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Prodject ZeroToWow

zero2wow said:
lol:D A friend of mine just sent that to me a few months ago. Here is another picture that I am glad I have...well sort of ;) My very first trail damage and go figure :shrug: so much for a spotter..... and they didn't say a word :banghead: The very 1st boo boo:eek: If you look close to the left side of the front bumper you can see it is in the process of being bent. Another reason why I needed to do a few modifications on z2w.



:angry: z :angry:
Click to expand...

The trail was a little to your right. :D
 
Now to bring both sides/ends of the tub together.....

I knew that bringing the tub together would bring some new challenges. Had the tub been new, it would come together fairly easily. But at over 20yrs old; the tub had been used to carry and haul who knows what kind of heavy "stuff" and with that came a considerable amount of "warp". This part was some of the most time consuming. The little amounts of trimming, bending, hammering and just general placement of the rear section of the tub ready for welding was a bit of a challenge.

Take your time .. and be patient. It will come together...



 
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Putting the weld down... Not to warp the bed more..... the welding is done in spots before laying longer beads











 
Kept building on the welds along with grounding them down.....





With the rear portion of the tub positioned right where I wanted it over the cross member and body mount, we cleaned up the inner tub walls and welded in flat bar.







 
Next was welding and grinding the outside of the tub's sides and top. Preparing it for the corner protection and led tail lights.



 
I have thought about where to place the fuel filler for the fuel tank for some time. My concern with putting it back in the stock location was how protected it would be from my style of driving in the rocks. I had already banged and bent the filler cap protector on a couple of occasions as you have seen in earlier pictures.



So I decide to put it here. It was easy to place and cut using the filler cap protector to outline where the cuts would be. The fuel nozzle at the filling station fit well as did the spare fuel 5 gallon containers filler tubes.





I was surprised how well the filler cap protector bent back into shape... so I used it again.

 
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Neat

Great ideal! that is sweet!:popcorn:
 
Thanks guys. ... only down side so far is if you spill fuel....

never a good idea....

z :ZZZ:
..
 
Onto the corner protection....
I have always been surprised at what companies get for corner guards. So for just about $45 I picked up some steel blanks and paid another $20 to have the I think it was 3" radius bend put on.



then the 1st cuts



trimmed to fit and holes drilled



first side on....





then the other...



from the back...

 
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Very nice, Jeff. Something like that is on my to-do list, which unfortunately has started to get longer...
 
Randyzzz said:
Very nice, Jeff. Something like that is on my to-do list, which unfortunately has started to get longer...
Click to expand...

that "to-do-list" never seems to end does it.. lol
I can only imagine how long yours is.....

z
 
After getting the corner guards roughed in and bolted up. Next thing on the list is to place and cut the led tail light holes.

As many of you know there is a ton of light configurations one could go with. I chose to keep it simple with single round tail lights. This would minimize number of holes which could compromise strength. (most often when building stuff my priorities seem to go in this order:
1st practical
2nd expense and
3rd beauty.





Before using the P torch be sure to check n remove any wiring or hose that might be on the other side of the corner panel. Also no open fuel lines with potential fumes near by.... OUCH duuuuhh





then to the bench for some finishing work





along with some trimming to even up some edges.



there had been some overhang in a few places on both corners I didn't like when the corners were bolted up....

 
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? Need some input........?
How have any of you solved or thought thru what it looks like to have a full cage and still be able to remove the 1/2 hard top?(preferably not having to remove the front or rear portions of the cage)
also I would love to hear conversation about cage tied to frame or rock slider then tied to frame thoughts.....

Any pictures are welcomed as always.

thanks,
z :christmas:
 
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