01-SEP-2013
Test fit of the gussets
After figuring out the angles and notching the tube, a test fit showed that the gussets were ready for welding.
01-SEP-2013
Wind and TIG welding
There are a few things that should never go together and I was reminded of two of them today while tacking in the upper windshield gussets. WIND and TIG Welding! It was gusty here today while I was trying to tack in these gussets. I would wait for the wind to die before striking an arc but this one got me, right when I started the tacks the gusts came.
08-SEP-2013
Adding some reinforcments
I decided to add some 1/4" thick materiel to the windshield frame to be able to drill and tap the area for accessories if needed in the future.
Reinforcing the windshield frame
The piece is 8.5" long and will be welded all around the leading edge. The back edge is sealed with seam sealer to prevent moisture from getting behind and rusting underneath.
I have plans of making a couple light brackets to mount a 5" diameter light on each side. These plates will allow me to drill and tap some 5/16" fine threads for a good firm hold.
11-SEP-2013
New mirror brackets
Although I already made some mirror brackets that mount on my door hinges I decided to make a new set that will mount higher and will swing in for tight trails if needed. The "swing in" feature will also work out well when I put my car cover on the jeep for storage.
A big plus having the mirrors not mounted on the doors will allow me to still have mirrors if and when I build some tube doors.
12-SEP-2013
New mirror mounts
I finished welding my new mirror mounts last night and was able to bolt them up for a working over tonight. Overall I'm happy how they turned out and they actually work as intended!
12-SEP-2013
Folded back
They fold all the way into the Jeep if needed, and when I put the car cover on I don't have mirrors sticking out. I picked up these off road mirrors from Kartek in Riverside for about $10 each.
They seem pretty good, they are tight and they use SAE hardware, 5/16-24 thread which surprised me that it looks like they were actually made here in the USA!
12-SEP-2013
Folded forward
The brackets also allow the mirrors to be folded forward if they need to go that direction. I used stainless steel hardware to assemble the bracket and used some 1/4" 28 button heads to fasten the bracket to the new windshield frame brackets.
Now I can take these brackets apart, bead blast them and then powder coat them black like all the other brackets.
14-SEP-2013
Fire Extinguisher bracket
In my push forward to make sure that I have all the brackets and little trick things welded to my cage before I remove it to complete the welds and then prime and paint it, I made a fire extinguisher mount. This mount will bolt to the cage (on bungs that I weld on) and the extinguisher will clamp to the other mating bracket with hose clamps.
After making some patterns I used some 3/16" plate to cut my parts from.
14-SEP-2013
Pieces all cut and shaped
I got all the pieces cut with the exception of the base plate and the extinguisher plate. All pieces shaped and de-burred on the sander.
14-SEP-2013
Mock test fit
I did a test fit of all the pieces before I welded everything together.
14-SEP-2013
Bead blasted parts
I bead blasted all the parts before welding to remove the scale from the cold rolled steel, the scale doesn't weld well with the TIG welder.