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Thread: JKU homemade rock rails

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  1. #1
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    JKU homemade rock rails

    Hello,

    So I wanted rock rails for my '11 JKU. The only problem is that I'm extremely cheap. So what's a guy to do?

    I built my own! I think they turned out great so I thought I might add a bit of fabricating content for the site and do a write up.
    They were made over the course of a month, working whenever I had the spare time or the motivation. I am a Tool and Die maker by trade, but unfortunately don't have access to any of those great machines anymore, so all the work you see was done by file, hacksaw, sawsall, 10" drillpress and 4 1/2" angle grinder............it sucked hard sometimes!!
    All flat metal is .250" and the tube is 2" dia x .120" wall. They weigh about 80 lbs each!
    Well on to the pics

    Click image for larger version. 

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    Here the mounts have begun.....I choose to use the body-to-frame mounts (3 on each side) and had to fab up the mounting brackets to fit in the frame mount cups. Think like ACE hardware rock rails, but instead of the one frame bolt as the attachment point I used the two on either side in the mount itself. Using these allow for a larger bearing surface for my bracket and the mount, hopefully resisting any twisting forces better . That's a 2 1/4" hole on a mastercraft 10" bandsaw...slow and steady wins the race!!

    Click image for larger version. 

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    Here you can see the mounting brackets taking shape and how they fit into the frame mounts. I tried to keep the initial rail tight up to the bodywork, but with enough clearance to avoid crumpling the pinch seam if it takes a huge hit.

    Now for the secondary rail to offer side protection. I bent it up on my PA 12 ton pipe bender.
    Click image for larger version. 

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    All it needs is to have the notches cut into it. That was the hardest part. I found an .exe program online (it shows as "tubemitre" on my computer) and you put in some dimensions, print it out, cut it out and tape it to the tube you want to notch.
    Click image for larger version. 

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    Attached Thumbnails Attached Thumbnails IMG-20140326-00412.jpg   IMG-20140326-00414.jpg  
    Last edited by Dekooy; 05-02-2014 at 02:40 PM. Reason: picture fixing
    OF4WD member #7498

  2. #2
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    Well it looks like only the last two pics worked....anyone know what to do?

  3. #3
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    Looks good, of the pictures that worked, nice job. For pictures I use photobucket and then put the image link in the post.

  4. #4
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    Continued from first post to hopefully have the pictures work......

    It actually worked awesome......
    Click image for larger version. 

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    Here is the fit and final adjustments before tacking it on.

    Click image for larger version. 

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    That same drill press putting in some overtime as a tube notcher for the uprights!

    Here they are welded up......
    Click image for larger version. 

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    I welded one more arm in between the first two on each bracket and then prepped for paint.

    Hit it with a few coats of self-etching primer then a couple of coats of Dupli-colour bed armour. It goes on well but needs good prep work.

    Here they are on the truck.
    Click image for larger version. 

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    Click image for larger version. 

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    Overall it was a fun experience and really not too difficult. I hope this write up helps anyone doing their own!
    Last edited by Dekooy; 05-02-2014 at 02:43 PM. Reason: picture fixing

  5. #5
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    Here are the final pics.....
    Click image for larger version. 

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  6. #6
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    Nice job. Those look awesome!!

  7. #7
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    Quote Originally Posted by Dekooy View Post
    Hello,

    So I wanted rock rails for my '11 JKU. The only problem is that I'm extremely cheap. So what's a guy to do?

    I built my own! I think they turned out great so I thought I might add a bit of fabricating content for the site and do a write up.
    They were made over the course of a month, working whenever I had the spare time or the motivation. I am a Tool and Die maker by trade, but unfortunately don't have access to any of those great machines anymore, so all the work you see was done by file, hacksaw, sawsall, 10" drillpress and 4 1/2" angle grinder............it sucked hard sometimes!!
    All flat metal is .250" and the tube is 2" dia x .120" wall. They weigh about 80 lbs each!
    Well on to the pics

    Click image for larger version. 

Name:	IMG-20140221-00397.jpg 
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Size:	922.2 KB 
ID:	96554Click image for larger version. 

Name:	IMG-20140221-00398.jpg 
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ID:	96555Click image for larger version. 

Name:	IMG-20140303-00402.jpg 
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ID:	96556

    Here the mounts have begun.....I choose to use the body-to-frame mounts (3 on each side) and had to fab up the mounting brackets to fit in the frame mount cups. Think like ACE hardware rock rails, but instead of the one frame bolt as the attachment point I used the two on either side in the mount itself. Using these allow for a larger bearing surface for my bracket and the mount, hopefully resisting any twisting forces better . That's a 2 1/4" hole on a mastercraft 10" bandsaw...slow and steady wins the race!!

    Click image for larger version. 

Name:	IMG-20140315-00404.jpg 
Views:	63 
Size:	1,001.5 KB 
ID:	96557Click image for larger version. 

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ID:	96558Click image for larger version. 

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ID:	96559

    Here you can see the mounting brackets taking shape and how they fit into the frame mounts. I tried to keep the initial rail tight up to the bodywork, but with enough clearance to avoid crumpling the pinch seam if it takes a huge hit.

    Now for the secondary rail to offer side protection. I bent it up on my PA 12 ton pipe bender.
    Click image for larger version. 

Name:	IMG-20140315-00407.jpg 
Views:	64 
Size:	1.00 MB 
ID:	96560
    All it needs is to have the notches cut into it. That was the hardest part. I found an .exe program online (it shows as "tubemitre" on my computer) and you put in some dimensions, print it out, cut it out and tape it to the tube you want to notch.
    Click image for larger version. 

Name:	IMG-20140326-00408.jpg 
Views:	62 
Size:	920.9 KB 
ID:	96561
    Looks good. Nice job.
    2012 Wrangler Sahara 4DR

    2004 TJ Sahara-RIP
    1992 Jeep Renegade - RIP

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