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Skunkworks DCSB

Discussion in '2.5 Gen Builds (2014-2021)' started by Cruzer, Jun 6, 2023.

  1. Jun 6, 2023 at 7:29 AM
    #1
    Cruzer

    Cruzer [OP] Wheeling Full Size

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    Cruz
    Sunnyvale, CA
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    Build Page: Cruzer's Re-Build for the Rubicon
    8/11/2023

    Just bought this 2015 Limited DC. Need to fly up to Portland, OR next week and drive it back home.

    upload_2023-8-11_16-26-22.png
     
    Last edited: Aug 11, 2023
    Ryuu and 2mchfun like this.
  2. Jun 6, 2023 at 7:30 AM
    #2
    Cruzer

    Cruzer [OP] Wheeling Full Size

    Joined:
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    Cruz
    Sunnyvale, CA
    Vehicle:
    Build Page: Cruzer's Re-Build for the Rubicon
    Project: Gantry

    I need to build one of these

    https://youtu.be/S55DvPpfcjM

    Building Materials:
    11: 2x6x10 (wood at Lowes sucks)
    2: 2x12x8 (accidentally bought 2x12x10)
    1 ton Chainfall
    2x2 Angle iron
    1" steel rod
    Casters
    Additional chain
    Screws (GRK 1/4" x 2.5")
    Wood glue (got waterproof since it'll be stored outdoors)
    Thompson's Water Seal

    Will need to make it detachable in order to fit in the backyard.

    6/9/2023
    Got these casters from Amazon, pretty fricking beefy. Pretty much all steel. A box of 4 was pretty heavy.

    casters.jpg

    6/11/2023
    Went to HF and picked up this miter saw. Not looking for the best. I just need it to cut straight and cut angles.

    upload_2023-6-11_16-54-32.png

    Then I went to Lowes and got wood, glue, and screws. Gonna let the wood sit outside for a week and start putting shit together next week.

    upload_2023-6-11_16-55-42.png

    upload_2023-6-11_16-56-9.png

    upload_2023-6-11_16-56-33.png

    6/19/2023

    Made the uprights today. Used nearly the whole bottle of glue and most of the screws already.

    upload_2023-6-19_20-29-42.png

    upload_2023-6-19_20-29-59.png

    Gonna need a belt sander to make the bottoms flat.

    9/16/2023
    Took a lot longer to build than I thought it would. I applied Thompson's Water Seal so that it can last through the winter outdoors.

    IMG_9170.jpg

    IMG_9171.jpg

    IMG_9173.jpg
     
    Last edited: Sep 25, 2023
    RainMan_PNW likes this.
  3. Jun 6, 2023 at 7:30 AM
    #3
    Cruzer

    Cruzer [OP] Wheeling Full Size

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    Cruz
    Sunnyvale, CA
    Vehicle:
    Build Page: Cruzer's Re-Build for the Rubicon
    How to: Drop the frame

    (Notes to self)
    • order more jack stands
    • order engine hoist mounts
     
    Last edited: Jun 6, 2023
  4. Jun 6, 2023 at 7:30 AM
    #4
    Cruzer

    Cruzer [OP] Wheeling Full Size

    Joined:
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    First Name:
    Cruz
    Sunnyvale, CA
    Vehicle:
    Build Page: Cruzer's Re-Build for the Rubicon
    Project: Short Bed Install

    I'll be chopping the frame underneath the bed where the C-channel frame straightens out. This will force me to relocate the rear cab mount, which will be right above the forward leafspring hanger.

    upload_2023-9-24_18-5-3.png

    With the frame moving forward I will need to chop into the cab to allow this rise in the frame to fit underneath the cab.

    upload_2023-9-24_18-7-14.png

    The rise in the frame actually curves inwards. I will need to fab some sort of rising block and a beam to go across before I cut out the bottom of the cab.

    upload_2023-9-24_18-10-57.png

    Found footage from a back halfed CM Tundra with the rear cut out.
    Based on this the RED box is where the body mount would be and the BLUE box is where I could run a tube to fortify the cab.

    upload_2023-9-25_14-19-5.png

    upload_2023-9-25_14-18-5.png

    I guess I'd need to brace the top of the cab body mount to the brace

    upload_2023-9-25_14-21-31.png

    Looks like these are the parts:
    upload_2023-9-26_14-23-11.png

    upload_2023-9-26_14-24-35.png

    Rather than cut, I think I'll find the pinch welds and drill them out to remove whole.

    upload_2023-9-26_14-22-56.png
     
    Last edited: Sep 26, 2023
  5. Jun 6, 2023 at 7:30 AM
    #5
    Cruzer

    Cruzer [OP] Wheeling Full Size

    Joined:
    Oct 12, 2020
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    #53461
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    3,166
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    Male
    First Name:
    Cruz
    Sunnyvale, CA
    Vehicle:
    Build Page: Cruzer's Re-Build for the Rubicon
    Project: Boxing the Frame & LCA mounts

    Collecting some ideas.
    • Would like to use dimple dies to reduce added weight and actually increase rigidity
    • I like how this crossmember is welded onto the frame
    • I also like the notches to allow water to drain out
    upload_2023-9-25_8-19-48.png
     
    Last edited: Sep 25, 2023
  6. Jun 6, 2023 at 7:31 AM
    #6
    Cruzer

    Cruzer [OP] Wheeling Full Size

    Joined:
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    Cruz
    Sunnyvale, CA
    Vehicle:
    Build Page: Cruzer's Re-Build for the Rubicon
    Project: Atlas Transfer Case

    6/11/2023

    Went under the truck to see how the stock TC was clocked. This view shows the front drive shaft coming out of the TC.

    upload_2023-6-11_17-31-23.png

    So now I know it is positioned like this. 4 o'clockish

    upload_2023-6-11_17-34-2.png

    I'll unbox the Atlas TC next week to see how it needs to be clocked and also need to figure out how to mate it with the transmission. Making a homemade adapter will be super fun :rolleyes:


    6/19/2023

    Took some measurements and started drawing things out. I wish I could do CAD but this will do.

    This is the Atlas doubler that mates with the transmission. It has a Jeep/Dodge female 23 spline input shaft. Atlas doesn't make an input shaft for Tundras.
    upload_2023-6-19_20-39-38.png

    This represents the transmission tail housing with the male 22 spline output shaft sticking out:
    upload_2023-6-19_20-41-41.png


    This represents the spud shaft (spline adapter) I need to get custom made:
    upload_2023-6-19_20-45-13.png

    The grey piece is the custom 2.25" thick aluminum adapter I need to make by hand. The black squiggly line is a coil spring to keep the spud shaft from moving in and out.

    upload_2023-6-21_9-28-50.png

    The adapter will probably look like this. The transmission tailhousing is octagon shape and is about 10.25" wide. The Atlas is circular and is about 8" wide. The inner holes are for bolting the Atlas to the adapter, while the outer holes bolt to the transmission tailhousing.

    upload_2023-6-19_20-50-9.png

    10/18/2023

    Thanks to @snivilous recommendation I finally have a shop that is going to machine the spline adapter (aka spud shaft) out of 300M. Mofo will be strong!

    I've purchased transfer case punches in preparation for making a wood version of the TC/Transmission adapter.

    upload_2023-10-18_21-14-49.png

    However, I have not been able to find an M10x1.25 transfer screw so I ordered a bunch of bolts with the plan of making my own. Will cut off the hex side, place the threaded section into my drill press chuck, then use my grinder to create a pointy tip while the drill press is spinning. The tip should center itself.

    upload_2023-10-18_21-17-9.png

    When I ordered my Atlas TC I really didn't know all of the components so I winged it. I ended up with CV yokes for the front and rear output since they didn't have the flange yokes that fit the Tundra. Little did I know at the time was that it didn't matter if the flange yoke didn't fit the Tundra because I would have to get my drive shaft customized anyways and could put a matching non-CV yoke on it.

    Why am I changing it in the first place?
    These CV yokes stick out a lot, which would result in shorter drive shafts, especially the front, which will create steeper angles. I've also read that the 2 pins that secure the U-joint are weaker.

    Here's the current yoke.

    upload_2023-10-18_21-33-29.png

    I'm changing it out to this 1350 flange yoke, which looks like the Tundra flange but is not a match so the flange yoke on the driveshaft will not fit.

    upload_2023-10-18_21-35-32.png

    This Neapco N3-2-1579 will replace the ones on the driveshaft

    upload_2023-10-18_21-38-13.png
     
    Last edited: Oct 18, 2023
  7. Jun 6, 2023 at 7:31 AM
    #7
    Cruzer

    Cruzer [OP] Wheeling Full Size

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    Cruz
    Sunnyvale, CA
    Vehicle:
    Build Page: Cruzer's Re-Build for the Rubicon
    Project: Fuel Tank Tuck

    With the bed off the truck I can finally get a better look at what I have to deal with.

    • I'll need to move the fuel tank towards the rear diff so that this hump doesn't end up underneath the bed when the frame is chopped and moved forward.
    • I will need to cut into the cab where it hangs low. This is a supporting structure so I will need to make a long C notch
    • I'll probably get rid of this crossmember and replace it with one that goes under the tank and back over the drive shaft.

    upload_2023-9-24_17-47-24.png

    Once I can get the fuel tank lifted up I can then have a crossmember that would beneath the fuel tank then back up and over the driveshaft and exhaust to the other side of the frame.

    This crossmember will be where I mount my fuel skids to. The goal is to have 3/16 fuel skids at the same level as the bottom of the frame.

    upload_2023-9-25_13-40-46.png
     
    Last edited: Sep 25, 2023
  8. Jun 6, 2023 at 7:31 AM
    #8
    Cruzer

    Cruzer [OP] Wheeling Full Size

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    Cruz
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    Build Page: Cruzer's Re-Build for the Rubicon
    Project: Body mount swap
     
    Last edited: Jun 19, 2023
  9. Jun 6, 2023 at 7:31 AM
    #9
    Cruzer

    Cruzer [OP] Wheeling Full Size

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    Cruz
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    Build Page: Cruzer's Re-Build for the Rubicon
    Project: Reinforce sliders
    - brace ends
    - gusset middle
     
    Last edited: Jun 21, 2023
  10. Jun 6, 2023 at 7:31 AM
    #10
    Cruzer

    Cruzer [OP] Wheeling Full Size

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    Cruz
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    Build Page: Cruzer's Re-Build for the Rubicon
    Project: Relocate rear shock mounts
     
    Last edited: Jun 19, 2023
  11. Jun 6, 2023 at 7:31 AM
    #11
    Cruzer

    Cruzer [OP] Wheeling Full Size

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    Build Page: Cruzer's Re-Build for the Rubicon
    Project: Skid plates
     
    Last edited: Jun 19, 2023
  12. Jun 6, 2023 at 7:32 AM
    #12
    Cruzer

    Cruzer [OP] Wheeling Full Size

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    Build Page: Cruzer's Re-Build for the Rubicon
    Project: Rear diff truss and armor
     
    Last edited: Jul 11, 2023
  13. Jun 6, 2023 at 7:32 AM
    #13
    Cruzer

    Cruzer [OP] Wheeling Full Size

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    Placeholder13
     
  14. Jun 6, 2023 at 7:32 AM
    #14
    Cruzer

    Cruzer [OP] Wheeling Full Size

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    Placeholder14
     
  15. Jun 6, 2023 at 7:32 AM
    #15
    Cruzer

    Cruzer [OP] Wheeling Full Size

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    Placeholder15
     
  16. Jun 6, 2023 at 9:08 AM
    #16
    Cruzer

    Cruzer [OP] Wheeling Full Size

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    Placeholder16
     
  17. Jun 6, 2023 at 9:08 AM
    #17
    Cruzer

    Cruzer [OP] Wheeling Full Size

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    Placeholder17
     
  18. Jun 6, 2023 at 9:08 AM
    #18
    Cruzer

    Cruzer [OP] Wheeling Full Size

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    Placeholder18
     
  19. Jun 6, 2023 at 9:08 AM
    #19
    Cruzer

    Cruzer [OP] Wheeling Full Size

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    Placeholder19
     
  20. Jun 6, 2023 at 9:08 AM
    #20
    Cruzer

    Cruzer [OP] Wheeling Full Size

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    Placeholder20
     
    Sunnier likes this.
  21. Jun 6, 2023 at 9:11 AM
    #21
    memario1214

    memario1214 Hotshot Offroad Staff Member Vendor

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  22. Jun 6, 2023 at 9:21 AM
    #22
    Ghost Rider

    Ghost Rider Mods wouldn't be an issue if money wasn't.

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    :spam:
    This better be good, after all those "spoilers"
    I kid, getting popcorn and mountain dew like Colton is, waiting for the show to begin.
     
    Taco-Spike likes this.
  23. Jun 6, 2023 at 9:22 AM
    #23
    RobertD

    RobertD SSEM#123, ASCM#4 "I call it Vera" ~Jayne Cobb

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  24. Jun 6, 2023 at 9:31 AM
    #24
    Taco-Spike

    Taco-Spike Gateway from Tacoma World ~ ended up here

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  25. Jun 6, 2023 at 9:32 AM
    #25
    TaquitoBandito

    TaquitoBandito SSEM #91, KitKat Aficionado, A Dancer for Money Exotic Dancer

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  26. Jun 6, 2023 at 9:42 AM
    #26
    snivilous

    snivilous snivspeedshop.com

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    Well this was anticlimactic.
     
  27. Jun 6, 2023 at 10:10 AM
    #27
    Cruzer

    Cruzer [OP] Wheeling Full Size

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    Changed the title :rofl:
     
  28. Jun 6, 2023 at 12:43 PM
    #28
    reywcms

    reywcms New Member

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    Too many mods to come
    Skunkworks love it
     
  29. Jun 6, 2023 at 12:52 PM
    #29
    MedCityMoto

    MedCityMoto SciTech Nerd

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    And here I wish I could do the opposite, put a 6.5' on my CrewMax!
     
  30. Jun 6, 2023 at 12:58 PM
    #30
    Cruzer

    Cruzer [OP] Wheeling Full Size

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    That's doable. I'll trade you beds if you're on the west coast :D
     
    snivilous and Sunnier like this.

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