Sheetmetal fabrication

The floorboard modifications were an intensive undertaking to say the least! I underestimated the amount of time it would take for this phase of the project, but it was time well spent. I lowered the entire floorboard of the Jeep to the bottom edge of the frame, which gives me an additional 6" of depth in the cargo area, room for a larger gas tank, and additional storage. Once the floorboard was complete, the body mounts were fabricated, and welded in place.
I finally got around to modifying the front clip sheetmetal. I decided to just add on to the existing hood, as I was in a hurry to complete the project, which is already behind at least a month. As it turns out, I won't have it done in time to go to Moab Utah. So I'll have plenty of time to recreate a whole new hood. More on that later. The fenders are all new pieces, and are 6" longer and about 2" wider than the original pieces. An additional 6" piece was added to the tub behind the fender to make up the total 12". The extra width was an attempt to keep them proportioned. The longer something is, the skinnier it looks, and vice versa. Here are some photos with text to point out any details.

Front Floorboard Modifications

The front floorboard and firewall were cut out, refabricated with 12 guage steel, and welded in. It only takes 10 seconds to say it, 45 seconds to type it, but trust me, It takes 1 1/2 weeks to do it!

Driver's side floor mods

This picture was taken standing in the passenger area looking down at the floorboard. I lowered a section of floor on the driver's side flush with the frame, leaving room in the center of the Jeep for the driveline, and in front of the lowered area for the transfer case. Approximately 3" was left in front so the T-case can still be pulled out of the vehicle with the body on.

Passenger side mods

This shot shows the passenger side floorboard. What you can't see, is the floorboard was lowered beneath this area, to provide a larger storage compartment under the passenger seat. From beneath the vehicle it is apparent that the entire floorboard was lowered to the lower edge of the frame.

Passenger side after modification

I decided to add the hood extension on the front of the hood. This was the easiest direction to proceed. It allows the use of the original hood hinge, and keeps the windshield stops in the same location. A 14" piece was used to gain the 12" needed for the hood. There is a 2" overlap that is welded as well. The first series of shots were taken before the 1" strip for the fender lip was added.

Driver's side after modification

The front rolled lip was cut off the hood, and the cut was squared with a grinder. Close was all that was required, since this was a "temporary" hood. The hood and extension piece was mocked up on the grille, aligned, and tack welded. After checking and adjusting, final welding was completed.

Driver's side before edge added

Although the fenders were widened, they still don't come even close to covering those swampers on full width axles!

Passenger side before before edge added

In this shot you can see the back portion of the fender, and a little bit of the step that was added to compensate for the extra length added to the tub behind the fender.

Driver's side fender lip

For this part, I used a 1" strip of steel and tacked it to the end of the fender, folding it along the edge of the fender, I tack welded it in place as I went. Final full welding was then performed. The same procedure was used for the step and back of the fender.

Passenger side fender lip

The same technique was applied to the passenger side. The next series of shots are of the completed sheetmetal portion of the project. Enjoy!