A-man930 Posted May 29 Author Share Posted May 29 Mocked up an inner fender liner over the last couple nights. Figured the best way to protect all this fresh metal is to shield it from direct punishment. This might not seem like a big accomplishment, but I enjoy at least knowing that details like this are at least past the "proof of concept" stage. Used this stuff: https://www.speedwaymotors.com/Colored-Plastic-HDPE-Sheet-10-Ft-Rolled-1-8-Inch-Thick,1557.html?sku=910041-BLK Link to comment Share on other sites More sharing options...
GonzoTheGreat Posted May 29 Share Posted May 29 That looks like a perfect fit. How was the material to work with? Did you have to score it to get the harder angles? Or just use heat? Link to comment Share on other sites More sharing options...
A-man930 Posted May 29 Author Share Posted May 29 2 hours ago, GonzoTheGreat said: That looks like a perfect fit. How was the material to work with? Did you have to score it to get the harder angles? Or just use heat? Yes, I'm happy with the fitment. Material is easy to work with. I scored it to cut the roll in half. Using a fine tooth blade on a hackzall to trim, heat gun with light pressure in a brake for the bends. Link to comment Share on other sites More sharing options...
A-man930 Posted June 30 Author Share Posted June 30 Broke through the floor when attempting to invert the factory transfer case hump. A year later, it's finally (almost) patched Link to comment Share on other sites More sharing options...
A-man930 Posted July 1 Author Share Posted July 1 Coming together. Gonna test fit the seat later today Link to comment Share on other sites More sharing options...
A-man930 Posted July 8 Author Share Posted July 8 Glad I did a test fit. Had to make quite a large contour for the seat bracket. Ended up grinding on the seat side to clear. Link to comment Share on other sites More sharing options...
A-man930 Posted July 12 Author Share Posted July 12 Finally found a glass guy to come and remove the windshield. Urethane was super hard. Back glass is the next session... neither one of us are optimistic it'll survive Link to comment Share on other sites More sharing options...
Pete M Posted July 12 Share Posted July 12 it'll be fine. go slow, be thorough, and for the love of god don't force the glass in any way. Link to comment Share on other sites More sharing options...
A-man930 Posted July 13 Author Share Posted July 13 Not sure what I expected, but it looks like I've got some work ahead of me. Link to comment Share on other sites More sharing options...
Salvagedcircuit Posted July 13 Share Posted July 13 Thanks for the photos! Now I know what to expect whenever I do mine Link to comment Share on other sites More sharing options...
A-man930 Posted July 13 Author Share Posted July 13 13 minutes ago, Salvagedcircuit said: Thanks for the photos! Now I know what to expect whenever I do mine Hope it's helpful. I could not cut the urethane with the Harbor Freight Tool I had bought. It was simply too hard. Had a glass guy come give me a hand. Link to comment Share on other sites More sharing options...
A-man930 Posted July 13 Author Share Posted July 13 On 7/12/2024 at 9:35 AM, Pete M said: it'll be fine. go slow, be thorough, and for the love of god don't force the glass in any way. Can't believe how smooth this went. Took a bunch of time, two dozen razor blades, soapy water, and the Harbor Freight hook knife. As a bonus, the glass was already separating from the frame channels in a section, which gave me the confidence to peel it all apart. Link to comment Share on other sites More sharing options...
A-man930 Posted July 19 Author Share Posted July 19 @KYMJ, are you still around? I remember you telling me when I bought the truck that your son had ran into the back of the cab loading a four wheeler and tweaked the window channel. Happy to report that it's fixed Link to comment Share on other sites More sharing options...
A-man930 Posted September 2 Author Share Posted September 2 Put guts back in the transfer case and doubler so I could fab the shifter setup for them. Couldn't be happier. Link to comment Share on other sites More sharing options...
A-man930 Posted September 2 Author Share Posted September 2 Link to comment Share on other sites More sharing options...
A-man930 Posted September 2 Author Share Posted September 2 20240902_180117.mp4 Link to comment Share on other sites More sharing options...
A-man930 Posted October 18 Author Share Posted October 18 Trying to tie up all the "engine installed" mockup items. The TDi radiator hose arrangement is awkward for most swaps. It is possible to flip the housing upside down (as I did), but it does create a clearance issue... good thing I'm beyond the point of caring about hacking away sheet metal 😁 Link to comment Share on other sites More sharing options...
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