parts.

Building my plan in OneNote

 

[FarFire70]

I'm still deciding if I go with Meguiar's NXT 2.0....

Because their website is not existent...

https://www.meguiars.com/automotive...-generationr-tech-waxr-20-g12718-18-oz-liquid

 

[FarFire70]

So maybe thinking to move to a ceramic... The NXT was hot when I bought it but I don't feel good to use it when even the company doesn't support it... (even though you can still buy it on Amazon...)

 

[FarFire70]

I hate to waste a product I have on-hand but I also don't know that I trust my time to a product a company has appeared to abandoned...

 

[FarFire70]

Despite the cold (because I plan to hit the paint this weekend before we all got sick) was to hit the paint foremost because I realized the paint was un-protected after washing it with degreasing soap and never getting wax back on the paint.

So I need to re-protect the paint before I do any other projects...

 

[FarFire70]

Parts ordered for amp mount under the dash.

Soundstream PN5.640D Picasso Nano

I thank @NashvilleTJ for blazing the trail on an underdash mounting bracket to steal ideas from in my design. They say - plagiarism is the best form of flattery...

Post in thread 'Nashville TJ's Build - Continued'

Jan 16, 2022

Yesterday I built the mount for the new amplifier. Using the pattern I made earlier in the week, I cut out the main piece. To much of a pain to pull out the plasma to make two short cuts, so I used my trusty old circular saw / abrasive blade trick. Unlike the plasma, it makes a very clean cut that requires zero cleanup.

Then I cut and drilled the two tabs out of 1/4" bar, and beveled the lower edge for welding.

I did have to make a change from the pattern. I originally had the tabs centered on the plate, but there was not enough room to slide...

• NashvilleTJ

• 
• 

Images of my design:

I'm going to post with @Chris to see if we can upload .dxf files because I can't attach them right now.

Designed in Autodesk Fusion 360.

Between getting the raw materials and creating something in the garage - this was money well spent. Saves me time with the twins and can use garage time for the projects I need to be hands-on.

 

[FarFire70]

I also ordered a couple other parts.

First one:

@jjvw was right here:

Post in thread 'Windstar Intake Clearance - Hitting Hood'

Aug 21, 2024

@FarFire70 To fix this problem, pop rivet a patch panel over most of the hole. Then redrill it further down and over. Use my pic of the ground bolt and the overlapping seam as a reference. You new hole cuts through that seam and the bottom is below the bolt.

And before you do anything, go back and get the rubber insert. Use that to determine the size hole saw you need to use. My memory says it was 3.25".

• jjvw

I looked into all the options and adapters proposed and ultimately — I need to fix my mis-drill in the firewall to move the intake hole...

So I ordered up a patch panel because it was easy to CAD and cheap to have Send-Cut-Send make it up as part of the above order - cost was about $11. I'd spend more time getting the raw materials + cutting the part than this laser-cut part, delivered.

I'll bang it into shape, seam seal it, rivet it, and fix my error...

Planning to Khaki paint it so it'll also be a practice piece on painting metallic paint. (after the 'bang it into shape' )

—-

I also picked up a radiator skid from EMP - I'll get pics of it when I work on it. But it has a huge logo and I am anti logo on my Jeep itself. I'll sticker my garage but the Jeep stays clean... It's my OCD think on Homer.

So I ordered a replacement panel while I was in CAD and ordering steel anyway...

Saves me time cutting this out and avoid same issue of 'on-hand' raw stock.

—-

I need to build out my on-hand stock of steel for quick work in-time.

But I also don't want to be where I was with my recent cleanse of my wood pile where I have a ton of 'I'll use this some day' stock... So including these small parts in a bigger order are great so I don't then have a 4'x4' left over of every thickness of steel imaginable. Most would rust before I'd use them...

 

[FarFire70]

Was going to go with Meguiar's NXT 2.0 but I was really worried when I went to their website for a reference on instructions (while on the couch rather than in the garage reading the bottle).

And found it was non-existent...

https://www.meguiars.com/search?sea...xt generation tech wax 20 g12718 18 oz liquid

So, despite great feedback, I pivoted.

Going to try ceramic coating.

Seen good use of this product from Avalon King:

https://avalonking.com/products/armor-shield-ix-diy-kit

Picked up a deal so trying it out.

Apparently it can also be used on the black plastic. So that's a nice feature vs the white film from traditional wax. May try it on interior trim if my experience is positive...

I'll share my experience using this product.

 

[FarFire70]

Ordered from Send Cut Send late Sunday evening; parts arrived Friday afternoon. That'll work for me on most/all projects.

Comes vacuum packed:

I'm glad I did these reference marks. They came out great:

Pretty happy with how the amp bracket came out:

More residual around the interior cuts than on the perimeter. Should clean up pretty quick with the dremel.

Now that I have the parts, I wish I had included a fillet on these corners (red lines). I can hit them with the dremel too, to round them off.

And, as always with Send Cut Send, you get a snack in every shipment:

 

[sab]

Now that I have the parts, I wish I had included a fillet on these corners (red lines). I can hit them with the dremel too, to round them off.

I love me some SendCutSend! Hot tip - always use fillets and radii on corners. Sharp corners concentrate strain. Strain = cracks.

And, as always with Send Cut Send, you get a snack in every shipment:

I can save mine up and send 'em to you - I usually just throw them in the trash. I don't eat that nasty crap anymore...

 

[FarFire70]

I love me some SendCutSend! Hot tip - always use fillets and radii on corners. Sharp corners concentrate strain. Strain = cracks.

Great tip. I should have known better...

I can save mine up and send 'em to you - I usually just throw them in the trash. I don't eat that nasty crap anymore...

lol. I'm good. It's just a funny little marketing thing they do and I like outside-of-the-box marketing.

Definitely not something I'd spend coin on - but I'll snack on it at some point since it's there.

 

[Blake Stamper]

Great tip. I should have known better...



lol. I'm good. It's just a funny little marketing thing they do and I like outside-of-the-box marketing.

Definitely not something I'd spend coin on - but I'll snack on it at some point since it's there.

It’s a very appreciated little detail, back when I sold scx24 chassis I always included a jolly rancher, they’re cheap and is a fun surprise you wouldn’t expect.

 

[FarFire70]

I love me some SendCutSend! Hot tip - always use fillets and radii on corners. Sharp corners concentrate strain. Strain = cracks.


I can save mine up and send 'em to you - I usually just throw them in the trash. I don't eat that nasty crap anymore...

I have updated the model with fillets now. So, when I get this installed and can show success, I'll post up the .DXF files (Thanks to @Chris for the update to enable attaching .DXF files!) that will include the fillets.

It does look better with the fillets ... But I won't see my box version once its installed under the dash.

 

[FarFire70]

I knew I wanted/needed a new top as I mentioned earlier in the thread since the second one I picked up years back was also original 20+ year old top finally gave out to ripping...

But I was hopeful Bestop would run a Black Friday sale and they didn't disappoint. 25% off + 10% cash back (rebate).

Saved about $120 on purchase and will land with more on the rebate.