10. Last month we showed you...
10. Last month we showed you how the supplied frame jigs allowed DC Customs fab guru Danny Howe to mark out exactly where each framerail had to be cut. Once removed, Howe ground a bevel on each side of the frame to prepare it for welding. Notice the two small holes where the frame jigs were bolted to the rails.
11. This shot shows the rear...
11. This shot shows the rear portion of Teal's frame after it was removed from the front half. A forklift was a very handy aid in completing this process.
12. Once both ends of the...
12. Once both ends of the frame were prepped, Danny began the process of merging each of the 24-inch frame extensions with the rear half of the TJ frame. Here you can see one of the internal frame sleeves prior to being tack-welded inside the rail. These internal sleeves will help add strength to the seam while also making the welding process much easier.
13. Though it may seem like...
13. Though it may seem like a complex process, lengthening the frame was actually pretty simple, thanks to the precision frame jigs provided by AEV.
14. Check out how the frame...
14. Check out how the frame jigs provide a small window accessing the seam between each framemember. Once this area is welded on each side, the frame jig can be removed and then the remainder welded all the way around.
15. This picture, shot from...
15. This picture, shot from the passenger side, shows exactly how the frame extensions look while clamped to the frame jigs. These jigs are a proven way to stretch the frame with minimal hassle. Once tack-welded in place, Howe double-checked the frame dimensions one final time and then proceeded to weld the framemembers together.
16. Once the first pass was...
16. Once the first pass was laid down, we stopped Danny so we could snap a few pictures of his handiwork. We were impressed with his welding skills. After a second pass, the beads were ground flat and the inside of each framerail was prepped for the fish-plate support braces.
17. Once the mid-frame extensions...
17. Once the mid-frame extensions were completed, Dustin started work on the rear frame extensions. First, the rearmost body-mount brackets were removed.
18. With the rearmost body...
18. With the rearmost body mounts removed, a bit of welding was necessary to fill in the gaps left behind. Dustin showed us his abilities with the MIG machine. Not bad for a body guy.
19. Here you can see Danny...
19. Here you can see Danny welding the rear frame extension to Teal's rearmost crossmember. A pair of AEV-built fish plates were added to reinforce the seams.
20. This is the finished rear...
20. This is the finished rear frame extension. Notice how it includes an integrated rear winch mount. Thanks to the added frame length, we have more than enough room to mount extra items such as the natural vacuum-leak detection equipment, or an air compressor, or an air tank, or...
21. The winch we chose for...
21. The winch we chose for Teal-Brute's caboose was the T-Max EWI-10000. We chose this winch because we wanted one that wouldn't mind under-water dunkings on occasion. We also liked the idea of having a wireless remote control, which surprisingly is stealthily packaged into the wired remote control. With this setup, you simply unplug the wired remote extension cord from the handheld winch controller, and voila, no wires necessary to operate it. Rated at 10,000 pounds, this winch should serve Teal's rear end without issue.
Stay tuned for more on Teal's transformation from Jeep TJ to Brute Pickup. In next month's issue we'll show off the new paint job as well as some of the tricks we used to make the new bed more useful.