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Thread: JKU homemade rock rails

  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?

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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.

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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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    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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    Thanks!

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    looks like some great work!!! you've got the horizontal figured nicely, any thought to vertical support?? either tying into the frame at the mounts or even the pinch seam?? just looks like even a small twist and you won't be able to get the doors open
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    Dude those look amazing, I have been toying with the idea of making my own sliders but not sure just how to go about it, now I know, not sure when I'll get around to making them. But now I know how to start. Thanks for posting this. I would love to see more pics.

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    @ Whiplash....I hear what you're saying. I addressed the up/down possibility by reinforcing the brackets with a third "leg" going to and from the tube and bracket, giving them the extra strength to resist any up/down movement. I also used the largest bearing surface I could between my bracket and the existing frame mount, hopefully to provide a large stable bearing surface to negate and torsion forces......I have put a jack under there and put the weight of the entire side on the rail with no noticeable flexing! It's hard to tell, but there is approx. 3/4" between the top of the upper tube and the bottom of the door, on the horizontal.....and if it does move and trap my doors, well its a jeep, so out the roof I go, and worry about it later! lol

    @derek1976....no time like the present! I worked on them slowly, whenever I could/wanted to spare the time. Let my know if theres any specific shots and I'd be happy to snap some more pics. I was just in newcastle last night, at the snug! small world

    And thanks everyone for the kind words

  11. #11
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    They look good, how much money and time do you have into them?


    BTW, here is a writeup on posting pics on JeepKings.ca, shows how to make albums to store/organize all your pics, no need for Flickr or Photobucket, etc.


    http://www.jeepkings.ca/forums/showt...n-JeepKings-ca
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    Quote Originally Posted by Dekooy View Post
    @ Whiplash....I hear what you're saying. I addressed the up/down possibility by reinforcing the brackets with a third "leg" going to and from the tube and bracket, giving them the extra strength to resist any up/down movement. I also used the largest bearing surface I could between my bracket and the existing frame mount, hopefully to provide a large stable bearing surface to negate and torsion forces......I have put a jack under there and put the weight of the entire side on the rail with no noticeable flexing! It's hard to tell, but there is approx. 3/4" between the top of the upper tube and the bottom of the door, on the horizontal.....and if it does move and trap my doors, well its a jeep, so out the roof I go, and worry about it later! lol
    good stuff Dekooy!!!!

  13. #13
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    [QUOTE=igotafrigginjeep;1346522]They look good, how much money and time do you have into them?




    Thanks for the link....I'm a bit computarded

    I tried to scrounge the tube, but wasn't able to find enough so I bought it all new.....I paid approx. $200 for the 2" dia tube at metal supermarkets in Mississauga. 3- 12' lengths, and I was able to scrounge all of the flat metal. I'd say the entire process took 25 hours or so, working here and there, whenever I found the time or motivation or both.

  14. #14
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    Here is some damage these took at JK101......they didn't budge a bit! Very happy with them!

    Click image for larger version. 

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  15. #15
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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. 

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ID:	96554Click image for larger version. 

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ID:	96555Click 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. 

Name:	IMG-20140315-00404.jpg 
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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. 

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Size:	920.9 KB 
ID:	96561
    Looks good. Nice job.
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