Started modifying the crossmember

[Steve F]

Originally Posted by Gojeep

You can bend it easy enough by just cutting into the back of where you want to bend it only part of the way.

That was the plan, I was just going to get a 3mm cutting disc and make a cut (or two) along the fold lines, fold side.

I cleaned the paint off with one of those wire brushes but a large one that goes on the grinder, low RPM and works wonders.

Cheers
Steve

[Steve F]

Bought the steel today and decided that 6mm wasn't thick enough, 1/4" was better, 5/16" better again but 8mm was the go Next up was 10mm but that was overkill.

Decided to get 2m x 200mm x 8mm, got it cut into 2 1m sections, one will be bent up for the transfer case skid with the left overs from both 1m pieces to be used as ribs for it.

Anyway, here's the comparision of the old t-case skid and the steel for the new.


And the thickness of the base for the crossmember compared to the piece I cut off.


And the new profile the crossmember will have


I've tested the slicing and bending and it works fine, looking forward to cuting it to shape and welding it up.

Cheers
Steve

[Agent Orange]

Good write up Steve, im watching taking notes

[Steve F]

Cut out the steel plate and welded it on to the top part of the crossmember today. It took a while to cut it all out and cut the holes to access the transmission mount bolts. I also drilled 4 more smaller holes and welded nuts to the back of them for bolting on the tcase skid plate later on.

The base welded to the top with all the holes drilled etc


Close up of the holes etc.


And my welding, it got better as I went along and I'm pretty happy with my effort at welding the 8mm plate to the thinner stuff. This is just before the end of the crossmember and I need to cut the back of the plate and fold it slightly here to follow the upwards taper of the crossmember and then weld some more.


Still some more to do (the ends need trimming, shaping and welding) but it will have to wait a couple of weeks now So far I'm happy though, it's tough as and pretty heavy.

Cheers
Steve

[Steve F]

Finished it off tonight, final bit of cutting, welding and painting (with a brush and some rustoleum I had) and its done. I'll bolt it up tomorrow night and then start on a new tcase skid plate.

Total cost so far is $44 plus my time and a few cuting discs at about $2 each so say $50 if I round it up

I'll take a pic side by side with the stock one tomorrow.





Cheers
Steve

[kyro]

looking good dude cant wait to see it on the jeep

[Steve F]

All installed, here's a couple of pics with a new versus old side by side.





Cheers
Steve