The Copper CJ

[carwash]

Been working on this build for a bit now... slowly. Customer is in no hurry, and that's good...

It's been a good time, but quite time consuming (read no time to work on my crawler) but that's what business is about i guess. My crap can wait.

On the list was rock sliders, with cage tie-ins to frame, rocker guards, redone rear cage with bracing added to the front cage and dash bar, seat mounts tied to frame to accomadate new PRP seats, rear bumper, paint inside of tub, paint all new parts hammered silver along with front bumper. There will probably be more stuff added as we get close to done. I'm happy with the way things are turning out so far.

Here are some pics!

Here it is as it came into the shop
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1000455.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1000460.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1000461.jpg

Here are the before pics of the cage
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1040343.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1040345.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1040346.jpg

[carwash]

In progress, and then out of the rig for finish weld and paint
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1040352.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1040389.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1040390.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1040391.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1040395.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010181.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010182.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010183.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010188.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010191.jpg

[carwash]

I would have hated to see this customer have to utilize this original cage in a roll with seeing the missing welds and the fact that the floor under the B-pillar feet was almost completely gone from rust. The rust images are a strong argument in favor of tying your cage to the frame...

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010192.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010157.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010155.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/DSC00390.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/DSC00392.jpg

[carwash]

Slider and frame tie-in fab...

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/DSC00394.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/DSC00394.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1040369.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1040368.jpg


http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1040366.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1040401.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010167.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010168.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010170.jpg

[carwash]

Rear bumper build...

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010159.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010161.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010162.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010163.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010173.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010175.jpg
http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010180.jpg


and a shot of the front bumper... built this about a year ago for this same customer, now just painting it to match.

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010194.jpg

[fabricator]

looks good...
slider and frame tie in = a bunch o work.

[sarge]

Looks good Mike ,

you going to do anything about that Rock Tattoo / soup bowl in the rocker ?

[tjjeepjeep]

Looks great Mike!

[GPER]

Those rocker/ cage tie ins are sweet.

[carwash]

looks good...
slider and frame tie in = a bunch o work.
yes, takes a while to get it all lined up and correct, then gotta pull it all out and weld it all up, hoping that it all the tacks hold in the pullout... then hope that in welding it all up, it didn't tweak from the heat... ugh.

Yes a lot of work, but very rewarding with how they turned out.

I will call you tomorrow Rob about cutter my rocker plates... i have my needed measurments.

[carwash]

Looks good Mike ,

you going to do anything about that Rock Tattoo / soup bowl in the rocker ?
there's one on each side... he dropped it down onto a rock ledge, first run out after the new paint...

covering them up with 3/16 or 1/4 rocker plates...

[94Dodge Truggy]

Very nice work! When can we see this copper beast wheel?

[eighty3bronco]

I love that hammer finish on the sliders, stinger and rear bumper!!!

[Coby]

vedday nice! High-5. I need to come down and check it out. Whats the word on his motor?

[BiggDaddy]

What's with the plating and bolts on the back side of the rear bumper? Are you going to bolt it on? I'm in the process of making very similar bumpers out of the same stuff. Really thick rectangular tubing.

BiggDaddy

[carwash]

What's with the plating and bolts on the back side of the rear bumper? Are you going to bolt it on? I'm in the process of making very similar bumpers out of the same stuff. Really thick rectangular tubing.

BiggDaddy
yes, the bolts go thru the rear crossmember and thread right into those plates, big 1/2 inch bolts, 12 total, should hold just fine.

[carwash]

Very nice work! When can we see this copper beast wheel?
This year i'm sure... he will probably do quite a few trips.

[carwash]

vedday nice! High-5. I need to come down and check it out. Whats the word on his motor?
motor is done and ready to be put back in...

for those of you that don't know, its a ridiculously built small block 400... very strong...

[carwash]

thanks for the props everybody.

[94Dodge Truggy]

So it has a chevy in it :(

[carwash]

So it has a chevy in it :(
yes, its the only way to get real power and dependability out of a jeep...

hahah

[itbrokeagain]

We have several chevys at work. I would never own one or stick a chevy engine in anything.

[TrooperII]

I like the Rust color.

whats the diamond plate on the back for? Ha Ha:D

love them cJ's

all looks sweet. keep it up.

[carwash]

cage painted and ready for install... painting hammered onto tubing sucks...

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010199.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010202.jpg

motor back from the builder and ready for install, with new serpentine belt system installed...

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010203.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010204.jpg

Atlas and 700R4 to be put in and custom x-member fabbed...

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010210.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010211.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010212.jpg

interior prepped for paint

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010206.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010207.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010208.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010209.jpg

taped off and any bare metal primed

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010213.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010214.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010217.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010218.jpg

cage installed, all parts reassembled, seats bolted in, etc...

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010223.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010225.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010227.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010228.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010229.jpg

some close ups...

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010230.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010231.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010233.jpg


Still have to drop motor/trans/tcase in, make crossmember, and put on the side plates to cover that body damage. I think it's turning out really nice.

[kyrel69]

looks nice,,, owner should like what you have done

[Bear Chow]

That's looks great, those seats look very low. Must be an optical illusion.

[94Dodge Truggy]

Good work CW! Chevy motor seems to be the only weak link.

[Freightdog]

Interior looks great!

[carwash]

Good work CW! Chevy motor seems to be the only weak link.
yer retarded.

[tjjeepjeep]

Looks great, carwash!!

[tinbeater]

Very nice work.

[carwash]

thanks guys.

[austynn2001]

Looking awesome. Hope to see it wheeling sometime.

[carwash]

it will be on the trail this spring...

[carwash]

fuel tank in... 15 gallon RCI cell. Chevy sending unit.

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010319.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010320.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010321.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010322.jpg

side plates on, 1/4" plate, covers the nasty body damage that was there, looks nice, same hammered finish.

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010323.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010324.jpg

working on the inner fenders right now, should have them done this weekend, then it will be the cross-member and that's it.

[94Dodge Truggy]

Instead of grade 8 hex bolts why not use flat head allen bolts? Fuel cell looks great!

[sarge]

Looks good Mike ,

I'm sure you know this but !!! you need to strap that tank down. There are several threads on Pirate about the tabs tearing off the bottom of the RCI tanks while wheeling rough with a full tank of fuel . Just FYI

[tjjeepjeep]

Looks great Mike!

[carwash]

yeah sarge, i have read that as well... never happened on my tank i had in the Pumpkin. I'm not gonna strap it, he can if he wants.

thanks for the props guys.

[itbrokeagain]

fuel tank in... 15 gallon RCI cell. Chevy sending unit.



What is your resistance on your sending unit? I might have a fuel gauge for you.

[carwash]

it's 8 ohm, utlizes the stock jeep fuel gauge. thanks tho tony.

but wait... what you got? I still need a gauge for the crawler...

[itbrokeagain]

Autometer fuel gauge

http://www.autometer.com/cat_gaugedetail.aspx?gid=2502&sid=3

Should be all the details you need. I opened it but found out it wouldnt work for me. So its never been used.

[carwash]

hmmm, how can i tell if it will work with this cell.

[carwash]

ah, wont work, this tank's sender says:

"Sender Ohm Range: 0 ohms empty, 90 ohms full"

yours says "Range: 240Ωs Empty / 33Ωs Full"

oh well. thanks for trying.

[carwash]

Well, the copper CJ left the shop today... parting is such sweet sorrow. The cat will be upset that it lost its sleeping spot. Who knew a PRP seat would be such a great place to have kittens.

Anyway, was waiting for jim to finish his motor/trans/atlas install so i could build his crossmember/skidplate for it...

I went a little over the top i think... had to incorporate a mount for the tcase, a mount for the anti-wrap bar, and some protection for the trans pan. Here are some photos of the build process.

Started by putting the fabsets on the frame in the places i wanted them and working from there. Used bendTech to get my bends perfect, man i'ts an amazing piece of software once you get your dies calibrated to it...

tacked in the first tube, then pulled it to make the bosses for what would become the mount.

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010917.jpg

All tubing is 1.75 x .125, except for the bosses. They are 1.25 x .375 wall, which leave a perfect hole for a 1/2" bolt.

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010918.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010919.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010922.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010923.jpg

[carwash]

Then the rear-most cross bar, and a nice jungle gym connecting them...

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010926.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010928.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010929.jpg

Then, just in case the rig comes in contact with land mines or anti-tank weaponery, i skinned it all in 1/4" plate.

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010930.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010931.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010932.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010933.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010934.jpg

[carwash]

I put some nice 1/4" wall tubing nubs for hardware protection. This will keep the heads of the t-case mount bolts from getting destroyed.

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010935.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010936.jpg

Some finished shots from the underneath...

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010937.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010938.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010939.jpg

Then of course a nice coat of the same hammered silver paint...

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010946.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010947.jpg

[carwash]

Some shots of the final piece installed.

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010949.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010950.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010952.jpg

[carwash]

Ah, and some money shots of the rig as it left the shop.

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010953.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010954.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010955.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010956.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010957.jpg

http://www.complete4x4.com/ImageFolio4_files/gallery/Shop_Projects/Jims_Copper_CJ/P1010958.jpg

So... this means big fat open bay at the shop... who needs work done?

[RuffedUpXJ]

Looks good Mike. Nice work.

Where is your shop located?

[94Dodge Truggy]

Very good lookin stuff! Hey do you need the front steer rockwell in the pic.?

[jfiscus]

you do some seriously nice work.

[tjjeepjeep]

Looks awesome Mike! Congrats on the completion!

[carwash]

Looks good Mike. Nice work.

Where is your shop located?
Walton, KY. Right on US Hwy 25 / Dixie Highway. About 5 minutes off the Walton exit on I-75.

[carwash]

Very good lookin stuff! Hey do you need the front steer rockwell in the pic.?
If i didn't need it, it would already be gone.

[carwash]

If i didn't need it, it would already be gone.
Thanks for the props guys.

Find someone to fill this empty bay before i start putting race cars in it....