Safari Pacific MX2 Build

[schanusa]

Current Status

Progress on the MX2 ( Before Mods | During Cab Extension | Current )
http://www.safaripacific.com/vehicles/mx2/progress.jpg

Action Shots
http://www.safaripacific.com/vehicles/mx2/action.jpg




Original Post
It's about time I started a thread for all my mods....so here it goes.... With the first set of mods already completed, I'm going to jump right into my second phase of modifications. The main goal of the second round is to prepare for a much larger adventure that I'm currently planning. To drive around the world. :smiley_drive:

First things first, removing the old camper shell. It served its function well, but its time to move on. I've crawled through the cab into the camper one to many times and have broken a few interior parts while climbing through. With a few big trips now under my belt I can see new ways to make things much easier as well, especially in gear storage. Attached are two photos. One is the last shot of the camper in use. The second is the rough concept for the new cage to fit on the bed. The new "cage" concept, for lack of better words, will have a low profile and will contain many storage compartments.

http://www.safaripacific.com/vehicles/mx2/oldcamper.jpg

To solve my problem of crawling through windows I'm going to toss on an Eezi-Awn tent, but not in an ordinary fashion. The tent will be mounted on sliders level with the truck's bed inside the cage. When I'm ready to camp I can slide out the tent. Once pulled out on the passenger side, the tent will unfold as usual. My idea is to keep the tent lower to the ground while maximizing space above the tent when stashed away.

Storage areas will consist of:
- An upper rack, over the Eezi-Awn,
- Large enclosed box for tools and parts just behind the cab
- Rolling storage boxes under the "cage" accessible from the tailgait

Another idea I'm playing around with is to have a canvas cover made to hide everything inside.

More to come as I plan and start building.... All comments/critiques welcome :)

I started the most difficult part of the modifications this monday. Adding 2 feet onto the rear of the cab and building a small inner cage. I'll post photos as I start to tear into it. The extra 2 feet will contain a future closet and pantry. The exact design is not worked out yet. I'll figure that out once the cab and cage is mostly completed.

Should be fun cutting apart the cab....right? :yikes: I'm a little nervous, so wish me luck...


This is what it should look like when completed........

http://www.safaripacific.com/vehicles/mx2/cage_concept1.jpg

[schanusa]

H...e...r...e.... I go... Monday I started chopping up the bed without my body guys. They're a bit busy. Besides, how bad can I mess up.....:D First I pulled the bed of the truck with a forklift. Next came the sticker removal.

http://www.safaripacific.com/vehicles/mx2/build/bed/001.jpg


Now since I'm adding two feet onto the cab, I will be removing the front portions of the bed for filler material. Easier for keeping the body lines. Leaving 2 inches near the front allows me to keep the original curve around the backside of the bed.

http://www.safaripacific.com/vehicles/mx2/build/bed/002.jpg


These are the two sections cut from the bed fenders.

http://www.safaripacific.com/vehicles/mx2/build/bed/003.jpg


Next I drill out all the spot welds holding the boxes' backing and end caps.

http://www.safaripacific.com/vehicles/mx2/build/bed/004.jpg


Using a dead-blow and chisel I separate the two pieces.

http://www.safaripacific.com/vehicles/mx2/build/bed/005.jpg

[schanusa]

Backing removed.

http://www.safaripacific.com/vehicles/mx2/build/bed/006.jpg

I use a laser level to determine the exact line to cut over the wheel well and other curves in the bed's box. The lines at the bottom were measured at 48 inches.

http://www.safaripacific.com/vehicles/mx2/build/bed/007.jpg


Double checking myself and making sure the cut would be accurate near the top.

http://www.safaripacific.com/vehicles/mx2/build/bed/008.jpg


Now I simply trace the laser line, then repeat on the other side.

http://www.safaripacific.com/vehicles/mx2/build/bed/009.jpg


The bed is cut to size. In the background you can see the portion removed.

http://www.safaripacific.com/vehicles/mx2/build/bed/010.jpg

[schanusa]

I clean up the edges and start fitting the backing portion to the bed.

http://www.safaripacific.com/vehicles/mx2/build/bed/011.jpg

http://www.safaripacific.com/vehicles/mx2/build/bed/012.jpg

Not too shabby if I do say so myself. I'll start welding and bracing in the next few days.

[schanusa]

Right, back to work.... After measuring the portions removed to add onto the cab I realize, the wheel well will be 3 inches off. I'll have to scrounge some body parts from a junk yard to complete the cab.

I needed material for welding the backside to the bed, so I used the pieces intended for the cab. I cut two 1 inch strips.

http://www.safaripacific.com/vehicles/mx2/build/bed/013.jpg

The strips are placed and tack welded inside of the bedsides. This will keep the two exterior pieces closely aligned, resulting in less body filler. Got this tip from my friend.

http://www.safaripacific.com/vehicles/mx2/build/bed/014.jpg

Strip tacked in place. When I cut the bedsides I didn't cut them completely strait. Around the wheel well there is a small ridge that I wanted to keep. You may see the slight curve near the bottom of the bedside.

http://www.safaripacific.com/vehicles/mx2/build/bed/015.jpg

After the small strips are tacked in place I start aligning the backside piece.

http://www.safaripacific.com/vehicles/mx2/build/bed/016.jpg

[schanusa]

The seems are welded up completely.

http://www.safaripacific.com/vehicles/mx2/build/bed/017.jpg


Then ground to a semi-smooth finsh.

http://www.safaripacific.com/vehicles/mx2/build/bed/018.jpg


I refit the bed onto the chassis to start aligning new bolt holes. There will need to be a new brace build along the front as well.

http://www.safaripacific.com/vehicles/mx2/build/bed/019.jpg

http://www.safaripacific.com/vehicles/mx2/build/bed/020.jpg

http://www.safaripacific.com/vehicles/mx2/build/bed/021.jpg


The entire bed has been done by myself and its my first time doing any bodywork... Now I'm feeling confident enough to attempt the cab.... we'll see what happens...hehe :D

[compleckz]

awesome! looking forward to following this

[odie1969]

wow nice job. and if you need any help just send me a p,m I live right down the road, I'm not very skilled but I can learn pretty fast, and play go4. plus I only work 11days a month.

[DRangerd]

awesome! looking forward to following this

X2 !

Concept pic looks great, keep up the pics.........:beer:

[JFA_Spyderman]

Looking awsome!

[Bray D]

very nice, looking forward to following the progress.

[OldRedB2_84]

looks good, ill be following too! It almost looks like you could put a extended-cab cab on it and modify it to flow with the wheel well lines.

[dusto2]

wow that is goin to be bad ass when done, i have always thought about putting a b2 body on a extended cab frame and graffting bed sides on to it but yours looks like it is going to be sweet

[Branman]

Looks good.

[ZMan]

cool!

[schanusa]

Time to rip into the cab. First I strip down the cabin of all extra electronics and interior parts. I kept the dash in tacked since there will be no alterations planned to that area.

http://www.safaripacific.com/vehicles/mx2/build/cab/001.jpg


http://www.safaripacific.com/vehicles/mx2/build/cab/002.jpg

Photo taken before wiring was removed.

http://www.safaripacific.com/vehicles/mx2/build/cab/003.jpg

[schanusa]

With the cab being the most important part of the body modifications, I enlisted the assistance of my friend Marc. Although he's never done any extensive body work like so, he does have tons of experience in the auto body field.

Before the cutting started we worked out a game plan as to where the cuts should be made. We agreed on cutting in three external locations. The first being an inch behind the door jam on the b-pillar. Secondly along the edge of the roof line in the door jam. With keeping the roof curve intact we will make a final cut across the highest point of the roof's curve. The interior structures will be cut along the flattest portions to make extensions as easy as possible.

http://www.safaripacific.com/vehicles/mx2/build/cab/004.jpg

http://www.safaripacific.com/vehicles/mx2/build/cab/005.jpg

http://www.safaripacific.com/vehicles/mx2/build/cab/006.jpg

http://www.safaripacific.com/vehicles/mx2/build/cab/007.jpg

Suddenly the air pressure dropped. When we went to investigate we found the compressor had simply died. The motor had seized after 3 years of use. Thankfully the most important body pieces were cut, so a sawzall will be used until we can replace the compressor.

[ZMan]

you're gonna have alot of fun welding your roof back together!

[Shoeboy]

This is, by far, one of the most interesting builds I have seen on this site, I am defiantly going to be keeping an eye on this. Looking good so far.

[Shran]

This is, by far, one of the most interesting builds I have seen on this site, I am defiantly going to be keeping an eye on this. Looking good so far.

Agreed. I'm really looking forward to seeing the results. Good luck with the compressor situation.

[Destroyer000]

why not use a 4/1/2 inch angle grinder?

[Maverick]

I dig it. But a 2wd expedtion vehicle?

[AgPete139]

This is, by far, one of the most interesting builds I have seen on this site, I am defiantly going to be keeping an eye on this. Looking good so far.

Were you here on the old forum for Punisher's build?

How many inches are you extending the cab? You gonna do a half door or suicide door idea like on the 98+ years?

[philzilla]

http://www.safaripacific.com/vehicles/mx2/cage_concept1.jpg

NICE PHOTOSHOPING !!!:icon_thumby:

[schanusa]

I dig it. But a 2wd expedtion vehicle?

No more 2wd, gathering all the parts for a 4x4 swap. I posted a want ad here for the parts... http://www.therangerstation.com/forums/showthread.php?t=20970

I'm also considering a solid front instead of the ifs. I need to take a look at a 4x4 ifs before I make a decision.

[schanusa]

Were you here on the old forum for Punisher's build?

How many inches are you extending the cab? You gonna do a half door or suicide door idea like on the 98+ years?

I was browsing before the new forum came up, but I don't remember half of the stuff I came across...

The total extension will be 30 inches and will be solid. Making doors is a lot of work. I may make the window swing out and up to access stuff.

[schanusa]

The big shop compressor is still out, so progress has been a little slow. On top of that my friend Marc won't be able to give me a hand for the next few weeks, so I'm back on my own. Using a home compressor I slowly finish cutting the inner structures. Cutting for 10 minutes then waiting for the pressure to rebuild. Eventually I finished all my cuts. The next thing to do is drill out the spot welds at the bottom backing and corners.

http://www.safaripacific.com/vehicles/mx2/build/cab/008.jpg


Underneath I had to use a chisel to break apart the seams connected with seam sealer. At one point I had to use an air chisel along the back panel.

http://www.safaripacific.com/vehicles/mx2/build/cab/009.jpg


With all the welds and seams dismembered I pull the lower corners back. You can see I'm leaving an overlapping portion. I'm hoping this will make building the extensions much easier.

http://www.safaripacific.com/vehicles/mx2/build/cab/010.jpg

[schanusa]

Before I remove the back chunk I check the structures for strength. Surprising they don't flex much, so no need for braces. Next I need to create a new rear body mount. After that it's to creating a floor, cage and inner structure extensions. Then comes the body work...

http://www.safaripacific.com/vehicles/mx2/build/cab/011.jpg

http://www.safaripacific.com/vehicles/mx2/build/cab/012.jpg

http://www.safaripacific.com/vehicles/mx2/build/cab/013.jpg

http://www.safaripacific.com/vehicles/mx2/build/cab/014.jpg

[goldxlt]

are you going to have any issues with the wheels rubbing on the back of the cab?

[schanusa]

are you going to have any issues with the wheels rubbing on the back of the cab?

That will be cut to make way for a wheel well. I'm holding off making that cut until the back piece is welded into place by new body structure.

[schanusa]

Onto building the new floor. I started with 16 gage flat steel in a four foot square. Measured then cut to size. Since a flat floor wouldn't be to structural, and not to mention would stand out, I use a bead roller to create some creases.

http://www.safaripacific.com/vehicles/mx2/build/cab/015.jpg


Outer step down, liner grooves and a 90 degree bend to wrap it up. Closeup of the groves.

http://www.safaripacific.com/vehicles/mx2/build/cab/016.jpg


To reinforce the floor I fab up some C channels from the flat 16 gage steel.

http://www.safaripacific.com/vehicles/mx2/build/cab/017.jpg


Finished welding up all parts. The upper left junction will be where a new body mount will be.

http://www.safaripacific.com/vehicles/mx2/build/cab/018.jpg


New floor set in place. Still much more to do.... :)

http://www.safaripacific.com/vehicles/mx2/build/cab/019.jpg

[Ranger44]

Great! Keep it going!:clapping:

[ZMan]

nice work.

[schanusa]

Thanks all!



Not a whole lot has been accomplished for this next section. Most of the time was measuring over and over again. I wanted to make sure the cab's back would be perfectly square.


Lower cross support

http://www.safaripacific.com/vehicles/mx2/build/cab/020.jpg


My brother in-law, Jeremy, gave me a hand fabing up the upper cross supports. His brother Zach took the photos for the day.

http://www.safaripacific.com/vehicles/mx2/build/cab/021.jpg


Upper cross support ready to be welded in.

http://www.safaripacific.com/vehicles/mx2/build/cab/022.jpg


Me welding the inner and outer upper cross supports. The rope was used to align the back portion with the rest of the body lines.

http://www.safaripacific.com/vehicles/mx2/build/cab/023.jpg

[Dishtowel]

Wow. Beautiful idea, beautiful work, beautiful shop. Top marks man.

[schanusa]

I'm getting behind on my updates. Here's some stuff I did last week.

To stop water and dust getting into the channels on the new floor pan I used some seam sealer.

http://www.safaripacific.com/vehicles/mx2/build/cab/024.jpg

The raw steel parts started rusting in the shop. I'm thinking the swamp coolers are the culprit. To stop the surface rust I sprayed on some pain.

http://www.safaripacific.com/vehicles/mx2/build/cab/025.jpg

Using a hole punch to create the rounded corners of the fuel tank access panel.

http://www.safaripacific.com/vehicles/mx2/build/cab/026.jpg

The access panel isn't very big since the cross supports are close by.

http://www.safaripacific.com/vehicles/mx2/build/cab/027.jpg

[schanusa]

For body material I picked up two doors from the junk yard. It was half price day, so I scored two doors for $75 bucks! I measured the gap, added 2 inches for a buffer then cut chunks out of the doors

http://www.safaripacific.com/vehicles/mx2/build/cab/028.jpg


Dry fitting the new body material. Once lined up, I marked where the cuts needed to be exactly.

http://www.safaripacific.com/vehicles/mx2/build/cab/029.jpg


I trimmed of the extra material on one side and ground the edges of the other.

http://www.safaripacific.com/vehicles/mx2/build/cab/030.jpg


Perfect fit!

http://www.safaripacific.com/vehicles/mx2/build/cab/031.jpg

[Ranger44]

Once again, awesome!

BTW, that is a very nice, big, clean shop. Wish I had something like that.

[schanusa]

I used the excess trimmed off for backing on the edges of each seam. Same routine as the bed shortening.

http://www.safaripacific.com/vehicles/mx2/build/cab/032.jpg


New side panel clamped into place.

http://www.safaripacific.com/vehicles/mx2/build/cab/033.jpg


To avoid any warping I slowly weld small spots a few inches apart. After cooling a bit I run a few more spot welds. I repeat this quite a few times before the panel is fully welded. Then I repeat everything on the driver side.

http://www.safaripacific.com/vehicles/mx2/build/cab/034.jpg

[Shoeboy]

The trucks look likes its coming along well. What are you going to do with the roof, fill it in with sheet metal and just make it a solid roof, or are you going to do a glass top.

[schanusa]

Thanks. Slowly I getting it finished. It will be a month tomorrow when I started chopping. I'm starting to get impatient, but I have to take my time so I don't screw up! The roof will be solid. I thought about a sunroof, but I think it will be too much work for something I don't need. I'm even considering running solid sides on the extension instead of windows. The back will be filled with gear, so windows are useless and show off all the get to thiefs. Hmmm...decisions....decisions

[Ranger44]

I'd say just make it solid. Easy.

[dogboy]

I think you should just panel the sides. Thieves can't see in, you don't need windows, and it is alot easier! And, not to mention, I think you would have the first mini-panel wagon type Ranger!

I think it would look good both ways. Windows gives it more of a stock look.

[joeydeluxe]

This is a very cool build im excited to see it complete. you are doing a very good job and completing in quickly. keep up the good work

[maitee1]

Awesome work. Keep it up. I am looking forward to seeing this thing come to fruition.

[RyanD2]

Looks great, I think the solid sides would be a nice look. Keep up the good work.

[schanusa]

Thanks everyone! I'm leaning more to doing solid sides. A lot easier....

[schanusa]

More updates....

Missed this photo. Its before the side panels were fitted. I aligned everything onto the new body mounts and welded the floor to the remaining cab parts.

http://www.safaripacific.com/vehicles/mx2/build/cab/035.jpg


Angle shot of the passenger side. Thats as strait as I can make it

http://www.safaripacific.com/vehicles/mx2/build/cab/036.jpg


Killing time while waiting for the metal to cool. Maybe just a bit to much time :D

http://www.safaripacific.com/vehicles/mx2/build/cab/037.jpg


Driver side panel installed same as the passenger.

http://www.safaripacific.com/vehicles/mx2/build/cab/039.jpg

[schanusa]

Removing the fuel filler off the old bed side.

http://www.safaripacific.com/vehicles/mx2/build/cab/038.jpg


Tracing the shape onto construction paper.

http://www.safaripacific.com/vehicles/mx2/build/cab/040.jpg


On the front side I press the construction paper into the groves. I cut the piece a bit crooked so I used the ridge to find a level point to measure.

http://www.safaripacific.com/vehicles/mx2/build/cab/041.jpg


Using the pattern I align the ridge to the body line and trace the edges.

http://www.safaripacific.com/vehicles/mx2/build/cab/042.jpg


Then I cut.

http://www.safaripacific.com/vehicles/mx2/build/cab/043.jpg

[schanusa]

Working slightly different from the body panels, I wedge pieces into the edges of the filler backing.

http://www.safaripacific.com/vehicles/mx2/build/cab/044.jpg


I clamp into place and check the alignment.

http://www.safaripacific.com/vehicles/mx2/build/cab/045.jpg


Now I weld in the same fashion as the body panels. The filler isn't in the best location, but there would of been a lot more work to move the whole thing. My fuel tank won't move back anymore due to the axle. So I have to work with what I have.

http://www.safaripacific.com/vehicles/mx2/build/cab/046.jpg

[bigpotato555]

Are you gonna put seat back there? where the tire gonna go?

[Slingblade]

where the tire gonna go?

Look at the first post pics


Chris

[dude772]

Is there enough space to put an explorer rear door upper half portion for a window? If you dont like having an actual window you could tint it so dark that no one could ever look in.

I think that it would look a million times better if you had a window in the back rather than it being solid in the back.

[koda6966]

Almost reminds me of the South American four door rangers.. except with just two doors.

[ZMan]

Is there enough space to put an explorer rear door upper half portion for a window? If you dont like having an actual window you could tint it so dark that no one could ever look in.

I think that it would look a million times better if you had a window in the back rather than it being solid in the back.

thats a pretty good idea

[AgPete139]

Good job with the progress & the sheet metal bracing/line grooving/welding. You do good metal work. I think the Explorer idea mentioned above is cool. It's almost getting into that "explorer sport / SUV coupe" realm. Are you considering using the window actuators from the used doors and using those on the rear quarter windows? I'm wondering how you are going to do the lower body/cab rails... Also, I know it's kind of late, but did you consider removing the hump in the rear & evening the floor of the cab, or does the gas tank get in the way? Or will it make way for the 4x4 system you are gonna throw up there?

Good luck again with more of your build. Can't wait for more updates...:beer:


Pete


.

[goldxlt]

the explorer window would be a neat idea because then you could lower the window for better ventalation.

[86freebie]

awesome dude. and 10,000 kudos to anyone doing there own work. going to be great.
but "To drive around the world" get bigger tires. i know those wont float. :)

[schanusa]

Is there enough space to put an explorer rear door upper half portion for a window? If you dont like having an actual window you could tint it so dark that no one could ever look in.

I think that it would look a million times better if you had a window in the back rather than it being solid in the back.

Great idea!!! Anyone have measurements?

[schanusa]

Onto the roof...

Since I'll be creating a completely new roof section I'll need to meet the stock curve. To accomplish this I start with some scrap 3/4 inch plywood. I then measure the front section of the roof's curvature. From the measurements I create and ark on the plywood. Then I rough cut with a bandsaw and clean up with a belt sander.

http://www.safaripacific.com/vehicles/mx2/build/cab/047.jpg


Now I create a wooden frame to hold the arc molds in place and at the right hight.

http://www.safaripacific.com/vehicles/mx2/build/cab/048.jpg


Verifying the two pieces are the correct hight I place a strait metal bar across the gap.

http://www.safaripacific.com/vehicles/mx2/build/cab/049.jpg


Next I cut a piece of 20 gauge steel to fit into the gap. I cut 2 inches longer than I need to rough fit everything and slide it under the current roof sections

http://www.safaripacific.com/vehicles/mx2/build/cab/050.jpg


The roof is marked then cut to fit. As you can see from the additional line I messed up, luckily I caught it before I started to cut. Measure twice, cut once!!!

http://www.safaripacific.com/vehicles/mx2/build/cab/051.jpg

[schanusa]

More of the same overlapping backing to weld on.

http://www.safaripacific.com/vehicles/mx2/build/cab/052.jpg


Roof welded into place. Since there is a lot of room for warping, I'll be taking a day or two to weld this up. I start by running spot welds a few inches apart. Over time I will continue to spot weld between the other welds until its fully welded.

http://www.safaripacific.com/vehicles/mx2/build/cab/053.jpg


While between welding the roof, I start to get ready to work on the wheel well of the cab.

http://www.safaripacific.com/vehicles/mx2/build/cab/054.jpg

More in a day or two...

[Shoeboy]

Excellent progress, what have you decided about the rear "windows", or are you undecided yet? I'm amazed at how quickly this build is going, I thought I'd see an update every month or so, and have it go on over the length of a year, its been, what a month and a half and you're about, what, a little under half done?

[alaskan155]

an electric T-case, http://www.safaripacific.com/vehicles/mx2/build/drivetrain/tcase02.jpg :icon_surprised: might to swap that to a manual less stuff to go wrong


other than that this is turning out to be a great build

[schanusa]

an electric T-case, :icon_surprised: might to swap that to a manual less stuff to go wrong other than that this is turning out to be a great build

I'm going to try and fab up a manual shifter linkage where the electric solenoid goes. Shouldn't be to difficult.

[Not All There]

awesome build! just stumbled across this, keep it up!

[koda6966]

I bet you could make good money if you built these for people.

[Gabe8810]

that is some talent there man. nice work

[schanusa]

I bet you could make good money if you built these for people.

If the price is right..... :D

[schanusa]

To fill in the upper side panel, I start with constuction paper roughly cut and taped in place.

http://www.safaripacific.com/vehicles/mx2/build/cab/055.jpg


From the inside I trace where the pattern should be cut. After Cutting I tape it into place for a dry fitting.

http://www.safaripacific.com/vehicles/mx2/build/cab/056.jpg


Once the pattern is correct I trace onto sheet steel and cut out the filler panel.

http://www.safaripacific.com/vehicles/mx2/build/cab/057.jpg


At the bottom of the panel there is a small curve that I will have to recreate. I mark the top, bottom and middle of the curves position. You can also see the backing strips that I've been making to merge the bodywork together.

http://www.safaripacific.com/vehicles/mx2/build/cab/058.jpg

[schanusa]

Using a custom built bender I create the smaller curve.

http://www.safaripacific.com/vehicles/mx2/build/cab/059.jpg


Once bent into shape I clamp the panel in place and begin to weld.

http://www.safaripacific.com/vehicles/mx2/build/cab/060.jpg


Side shots of driver and passenger side panel in place.

http://www.safaripacific.com/vehicles/mx2/build/cab/061.jpg

http://www.safaripacific.com/vehicles/mx2/build/cab/062.jpg

[Ranger44]

Nice....I like the way this truck is turning out.

[holyford86]

very nice work, very clean, excellent job.

[fordguy64]

very nice... i like it...

[dusto2]

I'm going to try and fab up a manual shifter linkage where the electric solenoid goes. Shouldn't be to difficult.

good luck to you on that one i tried, but its hard to make it rotate and stop at 4hi, and just rotate to 4lo is just under 360degrees, other than that great job i really like it, coming along quickly

[schanusa]

ROAD TEST!!! Before I get to far I wanted to see how much the new body parts rattled or puckered. This was the first time I had ever driving with ear plugs too... The wheel wells were open and created a lot of noise.

http://www.safaripacific.com/vehicles/mx2/build/cab/063.jpg

Couldn't resist photo-shopping a finished product.

http://www.safaripacific.com/vehicles/mx2/build/cab/064.jpg

The bed appears to twist quite a bit, although the rear cab mounts are not connected. This was a problem I thought I would have. With the frame flexing about an inch I worry it will tweek the cab. I may build a pivoting body mount for this.

http://www.safaripacific.com/vehicles/mx2/build/cab/065.jpg

http://www.safaripacific.com/vehicles/mx2/build/cab/066.jpg


All in all, everything handled well. None of the panels puckered or popped while driving. Now its onto finishing the wheel wells!

[UrbanRedneckKid]

Wow, that truck is going to be soo nice when it's done.
Your doin an awesome job with your sheetmetal work.

Only one problem I have with your build,
It's cying for a snorkel. Just look at that "road test" picture and tell me that truck isn't screaming for a snorkel.

[Twitch57]

looks great

what exactly does safari pacific do?

[schanusa]

Wow, that truck is going to be soo nice when it's done.
Your doin an awesome job with your sheetmetal work.

Only one problem I have with your build,
It's cying for a snorkel. Just look at that "road test" picture and tell me that truck isn't screaming for a snorkel.


Thanks! Once I'm done with all the bodywork I'll start on equipping it. Yes, I will have a functional snorkel. I'll need one when I get into South America and jungle environments. Here's a concept photoshop from a few days ago.

http://www.safaripacific.com/vehicles/mx2/concept_2008-08-07.jpg



what exactly does safari pacific do?


Quote from our about page.

About Us

Safari Pacific is a promoter of travel and exploration. From travel stories & travel guides to photography, equipment testing, logistics, expedition consulting, vehicle design and expedition gear, we accommodate all whom seek adventure.

And then some..... :icon_thumby:

[Boggin]

that thing is coming along bad ass, very good job, I am impressed

[Dishtowel]

As has aready been said. I am in awe of your courage/ambition. Props to you man. You are building a wicked machine.

http://www.safaripacific.com/vehicles/mx2/concept_2008-08-07.jpg



Just an observation from this picture. You have very good approach angle, and rather poor departure angle in comparison. (plus, I think you need some swampers, lol. SSR types.)

[turbo cat]

:icon_thumby:

[ZMan]

the main reason you had so much frame flex on your test run is because you did not have the cab mounted, though if you did you may have ran into problems because it isn't done. Right now you don't have a whole lot of structure in the cab, and it may have twisted the cab if it were mounted. I'd say get it done, and then worry about "road testing" it.

[schanusa]

Just an observation from this picture. You have very good approach angle, and rather poor departure angle in comparison. (plus, I think you need some swampers, lol. SSR types.)

Unfortunately there's not much I can do there. I'll most likely be putting a new type of camper on the back. So I'll still need the tailgate to drop leaving me little room to tuck everything up. Once I get the camper I'll play around and see if I can't figure something out.

Swampers won't last 50,000+ miles. I'll be running BFG All Terrains (or muds), but I'll be running a bigger size. The ones I used in the picture are 315x75r16 (34.5 inch tall)

[schanusa]

This week mostly consisted of cleaning the shop. So nothing major took place on the Ranger. I did start working up some designs for the interior and work out more of the trip route.

One major item was purchased this week however... I've been on the prowl for a donor vehicle for 4x4 parts and I found one, 1996 Ford Explorer XLT.

http://www.safaripacific.com/vehicles/mx3/purchased/01.jpg

http://www.safaripacific.com/vehicles/mx3/purchased/04.jpg

I pictured a beat up old suv with a functioning drivetrain when I talked to the guy on the phone. Needless to say, the Explorer was in way too good of a condition to rip apart. Even the interior, blue it may be, was in good shape. I think we have the making of MX3 down the road :D

Some details: 1996 Ford Explorer 4x4, Miles: 133000, Motor: 4.0L V6, Trans: 3 Speed Automatic, A/C Works as if new!

For now I'll be using this as a daily driver and a parts runner.

[koda6966]

What happened to MX1?

And if you ever do decide to tear apart the Explorer, you could put the windows in the rear of MX2! Ha.

[alaskan155]

the original setup
http://www.safaripacific.com/vehicles_mx1.php

[02_FX4]

What A Awesome Truck!!!

[koda6966]

the original setup
http://www.safaripacific.com/vehicles_mx1.php

Oh, okay.

[schanusa]

What happened to MX1?

And if you ever do decide to tear apart the Explorer, you could put the windows in the rear of MX2! Ha.

As alaskan155 pointed out, MX1 was the original mods. Since MX2 will be a major rebuild I bumped up the version number. I'll hold off on ripping into the Explorer until the Ranger is complete. Too hard building two projects, but my mind is wandering. :D

On a build note: Fixing the big compressor today. After that progress should speed up as well.

[Danger06Ranger]

Glad to here your still moving foward, looking real good. Keep up the good work.

[schanusa]

So, I've been a little side tracked the past few weeks. First I deep cleaned the shop to make the build easier. And made some extra space to work around.

http://www.safaripacific.com/vehicles/mx2/build/cleanshop.jpg



Then played with the new toy....just a little....

http://www.safaripacific.com/vehicles/mx3/build/firstrun/07.jpg

http://www.safaripacific.com/vehicles/mx3/build/firstrun/01.jpg

http://www.safaripacific.com/vehicles/mx3/build/firstrun/03.jpg

[schanusa]

:nono: Now its time to get back to work. Sometimes my boss can get a bit rough :p


Today I started to tackle the wheel wells. Since I want to keep the little curve, where the body line rolls into the back of the cab, I cut those pieces from the cab.

http://www.safaripacific.com/vehicles/mx2/build/cab/067.jpg


The small portion to the bottom is the little curve I mentioned above. Roughly cutting the two pieces to fit I then clamp them into place.

http://www.safaripacific.com/vehicles/mx2/build/cab/068.jpg


No backing material was used to weld this up. As you can see, things got a bit ugly.

http://www.safaripacific.com/vehicles/mx2/build/cab/069.jpg


I repeat on the driver side pieces.

http://www.safaripacific.com/vehicles/mx2/build/cab/070.jpg


After welding the driver side, I realize the angle was way off. I replace the part cut off from the wheel well edge.

http://www.safaripacific.com/vehicles/mx2/build/cab/071.jpg

[schanusa]

Grinding off the welds I smooth the edges.

http://www.safaripacific.com/vehicles/mx2/build/cab/072.jpg


Next I cut a extra piece of 18 gauge steel to reinforce the curve. Unfortunately I didn't snap a photo until I was finished. You can see the slight bulge where the reinforcing strip was welded on though.

http://www.safaripacific.com/vehicles/mx2/build/cab/073.jpg

[schanusa]

Wanting a better picture of the body line curves, I went outside into the sunlight. With better lighting they don't look half bad.

http://www.safaripacific.com/vehicles/mx2/build/cab/074.jpg


Next I dry fit the passenger side onto the body panel. I have to push the panel inward to align with the door.

http://www.safaripacific.com/vehicles/mx2/build/cab/075.jpg


I make my trimming marks

http://www.safaripacific.com/vehicles/mx2/build/cab/076.jpg
http://www.safaripacific.com/vehicles/mx2/build/cab/077.jpg


Then I trim and clean up the sharp edges.

http://www.safaripacific.com/vehicles/mx2/build/cab/078.jpg

[maitee1]

You should change your name to the Mad Scientist. You are a great fabricator. This build is awesome. I can't wait to see it done.

[schanusa]

Going in the same fashion I use a strip of 16 gauge steel behind the seams. Tack welded wheel well curve into place.

http://www.safaripacific.com/vehicles/mx2/build/cab/079.jpg


After tack welding, I tie a piece of string to hold the panel in place.

http://www.safaripacific.com/vehicles/mx2/build/cab/080.jpg


I finish up welding the passenger side and repeat on the driver side.

http://www.safaripacific.com/vehicles/mx2/build/cab/081.jpg

http://www.safaripacific.com/vehicles/mx2/build/cab/082.jpg

[84projectFORD]

absolutly amazing man! you have come a loooong way

[Dishtowel]

I would almost be afraid to drive this, much less wheel it because of the risk of damaging this one of a kind vehicle that has XXX hours sunk into it. Props to you for knowing what you want and going for it!

[motohead771]

I enjoy looking at your build. Its so unique. Great job so far, can't wait to see the finished product.

[schanusa]

I would almost be afraid to drive this, much less wheel it because of the risk of damaging this one of a kind vehicle that has XXX hours sunk into it. Props to you for knowing what you want and going for it!

I'm not to worried since crap happens no matter what. But I will say I won't be running this to the store.... :D

[schanusa]

Onto the roof... I start by creating a pattern for the curve. The old groove where the roof and side meets will be rounded as well.

http://www.safaripacific.com/vehicles/mx2/build/cab/083.jpg


With the pattern in hand and some sheet steel I head over to another shop. There I get the metal for the roof rolled as well as the wheel well pieces.

http://www.safaripacific.com/vehicles/mx2/build/cab/084.jpg

http://www.safaripacific.com/vehicles/mx2/build/cab/085.jpg


Back at the shop I start to dry fit the rolled piece. Roof is very rusty!

http://www.safaripacific.com/vehicles/mx2/build/cab/086.jpg


With the swamp coolers rusting out all the exposed metal I decide to prep everything for primer.

http://www.safaripacific.com/vehicles/mx2/build/cab/087.jpg

[schanusa]

Along with prepping for paint I remove all stickers and clean off the glue.

http://www.safaripacific.com/vehicles/mx2/build/cab/088.jpg


Primer shows all the small tweeks in the metal.

http://www.safaripacific.com/vehicles/mx2/build/cab/089.jpg


Painted the roof and leaving a small gap to weld onto.

http://www.safaripacific.com/vehicles/mx2/build/cab/090.jpg


I sanded and painted all the inside pieces as well.

http://www.safaripacific.com/vehicles/mx2/build/cab/091.jpg

http://www.safaripacific.com/vehicles/mx2/build/cab/092.jpg

[odie1969]

It is amazing what you are doing with your truck. I would like to stop by and check it out in person sometime.

[koda6966]

Now that's what I call progress!

[stegomon]

holy cow dude.....when you are done....get this over to ford...bet they could use this dezine or somethin...that is just awsome

[koda6966]

holy cow dude.....when you are done....get this over to ford...bet they could use this dezine or somethin...that is just awsome

"Ranger Mega Cab"

:icon_thumby:

['95 ranger]

dude what do you do for a living?

[84projectFORD]

where are you off of in gilbert? Ill be down in phoenix next weekend to do some more work on my project ranger and want to stop by. this thing just keeps gettin better every weekend!

[schanusa]

dude what do you do for a living?

:D http://www.safaripacific.com/store.php

[schanusa]

where are you off of in gilbert? Ill be down in phoenix next weekend to do some more work on my project ranger and want to stop by. this thing just keeps gettin better every weekend!

I think I need to setup one night for everyone to come over. I've been getting tons of requests for people to stop by. Once the body work is complete I'll put something together and post it here.

[schanusa]

After finishing up primering I resume completing the curve of the cab. First I clean up the edges for backing strips.

http://www.safaripacific.com/vehicles/mx2/build/cab/093.jpg


Using some fancy unistrut and visegrips I clamp down the roof and side panel. The unistrut kept all the sheet steel flat while I added the packing strip.

http://www.safaripacific.com/vehicles/mx2/build/cab/094.jpg


Placing the pre-curved steel over the gab I mark cut points.

http://www.safaripacific.com/vehicles/mx2/build/cab/095.jpg


After shearing off one side I double check the second cut's location.

http://www.safaripacific.com/vehicles/mx2/build/cab/096.jpg


Now I need to create the tapered edge to meet with the old molding groove.

http://www.safaripacific.com/vehicles/mx2/build/cab/097.jpg

[schanusa]

I then create the taper and tack weld everything into place.

http://www.safaripacific.com/vehicles/mx2/build/cab/098.jpg

http://www.safaripacific.com/vehicles/mx2/build/cab/099.jpg


Now for the tiny, quarter inch, rounded edge above the door. My friend Kirk created the curve while I was working on the bigger one. After Kirk finished I welded tiny 1/8th inch backing strips along the roof and door edges. Then I started from the front welding the curve in place.
http://www.safaripacific.com/vehicles/mx2/build/cab/100.jpg


As I welded I had to use a body hammer to beat the curve into place.

http://www.safaripacific.com/vehicles/mx2/build/cab/101.jpg


Curves completed, just need to create the filler piece between the two.

http://www.safaripacific.com/vehicles/mx2/build/cab/102.jpg

[schanusa]

While between welding the roof curves I started creating the final rocker panel piece. For this I used a English Wheel to create the curve. (My first time on using one as well)

http://www.safaripacific.com/vehicles/mx2/build/cab/cab103.jpg

http://www.safaripacific.com/vehicles/mx2/build/cab/cab104.jpg


Dry fitting.

http://www.safaripacific.com/vehicles/mx2/build/cab/cab105.jpg


Then its onto welding everything up.

http://www.safaripacific.com/vehicles/mx2/build/cab/cab106.jpg

[hihoslvr]

man, while I totally respect all the time and work you put into this creation, I woulda just bought a toyota crew cab. of course I'm also unemployed right now, so what do I know :)

[84projectFORD]

man, while I totally respect all the time and work you put into this creation, I woulda just bought a toyota crew cab. of course I'm also unemployed right now, so what do I know :)

yeah but when you have the time and a bit of cash, why the hell not?? lol, definitly cant say you would EVER find one of these on the road

Hey maori, why not SAS teh front on that baby? then it would look just trick! let alone go or do whatever you want with less problems than the IFS IMO. just a thought though

[schanusa]

man, while I totally respect all the time and work you put into this creation, I woulda just bought a toyota crew cab. of course I'm also unemployed right now, so what do I know :)

Thanks. The money spent on a new truck would of eaten into my budget for the trip. Especially since I've only spent about $400 in steel and parts for what I've done to the truck so far... Yep only $400, I'm a tight wad.. :D


yeah but when you have the time and a bit of cash, why the hell not?? lol, definitly cant say you would EVER find one of these on the road

Hey maori, why not SAS teh front on that baby? then it would look just trick! let alone go or do whatever you want with less problems than the IFS IMO. just a thought though

Yep, I'll be doing a SAS after the body is finished and I get all the parts for the drivetrain. I'll be getting a new beefy rear axle as well. There's still a lot more to do before its complete.

[metalmacguyver]

Wow man, amazing fab skills.

[schanusa]

After welding all of the odds and ends, I cleaned up the welds.

http://www.safaripacific.com/vehicles/mx2/build/cab/107.jpg


Then I rough sanded everything and painted on a white primer.

http://www.safaripacific.com/vehicles/mx2/build/cab/108.jpg


Onto the interior panels. I created the filler neck bulge on the new wheel well. (somehow I lost the photos of creating this)

http://www.safaripacific.com/vehicles/mx2/build/cab/109.jpg


Underneath where the filler neck is accessible for repairs.

http://www.safaripacific.com/vehicles/mx2/build/cab/110.jpg


Next I use construction paper to create a template of the top potion. This will be where the cab is sealed from the wheel well.

http://www.safaripacific.com/vehicles/mx2/build/cab/111.jpg

[schanusa]

Upper piece created and tacked into place

http://www.safaripacific.com/vehicles/mx2/build/cab/112.jpg


I then start on the lower piece on the passenger side. Since I didn't have to mess will the filler neck on this side I left the original support.

http://www.safaripacific.com/vehicles/mx2/build/cab/113.jpg


Another upper piece in place.

http://www.safaripacific.com/vehicles/mx2/build/cab/114.jpg


After I finished welding everything up I sealed the edges with seam sealer and painted everything.

http://www.safaripacific.com/vehicles/mx2/build/cab/115.jpg

http://www.safaripacific.com/vehicles/mx2/build/cab/116.jpg

[schanusa]

EXTERIOR METAL WORK COMPLETED!!!!!! Now its to all the easy stuff...

http://www.safaripacific.com/vehicles/mx2/build/cab/117.jpg

http://www.safaripacific.com/vehicles/mx2/build/cab/118.jpg

http://www.safaripacific.com/vehicles/mx2/build/cab/119.jpg

[koda6966]

God I love this truck.

[dude772]

EXTERIOR METAL WORK COMPLETED!!!!!! Now its to all the easy stuff...

http://www.safaripacific.com/vehicles/mx2/build/cab/cab119.jpg

did you paint on a window!? haha


When you going to start on mine :P

[240cubes]

i dont even have words to explain the shock and awe that has just come over me. simply gorgeous truck

[Ranger_Boi]

wow nice build man very impressive

[schanusa]

Thanks all! There's still a lot more to do.

- SAS
- Motor Swap
- Drive lines
- Camper
- Bumpers
- To much to list!


Just got back from a road trip. Didn't do anything crazy, but here are some pics.

Navajo Nation Arizona
http://www.safaripacific.com/vehicles/mx2/build/cab/120.jpg

Mirror Lake Utah
http://www.safaripacific.com/vehicles/mx2/build/cab/121.jpg

Somewhere in the middle of Nevada.
http://www.safaripacific.com/vehicles/mx2/build/cab/122.jpg

[Ranger44]

I would like to do something like this to my Ranger. I love the short wheel base of my Reg Cab/ short bed, but hate not having storage in the cab.

My thought would be to take an extended cab and adjust/move the body mounts on the frame....drop the cab on.

Then just shorten the bed the same way you've done.

Maybe one day...lol

[odie1969]

So when is the meet and greet, I would really like to come down and check it out. also a bunch of the prerunner guys get together every thursday, at mill and baseline about 7pm for pizza at barros, I'm sure that they would be really impressed with it, i am. If you want more info about the pizza night, check out dezertranger.com in the arizona section, the thread is pizza and prerunners. also a good place to network with folks that have fab skills and mechanical skills. alot of the guys and gals that show work in race shops.

[swiperfoxx]

Thanks all! There's still a lot more to do.

- SAS
- Motor Swap
- Drive lines
- Camper
- Bumpers
- To much to list!


Just got back from a road trip. Didn't do anything crazy, but here are some pics.

Navajo Nation Arizona
http://www.safaripacific.com/vehicles/mx2/build/cab/cab120.jpg

Mirror Lake Utah
http://www.safaripacific.com/vehicles/mx2/build/cab/cab121.jpg

Somewhere in the middle of Nevada.
http://www.safaripacific.com/vehicles/mx2/build/cab/cab122.jpg


I wish I knew you were coming through Flagstaff. I would have loved to see that truck. Nice Build! :icon_surprised:

[PaleBlue90]

wow! i bet that painted on window throws off theives lol

[robbieo11]

Travis did u tie the interior side supports together from font to rear got a pic of the finished interior??
thanks
rob

[84projectFORD]

I wish I knew you were coming through Flagstaff. I would have loved to see that truck. Nice Build! :icon_surprised:

x2!!!

[ak96]

this is insane! i love it! awsome work dude, your crazy haha

[BDAB]

I'll never get to see it here in Michigan ....... gonna have to take a trip to tombstone and stop in phoenix.

[Will]

Will you be offering the weapon mount on your retail page?

http://www.afgha.com/?q=system/files/images/Afghan+Police+with+new+truck.preview.jpg

[gatlin04]

are you going to have to put in seats from like a taurus or something? (so that it slides up when someone gets into the back)
just a thought...

[odie1969]

are you going to have to put in seats from like a taurus or something? (so that it slides up when someone gets into the back)
just a thought...

I don't think he is planning to use it for a seating area, if so I prob. would have put the window in and not just paint a window. it more for storage. you know for the trip around the world that he is planning and building this truck for.

[Wicked_Sludge]

sounds like gatlin is talking about replacing the front seats with those from a car. that way the seats will slide forward and lean forward with the flick of a lever for easy access to the storage area in the extended cab.

[KCBFord1]

now all you need is to mount a digital picture frame somewhere so guys out on the trail can see your build pics. lot of work! i bet you take pride driving that thing around. truly awsome!

[gatlin04]

sounds like gatlin is talking about replacing the front seats with those from a car. that way the seats will slide forward and lean forward with the flick of a lever for easy access to the storage area in the extended cab.


Exactly

[PaleBlue90]

any kno if there any updates?

[pud]

how bout BII seat bases? that way the pass side will tip right up and out of the way.
Good job on the build....I would have moved the rear axle back and not put the wheel well in the cab corner. Better depart angles. But all in all it looks awsome, better than anything i can and will ever do!

[AKBroncoII]

I saw a ranger very similar to this a couple years ago. It was green though. I have a picture somewhere around here. I will see if I can get it scanned. Great work, only thing I don't like is the fuel filler. Looks wierd.

[schanusa]

:secret:



http://www.safaripacific.com/vehicles/mx2/concept_2008-12-02.jpg

[Wicked_Sludge]

thats not a bad idea, but heres what i'd do:

extend the over-cab part of it and make it a pop-up with canvas sides. pop it up at night and you have yourself a sleeping area over the cab without wasting any storage space in the "main part" of the bed. pop it down in the morning to lower your CG and reduce wind resistance.

[schanusa]

The box has a few tricks up its sleeves.

http://www.safaripacific.com/vehicles/mx2/concept_2008-08-07_tent.jpg

[Wicked_Sludge]

that works too i suppose :icon_thumby:

EDIT: gonna have to ditch the light bar for that plan though..

[schanusa]

The light bar will fold down over the window. I'll have to do that to get into the cargo containers for shipping as well.

[Wicked_Sludge]

sounds like a solid plan.

have you considered upgrading your amenities? a house battery for engine-off power, fresh water supply with a hand or foot pump (and maybe a little sink), propane stove, heater?

i realize that all adds weight and complexity...but its hard to turn down those kind of "luxuries" if youve got the room.

[schanusa]

Yep. I'm working with a few people to build the inside with new materials that are very light yet strong. Cabinets, small sink, cook area, small desk/table, power systems w/ solar, outside shower, toilet and a lot more. Everything will have multiple functions. This project is turning more into an offroad RV. Even though the goal is to keep it light, I have to remember I will be living & working out of the truck for 2 years.

EDIT: Also, with storage area being an issue I've decided to build a new bed with additional storage in the bed sides.

[Wicked_Sludge]

i actually really like the idea of an off-road RV. my dad and i were THIS CLOSE to taking the "RV" part of a 1976 chinook motorhome (on a 2wd toyota chassis) and mounting it on an 86 4wd ranger. the chinook body was all fiberglass with a pop top (where i got the suggestion), and had a fullsize bed/couch, sink, propane range and heater, stereo, cabinets, fresh and grey water tanks, and a power inverter. it was a livable little RV. we got as far as taking all the measurments and discovering the wheelwells would line up and everything should clear...but the donor ranger started to fall apart before we started so we abandoned the idea.

speaking of fiberglass though...that might not be a bad idea for the that box as it'll save you a lot of weight.

[dogboy]

Bed side storage (like old F250 and such) was going to be my suggestion, then I read that it's what you doing, haha.

Looks really good!

Ultimate camping rig I think!

I think you would have more space in the camper area if you were to remove the bed for that camper/ shell apperatus (like the second to lat picture), but I think it deffentally looks way better with the bed below it (last pic). But, I'm sure looks don't play a HUGE roll in this build!

[97BlackBetty]

Fiberglass would be an excellent choice, using aluminum straps for reinforcement in large panels. I do a lot of fiberglass work as well as using resin on other materials. It is light weight, yet it gets heavy fast, especially when it needs to support 200-300 pounds. It is also important to account for all of your weather extremes, mainly temperatures. But I a sure that you know most of this information already.

I love the build and I am looking forward to seeing the new additions.

[Wicked_Sludge]

i think those two pics are related.

the over-cap part of the bed is a "clam shell". the first pic shows it stored, the tent sandwhiched between the two halves. the second pic shows it opened up, with the tent deployed.

[Randy960]

Amazing work, man. If your business doesn't workout, this project alone could get you a job making limos. I love the painted on windows. You should have someone airbrush on them, so it looks like your looking through a tinted window, and even make it look like theres expensive things in there so people try to break in. Paint in the lock popper in the unlocked position, so theives will spend hours trying to figure out where the back handle is.

[gatlin04]

How is the MX3? Have you started a thread?


I think alot of us envy the shop that you have....... I know that i do! I think if i had the shop that you do, i would do odd-ball shit........hahaha

Great work man!

[bmxryder]

woooooowwww. not only did you make a MAJOR mod but you did a perfect job. im sure that was the hardest part. when i saw this on the nominations for totm i was wondering what country sold a ranger like that.

goojob man :icon_thumby: cant wait to see what you do for the interior

[marcehboy]

That stuff makes me sacred a ton of hours in that im sure GREAT JOB :icon_cheers:

[koda6966]

How is the MX3? Have you started a thread?
I think alot of us envy the shop that you have....... I know that i do! I think if i had the shop that you do, i would do odd-ball shit........hahaha
Great work man!

http://www.therangerstation.com/forums/showthread.php?t=31121

[gatlin04]

http://www.therangerstation.com/forums/showthread.php?t=31121

Im an idiot..... thanks, bud!

[schanusa]

Updates! Holidays are over and the shop has been moved, its back to work.


With the metal work now complete it's time to start prepping for body filler. I brought the truck over to a friends auto body business to let a pro have at it.

http://www.safaripacific.com/vehicles/mx2/build/cab/123.jpg


Although, the body filler would be done by someone else, that doesn't mean I can't be useful. Equipped with a dual-action sander I clean all the welds and low spots.

http://www.safaripacific.com/vehicles/mx2/build/cab/124.jpg


Spencer sands off paint to fix the tin can effect from me welding the roof.

http://www.safaripacific.com/vehicles/mx2/build/cab/125.jpg


This is where experience pays off. Spencer uses a fancy slide hammer to rework the roof to the correct curve. During construction the metal warped inward. By a push of a button, the tool welds itself to the sheet metal. Then you slam the metal weight upwards.

http://www.safaripacific.com/vehicles/mx2/build/cab/126.jpg

[schanusa]

Using a special body hammer, Spencer whacks in key locations to stretch the metal into the correct shape.

http://www.safaripacific.com/vehicles/mx2/build/cab/127.jpg


The side panels also had the "tin can" effect. This happens when metal stretches and/or contracts during the welding process.

http://www.safaripacific.com/vehicles/mx2/build/cab/128.jpg


Once Spencer finished banding and beating the body into shape, he sprayed all the seams with etch primer.

http://www.safaripacific.com/vehicles/mx2/build/cab/129.jpg


Here's is the etch primer used and the Kevlar fiber body filler he'll be adding next. That's right, Kevlar!

http://www.safaripacific.com/vehicles/mx2/build/cab/130.jpg

[schanusa]

Like any body filler, you have to mix it with the right amount of hardener. Which seems to be, about yay.

http://www.safaripacific.com/vehicles/mx2/build/cab/131.jpg


Next the filler is spread along the weld seems. The purpose of this is to reinforce the welded areas.

http://www.safaripacific.com/vehicles/mx2/build/cab/132.jpg


Now, it's time to wait a few days for the filler to harden.

http://www.safaripacific.com/vehicles/mx2/build/cab/133.jpg
http://www.safaripacific.com/vehicles/mx2/build/cab/134.jpg

[97BlackBetty]

I am still in absolute amazement at how well this truck looks and functions. Absolutely incredible.

[ZMan]

a few days? lol.

[Sunk]

I am still in absolute amazement at how well this truck looks and functions. Absolutely incredible.

+1
It's looking awesome! :icon_thumby:

[koda6966]

Looks great.

[PaleBlue90]

that looks great, those slide hammers are great tools huh? good to see it comeing along

[koda6966]

Are you going to stick with white?

[schanusa]

For now I'm sticking with white, though I'm thinking of military tan.

[09ajmaros]

It is probably a good idea to stick with white because of the hot temps. Mine is white by the way:icon_thumby:

[schanusa]

Haven't got much done on the truck the past few months. I will be finishing up the body work soon and get the truck ready for the Overland Expo in April. I've also been holding off doing any major work until I get the camper, which I received word I should be able to pick it up within a few weeks. So things are progressing. More news to come.

[schanusa]

The truck is almost show ready! I'm finishing up the truck to be displayed at the Overland Expo this coming April 24th-26th in Prescott, Arizona. On top of that I will be making a presentation the first day of the show. My presentation will be from 11:00 AM to 11:50 AM in the Overland Theatre

Hope to see you there!

Come and check out the show! There will be many people from the Overland community, including Tom Collins from Camel Trophy. More info about the show at OVEXPO.com

[Beanmachine7000]

I'm all into your truck and the type of thing it's used for... I'm building up my Explorer kinda like this... You have any tips for me? I'm all over Expedition Portal, but they don't really have anything at all about Rangers or Explorers...

[schanusa]

I'm all into your truck and the type of thing it's used for... I'm building up my Explorer kinda like this... You have any tips for me? I'm all over Expedition Portal, but they don't really have anything at all about Rangers or Explorers...

Cool! Really the best tip there is when building expedition style vehicles is, keep it simple. Over complicating things will drive you nuts while on the road. Especially if you've been driving all day and late into camp. Half of the items you "think" you'll need are simply fluff. Take frequent trips and you'll start to notice what is and isn't necessary.

[schanusa]

Time to get some updated photos up!


With a delay in moving shops, both mine and the body guy's, we're back preping the body. Here Spencer sands down the kevlar filler.

http://www.safaripacific.com/vehicles/mx2/build/cab/135.jpg


After sanding down the first coat a second coat is applied.

http://www.safaripacific.com/vehicles/mx2/build/cab/136.jpg

http://www.safaripacific.com/vehicles/mx2/build/cab/137.jpg

http://www.safaripacific.com/vehicles/mx2/build/cab/138.jpg


After drying the second coat gets sanded

http://www.safaripacific.com/vehicles/mx2/build/cab/139.jpg

[schanusa]

x

[dusto2]

those things look sweet man great job

[schanusa]

Tons of updates coming up. Cab finishing, bed reinforcement, camper installation & demonstration, rear bumper build.





During the time bodywork was being done there were a few days I worked on the wheel well portion of the cab. To keep the tires from ever
rubbing against the cab I notched the edges with a plasma cutter.

http://www.safaripacific.com/vehicles/mx2/build/cab/147.jpg

http://www.safaripacific.com/vehicles/mx2/build/cab/148.jpg


After the rough cut I cleaned up the edges, then proceeded to create a paper template for a new edge.

http://www.safaripacific.com/vehicles/mx2/build/cab/149.jpg


Then I transfer the template onto a piece of 16 gauge sheet steel.

http://www.safaripacific.com/vehicles/mx2/build/cab/150.jpg


With a sheet metal break I bend the strait edges accordingly. Then I use a body hammer to beat each little tab into place then tack weld it.
As you can see by the number of small tabs this took a long time. The back of the cab has ridges making it very difficult.

http://www.safaripacific.com/vehicles/mx2/build/cab/151.jpg


Once fully in place I welded up every inch and repeated on the driver side.

http://www.safaripacific.com/vehicles/mx2/build/cab/152.jpg


When finished I sand blasted and smoothed the edges with seem sealer.

http://www.safaripacific.com/vehicles/mx2/build/cab/153.jpg


Once the truck was back together I took it out for a test run. Part of the test was to see if the tires would rub or even come close.

http://www.safaripacific.com/vehicles/mx2/build/cab/154.jpg


With the suspension fully compressed on the passenger side there is still three inches of clearance.

http://www.safaripacific.com/vehicles/mx2/build/cab/155.jpg

[odie1969]

wow your truck is so cool. It blows me away everytime I see it. Plus the camper is bad ass.

[AlwysBusted96]

I'm liking the camper.

[schanusa]

Thanks guys! The camper looks much better than the concept photos I did.



Onto finishing the bed's supports. The last changes to the bed
only consisted of the exterior sheet metal and not any
structural support. I borrow a rolling frame to work on the bed
easily.

http://www.safaripacific.com/vehicles/mx2/build/bed/022.jpg


With heavy gauge sheet steel I form a new front support.

http://www.safaripacific.com/vehicles/mx2/build/bed/023.jpg


The front support will tie into the bed floor and the front portion.

http://www.safaripacific.com/vehicles/mx2/build/bed/024.jpg


With the sheet metal being rusty from swamp coolers I toss the new
support into the sand blasting cabinet.

http://www.safaripacific.com/vehicles/mx2/build/bed/025.jpg


After sand blasting I paint the inside to protect from future rust
since I won't be able to paint it after its welded on.

http://www.safaripacific.com/vehicles/mx2/build/bed/026.jpg

[schanusa]

Now I weld the bottom of the support into place.

http://www.safaripacific.com/vehicles/mx2/build/bed/027.jpg


Then with vice grips I clamp the sheet metal to the support and slowly weld all of the spots welds previously drilled out.

http://www.safaripacific.com/vehicles/mx2/build/bed/028.jpg


To create the rounded corners of the wheel wells I cut strips of steel and bend them into the rough shape.

http://www.safaripacific.com/vehicles/mx2/build/bed/029.jpg


Then I go crazy with spot wells to fill the area with material. Kind of ugly, but neccesary.

http://www.safaripacific.com/vehicles/mx2/build/bed/030.jpg


After the welding madness I grind everything to the correct shape.

http://www.safaripacific.com/vehicles/mx2/build/bed/031.jpg

[schanusa]

Now its to extending the wheel wells to reach the front of the bed. I create two paper templates that fit the curves.

http://www.safaripacific.com/vehicles/mx2/build/bed/032.jpg


I then cut sheet metal to the templates pattern.

http://www.safaripacific.com/vehicles/mx2/build/bed/033.jpg


Using a rubber mallet and a hole dug in sand I beat the sheet metal close to the correct curve.

http://www.safaripacific.com/vehicles/mx2/build/bed/034.jpg


Then I slowly weld into place.

http://www.safaripacific.com/vehicles/mx2/build/bed/035.jpg


And repeat with the second half.

http://www.safaripacific.com/vehicles/mx2/build/bed/036.jpg

[schanusa]

Same process gets repeated for the other side.

http://www.safaripacific.com/vehicles/mx2/build/bed/037.jpg


Standing the bed on end I clean the area with a sand blaster.

http://www.safaripacific.com/vehicles/mx2/build/bed/038.jpg


Using a plasma cutter, I remove the excess material.

http://www.safaripacific.com/vehicles/mx2/build/bed/039.jpg


Creating yet another paper pattern for the small remaining piece of the wheel well.

http://www.safaripacific.com/vehicles/mx2/build/bed/040.jpg


New piece created then welded into place.

http://www.safaripacific.com/vehicles/mx2/build/bed/041.jpg

[schanusa]

Another piece is made from the template to cover the other side.

http://www.safaripacific.com/vehicles/mx2/build/bed/042.jpg


When every piece is fully welded I begin grinding down the welds. Then sand blast them.

http://www.safaripacific.com/vehicles/mx2/build/bed/043.jpg


Using seem sealer I smooth out the welds.

http://www.safaripacific.com/vehicles/mx2/build/bed/044.jpg


I then mask off the fender and spray bed liner in both wheel wells.

http://www.safaripacific.com/vehicles/mx2/build/bed/045.jpg

[schanusa]

Now I finish off the front support on the inside of the bed. I start by removing paint for clean welds.

http://www.safaripacific.com/vehicles/mx2/build/bed/046.jpg


Then cut and bend sheet steel to fit.

http://www.safaripacific.com/vehicles/mx2/build/bed/047.jpg


And weld into place.

http://www.safaripacific.com/vehicles/mx2/build/bed/048.jpg


Next I drill a large hole through the entire support beam, where a piece of steel tubing will be placed. The tubing will keep the sheet metal from crushing once the body mount is bolted down. With most of the camper's weight being up front, I use thicker material.

http://www.safaripacific.com/vehicles/mx2/build/bed/049.jpg

[schanusa]

Once aligned properly, it gets welded in place.

http://www.safaripacific.com/vehicles/mx2/build/bed/050.jpg


Flipping the entire bed over, I weld the under sides of the sleeve.

http://www.safaripacific.com/vehicles/mx2/build/bed/051.jpg


Then ground flush on both sides.

http://www.safaripacific.com/vehicles/mx2/build/bed/052.jpg


Body bolted back into place.

http://www.safaripacific.com/vehicles/mx2/build/bed/053.jpg

[schanusa]

Partly patching up a mis-cut and reinforcing I add sheet steel to the inside wheel wells.

http://www.safaripacific.com/vehicles/mx2/build/bed/054.jpg

http://www.safaripacific.com/vehicles/mx2/build/bed/055.jpg

[nopainnofear]

I just drooled on the keyboard a little. Def gonna be following this thread closely

[schanusa]

I just drooled on the keyboard a little. Def gonna be following this thread closely

:icon_thumby:

[schanusa]

Finally... Getting into other parts besides sheet metal...

Wrapping up the sheet metal work on the bed, I cap off the bed stake holes.

http://www.safaripacific.com/vehicles/mx2/build/bed/056.jpg
http://www.safaripacific.com/vehicles/mx2/build/bed/057.jpg
http://www.safaripacific.com/vehicles/mx2/build/bed/058.jpg


Next I start preparing for the camper. Since I have completely altered structure points on the bed, I decided to add some additional reinforcement.
I cut 1 1/2 inch square tubing to fit underneath the bed rails.

http://www.safaripacific.com/vehicles/mx2/build/bed/059.jpg

[schanusa]

I notched them to fit around some of the inner fender wells.

http://www.safaripacific.com/vehicles/mx2/build/bed/060.jpg

http://www.safaripacific.com/vehicles/mx2/build/bed/061.jpg


Then I cap off the notch.

http://www.safaripacific.com/vehicles/mx2/build/bed/062.jpg

Going a bit overkill here, I drill six holes on each side for bolts.

http://www.safaripacific.com/vehicles/mx2/build/bed/063.jpg

[schanusa]

Chush sleves are welded into the support to avoid bending when bolds are tightened.

http://www.safaripacific.com/vehicles/mx2/build/bed/064.jpg


After welding is finished, they get ground smooth.

http://www.safaripacific.com/vehicles/mx2/build/bed/065.jpg


I align them back in the bed rails and drill holes accordingly.

http://www.safaripacific.com/vehicles/mx2/build/bed/066.jpg


Then I give the supports a cleaning.

http://www.safaripacific.com/vehicles/mx2/build/bed/067.jpg

[schanusa]

Along the front of the bed another 1 1/2 inch square tube will connect either side.
The bed rail supports and the front support are given a bevel to accommodate bolting together.
Lock nuts are welded inside since no wrench will be able to reach them.

http://www.safaripacific.com/vehicles/mx2/build/bed/068.jpg

http://www.safaripacific.com/vehicles/mx2/build/bed/069.jpg

http://www.safaripacific.com/vehicles/mx2/build/bed/070.jpg


After bolted into place I measure and cut additional supports that will tie the front support into the truck frame.

http://www.safaripacific.com/vehicles/mx2/build/bed/071.jpg

[schanusa]

Here I start the outer welds on the supports.

http://www.safaripacific.com/vehicles/mx2/build/bed/072.jpg


Then I pull it out and fully weld everything up.

http://www.safaripacific.com/vehicles/mx2/build/bed/073.jpg


I give everything a quick paint job and reinstall.

http://www.safaripacific.com/vehicles/mx2/build/bed/074.jpg

http://www.safaripacific.com/vehicles/mx2/build/bed/075.jpg

[odie1969]

looks great. But are you afraid of the bolts messing with the camper seating?

[Rinny650]

Im not entirely sure but I believe the purpose of the bolts is to hold the camper.

Also to the OP, Not trying to offend or anything but is english your first language? The way you type sounds like someone who has english as a second language. I notice odd things and again no offense meant at all. If any was taken I appologize

[koda6966]

Also to the OP, Not trying to offend or anything but is english your first language? The way you type sounds like someone who has english as a second language. I notice odd things and again no offense meant at all. If any was taken I appologize
Sounds normal to me. :dntknw:

He's giving steps on what he's doing, not holding a conversation.

[TheNicky]

WOW!

What a wonderful build...

Great stuff man!

[DRIFTGOD187]

this truck looks badass !!!

[Rinny650]

It just he would say "first i create...." instead of created. Like I said I notice odd things

[Ranger Sport Honduras]

amazing truck!!!!!!! just awesome!! by the way if u plan to travel to latin america...let me know if u come to Honduras :D it would be sick to see that truck in person!

[MountainMike]

Wow man I just read all 14 pages on the edge of my seat. It looks awesome. Is your skid plate up front bought or made?

[TS6034]

I know this is a redundantcy, but man you have some mad fabrication skills!!! Very impressive work!

[ambivolent]

awesome build simply awesome im gonna be doing something similar with my ranger and you gave me a bunch of ideas keep up the great work

[schanusa]

Thanks guys!

No offense, and yes English my first language. But I am learning Spanish at the moment. I keep the steps as simple as possible. Nothing fancy. And to add starting every sentence with I or then can get a bit redundant.

[schanusa]

Time to install the FlipPac camper! First things first. pulled my camper out of the shop using a fork lift.

http://www.safaripacific.com/vehicles/mx2/build/flippac/001.jpg


Then a three strips of rubber seal were placed along the bed railing and one along the front.

http://www.safaripacific.com/vehicles/mx2/build/flippac/002.jpg


The ends were left long for extra play room.

http://www.safaripacific.com/vehicles/mx2/build/flippac/003.jpg


Next placed the camper on the bed and then lifting from inside with his back, slid the a few inches from its final location.

http://www.safaripacific.com/vehicles/mx2/build/flippac/004.jpg

[schanusa]

The fiberglass and window railing needed some trimming to clear the tailgate, so proceeded to cut off the necessary amount.

http://www.safaripacific.com/vehicles/mx2/build/flippac/005.jpg


Once trimmed, the FlipPac was slid into pace then secured temporarily with camps. Holes were also drilled accordingly along the bed rails.

http://www.safaripacific.com/vehicles/mx2/build/flippac/006.jpg


After bolting the camper down, the upper lid was opened to install the front support pins.

http://www.safaripacific.com/vehicles/mx2/build/flippac/007.jpg


Here, measures and marks where the pins need to be paces.

http://www.safaripacific.com/vehicles/mx2/build/flippac/008.jpg

[schanusa]

Next the hood is opened to access the fender's inner edge, where two holes are drilled.

http://www.safaripacific.com/vehicles/mx2/build/flippac/009.jpg


The holes are made to fit rivet nuts that are pressed into place by a special tool.

http://www.safaripacific.com/vehicles/mx2/build/flippac/010.jpg


Rivet nuts installed on both sides.

http://www.safaripacific.com/vehicles/mx2/build/flippac/011.jpg


Then the support pins are screwed into place with low button head bolts.

http://www.safaripacific.com/vehicles/mx2/build/flippac/012.jpg

[schanusa]

After installing the hood pins we close the hood and test fit the supports.

http://www.safaripacific.com/vehicles/mx2/build/flippac/013.jpg


Voilà, camper installed.

http://www.safaripacific.com/vehicles/mx2/build/flippac/014.jpg


Next I check out the inside of the camper, which there is tons of room. I'm standing fully upright when taking this photo.

http://www.safaripacific.com/vehicles/mx2/build/flippac/015.jpg


Lots of room in the sleeper too. Plenty of room above my head.

http://www.safaripacific.com/vehicles/mx2/build/flippac/016.jpg

[schanusa]

With the FlipPac installation finished, we took some photos with a Jeep Comanche and the MX2.

http://www.safaripacific.com/vehicles/mx2/build/flippac/017.jpg
http://www.safaripacific.com/vehicles/mx2/build/flippac/018.jpg


After we were all done working on the camper, we started brain storming about my gear storage. He brought out a few of his composite drawers to use for a mockup.
His idea is to stagger the drawers using different depths to create steps up to the bed. Still in the idea stages for gear storage.

http://www.safaripacific.com/vehicles/mx2/build/flippac/019.jpg
http://www.safaripacific.com/vehicles/mx2/build/flippac/020.jpg

[scott5640]

i want that camper thing!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!

[84projectFORD]

They make them things for full size trucks? say a crew cab long bed chevy?? :D:D

[schanusa]

They make them things for full size trucks? say a crew cab long bed chevy?? :D:D

Yep! http://www.flippac.com

[schanusa]

I didn't want to start on the rear bumper until the camper was fully installed, since I wanted to make everything the correct proportions. With the camper done I get started on the rear bumper.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/001.jpg


First I scrounge two scrap 1/4 inch plate pieces that have already been welded together. I drill holes to fit the stock bolting points.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/002.jpg


Next, I cut a piece of 3 x 2 square tubing to length and set in place.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/003.jpg


For alignment I use some clamps holding temporary braces.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/004.jpg

[schanusa]

After tacking into place I weld on additional 1/4 plating.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/005.jpg


Once the main bumper portion is fully welded to the mounts I remove and begin boxing in all the corners with plating.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/006.jpg


To add support for the outer edges of the bumper I add 1 1/4 inch tubing to tie into the mounts.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/007.jpg

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/008.jpg

[schanusa]

I bolt the bumper back onto the truck for the next phase.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/009.jpg


For the swing out section I opt for a two piece sleeve. The first piece is 1 1/4 inch round tubing notched at the end and welded onto the bumper.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/010.jpg


Next I mockup where all the gear will be and take measurements.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/011.jpg


The second piece is 1 1/2 inch round tubing slid over the 1 1/4 inch piece, cut to match. The two pieces form the hinge for the swing out, which has a very snug fit. Another 1 1/4 inch tube is cut and welded into place for the swing out's lower arm.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/012.jpg

[schanusa]

At the end of the swing arm I create a support and clamping point. I use 1 1/2 inch tube cut in half for the support. This gives a small lip for the arm to test on, keeping the arm from swinging open.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/013.jpg


Next I bend the spare tire loop and cut to fit. I use a magnetic square to keep everything in pace.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/014.jpg


With a paper template I mark and cut a spare tire mounting plate.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/015.jpg


Then I drill out the holes and weld a piece of tubing on the back.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/016.jpg

[schanusa]

After double checking my measurements I weld the spare mount into pace.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/017.jpg


Just a test fit I bolt the tire on the swing arm.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/018.jpg


The arm can swing 180 degrees without hitting the camper.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/019.jpg


Onto the remaining gear loop. I bend, cut then weld into place

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/020.jpg

[schanusa]

I completely spaced out at this point and forgot to take more photos. After the second loop was welded on I added a small hoop to hold two fuel cans. Then I created two tabs to hold my license place. Corbin of Zebra Sports also came over and have me a hand with making mounts for the hi lift jack and a few other tid bits.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/021.jpg


To keep things legal I had to install a license plate light. I search all over and find a small shop that makes custom LED lights.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/022.jpg
http://www.safaripacific.com/vehicles/mx2/build/rearbumper/023.jpg

[schanusa]

For latching the swing gate closed I used a cam latch. Same thing everyone uses for this. I found mine at Graingers for $20.


http://www.safaripacific.com/vehicles/mx2/build/rearbumper/027.jpg

I opted to weld the main latching portion onto the swing gate. I also paced it on an angle so the force would pull into the support evenly.
This also puts the handle higher and keeps anything from flipping it open on the trail.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/028.jpg

[schanusa]

I decided to create a shelf that folds down from the rear bumper. Since I'll be cooking outside, this extra space will come in handy. First I pickup some hinges and stainless steel cable.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/029.jpg


Then I measure the area needed for the shelf and cut a piece of sheet steel.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/030.jpg


I notch the ends and bend all the edges 90 degrees.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/031.jpg


Next I mockup where the hinges should go for weight distribution then drill holes.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/032.jpg

[schanusa]

The corners get welded and cleaned up.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/033.jpg


Small reinforcing strips are welded across the bottom side inline with the hinges.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/034.jpg


After cooling I bolt the hinges in pace, square the shelf up on the bumper then weld the other portion of the hinge in place.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/035.jpg


To hold the shelf in a level position I use the stainless steel cable. A small bolt is welded on the upper tubing on the swing gate. Another bolt is added at the shelf's far corners.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/036.jpg

[schanusa]

For securing the shelf when stored away I pickup some small cam latches.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/038.jpg


I need a pace for the latches to grab on to, so I weld on a small piece of steel above the shelf.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/037.jpg


Another little piece is welded vertical giving the latch an edge to grab on to.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/039.jpg


Two of these are created then the latch body is screwed into place.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/040.jpg

[schanusa]

Once completed, I take the shelf apart to be sand blasted.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/041.jpg


After cleaning a quick paint job is applied.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/042.jpg


The steel cable connections are backed with two washers and two nuts. This allows the cable to move a little when opening the closing the shelf.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/043.jpg


Strips of foam are added where the shelf will hit. This is to stop any rattling.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/044.jpg

[schanusa]

Once the paint is dry everything gets reassembled.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/045.jpg


http://www.safaripacific.com/vehicles/mx2/build/rearbumper/046.jpg


http://www.safaripacific.com/vehicles/mx2/build/rearbumper/047.jpg


Now I have a nice wrap around cook area and work space.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/048.jpg

[ryan]

the little things in this build are so well thought out - thanks for posting all of this!

[Sasquatch_Ryda]

Very well done and thought out. Lots of neat little ideas to be had here!

[schanusa]

Thanks guys!


More updates.


To further support the swing gate I build an upper hinge. Starting with a scrap piece of the same diameter inner tubing, I insert it into the top of the hinge.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/049.jpg


Next I mark the right side tail gait latch holes and length onto a piece of strap steel.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/050.jpg


I then drill the holes, cut to length, clean up the edges and install.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/051.jpg


An angle is cut onto the remaining strap steel and tack welded between the hinge and bolt plate.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/052.jpg

[schanusa]

Now I trim off the excess strap steel and full weld up.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/053.jpg


After the upper hinge is reinstalled I add an angled brace.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/054.jpg


Both sides are fully welded.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/055.jpg


To finish off the top I weld on a domed cap.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/056.jpg

[schanusa]

A few minutes with the grinder cleans the rough edges, then I sand blast clean.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/057.jpg


Then I give it a quick paint then install.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/058.jpg

[schanusa]

Adding the additional shelf space led me to create a special mount for my stove. First I mockup the position of the stove at the swing gate's rear.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/059.jpg


I use more of the smaller diameter tubing that slides into the end of the lower support. The tube is bent to the back of the stove.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/060.jpg


Next I cut some square tubing that will slide into the stove.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/061.jpg


The square tubing and a cap get welded on.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/062.jpg

[Boggin]

this is a good build and you do great work

[schanusa]

After creating the support arm I start on a mount. A larger diameter square tube is used inside the stove to keep the stove from rocking side to side.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/063.jpg


A 4 inch by 4 inch plate is welded onto the tubing.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/064.jpg


Everything is slid into place.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/065.jpg


Do keep the whole stove arm from flopping around the end of the swing gate is notched a quarter inch.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/066.jpg

[schanusa]

The reverse notch is cut on a larger diameter tube and welded on the stove support arm.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/067.jpg


Refitting everything I drill holes and place the mount and cut a hole in the rear of the stove.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/068.jpg

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/069.jpg


As a test I pace a pot full of water on the stove.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/070.jpg

[odie1969]

this a great truck. and great build we should go camping so I don't have bring all my shit.

[cargs]

amazing work!

i have a few ideas:
- Bedliner (linex or similar) the box once fabrication is complete. It would look great inside the camper and seal up any small holes in the box.

- Install an onboard welder in the engine compartment for trail repairs.

- Bolt on one of those white nylon cutting boards to the fold down shelf, that way you can flip down the shelf and your ready to cook! Plus it would be one less thing to find space for inside the truck.


just a few ideas.:)

[odie1969]

amazing work!
- Bolt on one of those white nylon cutting boards to the fold down shelf, that way you can flip down the shelf and your ready to cook! Plus it would be one less thing to find space for inside the truck.


just a few ideas.:)

but then you have to wash it before and after use. and I think he might be kinda limited on clean water in some of the places he plans on going.

[cargs]

true....

[schanusa]

amazing work!

i have a few ideas:
- Bedliner (linex or similar) the box once fabrication is complete. It would look great inside the camper and seal up any small holes in the box.

- Install an onboard welder in the engine compartment for trail repairs.

- Bolt on one of those white nylon cutting boards to the fold down shelf, that way you can flip down the shelf and your ready to cook! Plus it would be one less thing to find space for inside the truck.


just a few ideas.:)

Good ideas. I'm planning on a linex type of liner once finished. Which I'm getting closer to getting that done. I'm going to have the whole bed sand blasted fairly soon.

A welder would be a good idea. Especially since a lot of my mods are custom.

odie1969 is right. I'll have my "kitchen" loaded into a storm or pelican case so everything stays clean. I may be changing out the folding shelve though.



this a great truck. and great build we should go camping so I don't have bring all my shit.

Thanks. I'll be putting together a trail run and maybe a camping trip that everyone is welcome to join in on once the truck is "finished".

[schanusa]

I'm skipping ahead here. The stove arm isn't completed as of yet.


On to the body protection. I'm not going to go crazy here, just something simple. With the same material used for the bumper I cut two pieces to length.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/080.jpg


Then I cut an angle on one end for tire clearance.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/081.jpg


The angled ends get closed off by welding a fitted plate.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/082.jpg


Next the welds get ground smooth.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/083.jpg

[schanusa]

Using the hydraulic lift I position one side at the correct slope.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/084.jpg


Then I tack weld into place and repeat on the other side.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/085.jpg


Next I create a plate to cover the corner. I use a die grinder to make inside cuts allowing me to bend easily.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/086.jpg


After clamping in place I start welding.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/087.jpg

[schanusa]

After the seams are welded up I create top and bottom parts, which are also welded on.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/088.jpg


Once both corners are finished they get ground down for smooth edges.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/089.jpg


Next a coat of paint gets slapped on.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/090.jpg

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/091.jpg

[schanusa]

Now the bumper's major components are done. Mounts for a fuel can, shovel, an ax and the stove arm are still needed.


You can see now I have very good departure clearance.

http://www.safaripacific.com/vehicles/mx2/build/rearbumper/092.jpg

[TheNicky]

I love this thread!

good job man keep it up

[rngr4x4beast]

dam i jst read through the whole thread freakin amazing build sick fab skills man really good work

[triumphrider-1]

Anything new happening?

[shadow6]

crazy build. never seen anything like it. great work man. i love the funtionality in it all.

[schanusa]

Thanks everyone!

I've been on vacation for the past month, mostly because its way to hot to work in the shop through August with no AC. Like an oven at 120+ degrees...

I'm back from vacation now and its back to getting more posts up...


Although the lower portion of the bumper was built a few years ago, I've decided to keep it and built on additions. Here's an old photo during early construction.

http://www.safaripacific.com/vehicles/mx2/build/frontbumper/001.jpg


First things first. Adding a brush guard that will follow the existing contour. Starting with measuring the old main tubing. I cut another similar sized tubing. The length is a few feel longer to accommodate the bends.

http://www.safaripacific.com/vehicles/mx2/build/frontbumper/002.jpg


With a manual tubing bender I duplicate the curves. I use two pieces of strap bolted together to replicate the angles.

http://www.safaripacific.com/vehicles/mx2/build/frontbumper/003.jpg


Then place double check my bends. After the angles are correct I measure how high the brush guard will be then calculate where the bends need to start.

http://www.safaripacific.com/vehicles/mx2/build/frontbumper/004.jpg

[schanusa]

With the help of my dad, we square up the tubing so it will bend correctly. Once aligned I make the bends.

http://www.safaripacific.com/vehicles/mx2/build/frontbumper/005.jpg


Next I dry fit the brush guard where I want it to be. Then measure where the excess material will be trimmed off.

http://www.safaripacific.com/vehicles/mx2/build/frontbumper/006.jpg


Using a sturdy metal table I square up the guard and make cut marks.

http://www.safaripacific.com/vehicles/mx2/build/frontbumper/007.jpg


Then I grind off paint on the old bumper where the brush guard will be welded. I use a welding blanked to protect the truck's body.

http://www.safaripacific.com/vehicles/mx2/build/frontbumper/008.jpg