Randyzzz Scrambler Restification Thread!

[Randyzzz]

Well, aside from no regular paycheck, being off work has given me some time to work on the Scrambler. Here's the latest progress report, in photo-essay form for Eric's benefit!

First, I replumbed all the brake lines, even to the back. I had to move the rear flex-line when I did the exhaust and I wasn't satisfied with my "fix".

Here you can see where the line comes up by the master-

And the lines in the rear. Also, I changed rear shocks. I had the extra shorter set of remote reservoir IAS shocks from the front- they had about 3/4" more travel than the current rears, and they looked cooler too. I tried to sell them on EBay for $150.00, but no takers. So, I installed them on the rear.

The reservoir fit perfectly alongside the frame. Plenty of clearance for the tire too. I have the old (new) pair of Edelbrock IAS rears, $60.00/pair plus shipping if you're interested...

Then, I reinstalled my transmission cooler after tweaking the location and adding some cool heat insulating padding.

On to paint...yeah, more of that awful stuff. I truly admire good painters... Here's the fenders and grille-

 

[Randyzzz]

Next, install the vent screens, and bolt up the fenders...cool, I really like the color.

I like how the vents turned out, and the color...wow! Compared to the old stuff it POPS!

Then, the grille shell got assembled and bolted up. Assembly consisted of installing the A/C condenser and the power steering cooler. They're visible if you look closely. The radiator will go in after I build a shroud.

Had to throw in one of the battery boxes to see how the fit was with the cooler. Looks good! The vents in the fenders should help get some of the hot air out...

So, I still need to build the shroud, and then re-do the trans cooler lines. I'm going to be doing wiring before I know it!

 

[bigwalton]

Have you tried some rubbing compound and wax on the tub to see what it could look like next to the new fenders? I was shocked what I could get out of my grandpas old ranchero. Bet you can get it pretty close on that paint of yours.

Can't wait to see you button this up!!!

 

[Randyzzz]

I tried the rubbing compound/wax on the cowl. It comes out just OK, but it's not the same color. This new "mix" is a really cool color, it's close to stock, but it doesn't match exactly. That's OK to me, I really like it. I took the stock color and compared it to the new "Mango Tango", way more orange than stock. I compared the new color to the Mango Tango- same brilliance, but imagine more brown than orange. The guys at the Jeep dealership think I'm some kind of nut...dragging a grille out and comparing color to new ones...

 

[Bad Karma]

The guys at the Jeep dealership think I'm some kind of nut...

not real Jeep guys then. we are all nuts!!!

 

[jeffs396]

GREAT progress Randy!!!

Love the color!

Those fender vents look great too...many possibilities there...body color, black, or even the grayish hammerite you've used elsewhere.

She's getting close now!

 

[Randyzzz]

Well, been plugging away, but not much photo-worthy. First, I got the front shock reservoirs permanently mounted. Then, I ended up moving the trans cooler again, wasn't convinced there would be enough cool airflow back on the firewall. So, a different cooler is on order, and it moves to the front of the radiator. The heat sink cooler moves under the front crossmember to becomes the power steering cooler. I have a bunch of hose and AN fittings on the way, the trans and power steering will all be plumbed with AN fittings. I also got the dash pretty much finished, changed the latch on the glovebox to a lockable one out of a Waggy. Built the filler piece for under the column, and installed all the AC controls. Also got a sheet of UHMW plastic and built spacers for the radiator and a slick 5/8" body lift so the shock hoses and p/s hoses fit with no interference. Of course, now I'm out of $$, time to see what I can sell on EBay...

I'll post up pics of all this stuff once the hoses and cooler show up and are installed.

 

[48Bob]

Randy - Love the color. We bought a 2010 Dodge Ram PU in the Mango Tango color last fall, told my wife that it would make a great Scrambler color. Guess you beat me to it, going to have to come up with some other color now. Looking forward to the next installment of your usual fine work.

 

[Randyzzz]

Bob- Mango Tango has more orange to it, so it's all yours! Go for it! I really liked the Mango Tango, but it was one of the colors my wife nixed.

OK...progress report! On Wednesday, the big brown truck showed up, and again on Thursday! Looks like I have some work to do!

First on the agenda was relocating the trans heat sink cooler and using it for the power steering cooler. I mounted it under the front cross member, and ran AN style fittings and hoses for the complete return and cooling system. The one hose that looks like it's hanging in space will attach to the lower radiator flange.

Tight under the grille, glad I made the 5/8" body lift...

Next I ran the cooler lines from the transmission. I bent up steel brackets, and used some trick hose mounts from Summit. The portion of the hose behind the shock hoop looked like it might be in the line of fire from the tire, and also needed some heat shielding from the manifold. All the hardware I used is stainless.

From there into the in-tank stock cooler, and out again, through a grommet in the grille, and into the auxiliary cooler. You can also see the UHMW spacers I made for the radiator.

And the auxiliary cooler. Tight in there with my ham fists...

Next I installed then passenger fenderwell. Took a little trimming by the cooler hose shield, but I think it came out good. Probably overkill on the shield, but that's my middle name!

Tight, but it all clears!

And, a final shot of the hoses at the front. They are protected by the shock hoop.

Next task- radiator shroud. Not looking forward to that. Although I have gotten pretty good at pulling the radiator- must have had it in and out at least 20 times.

Tonight- off to McMenamins. They have a unique theater/pub there, True Grit is showing for $3.00, and you sit in couches and they serve beer! The Terminator Stout on Nitro is my favorite, Carol likes the Rubinator, which is a mix of Terminator Stout and Ruby. Yum! Just the thing after a productive week!

In case you're curious... http://www.mcmenamins.com/OldStFrancis

 

[Major Jack]

I like the extra detail you do. Can't you picture the tire catching a limb and jamming into your line.

 

[bigwalton]

I badly need to do AN stuff everywhere.... so jealous of you doing it right

 

[Randyzzz]

Time for a fan shroud.

I picked up a piece of 24"X24" 16ga aluminum. Marked out my layout and started with the corner cuts. Then I realized that my bending brake was too small. Being on a budget, I grabbed some scrap angle, a piano hinge, and some clamps and an hour later had a working brake. Not really heavy duty but good enough for the aluminum.

Then I got to work...bending, cutting, pulling the radiator AGAIN, and lastly cutting the round hole for the fan. This was the part I worried about the most... I used an air body saw and it came out perfect. I actually had to do it twice, made the hole another 3/8" bigger...

I ended up having to "contour" the shroud around the radiator hoses, and angle the corner by the steering box.

Installed! Fits great, and I'm only into it about $15.00! The fan is inset just the right amount, too! Looks like the next project is hoses!

 

[bigwalton]

Awesome work!!

 

[Sfisher]

Man that is sharp looking!

 

[Bugman]

I might have missed this earlier but what fan did you use and how many blades is it? What type of clearance do you have from the outside of the fan blade to the inside diameter of the shroud? This setup seems like it's stout and just what I need to solve my cooling problem.

 

[jak inc]

Great work as usual, Randy! What a clean install... looks like it could have come straight from the factory.

 

[Randyzzz]

Thanks, guys!

Wish I could TIG aluminum, I could have made the contour around the hose look better, but it will mostly be hidden once the hose is installed.

I priced fan shrouds, none were the right size and the prices were from 90-200$ Ouch! I like my price better...

Bugman- that's the stock fan from the 2004 Suburban. It's 18" and there's at least 3/4" from the clutch to the radiator, and about 1/2" all the way around to the shroud. I think it's 9 or 10 blade. Should move plenty of air, I hope. Not worried about the clearances, I think I have plenty and the motor mounts are the MORE mounts that use the poly sleeves. The fan sits about 3/4" into the shroud, depth wise. My research shows that to be about the optimum. Cooling is about my only valid concern on the whole build.

 

[tower210]

I love the way the vents came out, better than the example pic you posted. Pretty cool!

 

[zr10054]

Looking mighty good Randy, I finally ordered the A1 Electric power window kit and the power door lock kit that we both looked at earlier. I should have these in 3or4 days. I'll post pics on my thread when it's done.

 

[Randyzzz]

Sounds good, zr. I'm looking forward to seeing those.

This weeks progress...more plumbing. Got the heater hoses and valve ran, ordered a ton of A/C fittings and parts to make the A/C operational, and mocked up/designed/ordered parts for an air intake, similar to the TJ CAI. Can't say I'm a fan of the CAI airbox systems as a whole, but it was the best solution I could come up with. I'll post pics when I get the box bent up and the tubes installed.

(My other idea on the airbox was to use an enclosed ducted system and have the intake grille using the cowl vent- run the 4" hose around the engine, through the firewall, and into a box under the dash. It really cluttered up the engine compartment, and I was concerned about water intrusion and noise. I may still go that way...)

Also got the PCM bracket built, fuse panel finalized/mounted. Nothing picture-worthy...

Ordered radiator hose adapters too....

Now I'm just waiting on the big brown truck...

Oh...And I'm working on the wiring. It would have been simple to just start running wires, 50 or so and I'd be done. But...what about 2 years down the road when I need to diagnose something? I figured I'd better do a real wiring diagram...I think that's harder than doing the actual wires!!!