08-FEB-2014
Cover panels
Now that the cage is complete there are a few things that I need to complete on the tub and body before I do a final sand for the paint. One of the items is to relocate my 6x9 speakers because where the holes for the speakers are now they fall right behind the B pillar of the cage and I would have a hard time fitting them between the body and the tube of the B pillar.
My thought is to cut a new 6x9 hole that is out of the way of the roll cage tube and easy to install once the cage is back in the Jeepster. I will weld the new cutout piece in the old 6x9 hole and I will make some aluminum panels that will cover the complete area.
08-FEB-2014
Both panels complete
I made some paper patterns and laid them out on the aluminum. After they were cut out I figured out where the new speaker holes were going to be located so that they would clear the roll cage tube.
08-FEB-2014
Ready to mount panel
After a final fit and sanding of the edges the panels are ready to mount into place.
08-FEB-2014
Fasteners to hold panels
I decided to install nutserts in the tub to hold the panels firmly in place. I was going to just pop rivet the panels in place but I figured that rivets might come loose and start to rattle.
08-FEB-2014
Front speaker holes
I am installing some 5 1/4" front speakers to round off my little sound system so I decided to make some aluminum panels for the fronts as well.
08-FEB-2014
Front panels done
Almost ready to fasten on, nutserts set, and speaker holes are cut. One more final touch to do to them and they will be ready to go.
Testing the material thickness
I wanted to do a couple test beads on this 18ga aluminum before tackling the completed panels.
09-FEB-2014
Front speaker panels
I was able to finish both front speaker panels, mount them, and get the speakers mounted. After I spray the tub the panels will go in very easy.
09-FEB-2014
Rear speaker panels
The rear speaker panels are complete and mounted. I will need to pick up some shorter hardware for a couple of the mounting holes but all in all the turned out as I planned them.
08-FEB-2014
Rear fender well openings
I am planning on opening up my rear fenders for future larger tires and linked suspension so that I don't have to cut them later after the Jeep is painted. It is going to be some extensive work on the inner tub fender well after the fender is cut.
I will top them off with tube flares.
10-FEB-2014
Cutting the rear fenders
I used this trick Milwaukee metal saw to cut my fender wells. This saw cuts the thin body sheet metal like butter but it also cuts 1/4" thick steel plate petty easy as well!
10-FEB-2014
Rear fenders opened up
I cut the rear fenders with nice big openings so I won't have to worry about any rubbing now or in the future. I am only running 35" tires now but will eventually go up to 37's or 38's when I link the suspension in the future. After the body is painted I don't want to have to come back and cut the sheet metal because of tire rub.
I now have some sheet metal work to do on the inner fender wells.