Up armoring
I certainly didn't mean to offend if not.
Rock Crawling
Joined: Aug 2014
Posts: 379
Likes: 8
From: NorthWest Arkansas
software?
Iv been re-working the winch and frame mount. To show everyone why this process takes a while these are screen shots of the environmental stress and failure analysis. The loads simulate a 12000 pound winch pull, linear, offset and vertical. The welds don't fail but the material deflection is noticeable and excessive.
The design of the brush guard was simply following the lines of the grill. It is made from 1" x .120dia DOM. It was free and readily available in the shop. It is also very heavy so for future builds I would recommend 063. ERW. I live in northern Wisconsin and I need a stout brush guard to protect from suicidal deer. The brush guard plans are a guide and can be built however you want.
Welding the shackle mount to the bumper is risky. You would have to ensure you have excellent fit up with a decent sized weld and complete joint penetration. Incorporating the shackle anchor into the frame mount ensures a solid pulling point with out the worry of the weld failing. Thank you for your patience. I'm working as fast as I can to get this out before wheeling season.
Respectfully GIJoe
The design of the brush guard was simply following the lines of the grill. It is made from 1" x .120dia DOM. It was free and readily available in the shop. It is also very heavy so for future builds I would recommend 063. ERW. I live in northern Wisconsin and I need a stout brush guard to protect from suicidal deer. The brush guard plans are a guide and can be built however you want.
Welding the shackle mount to the bumper is risky. You would have to ensure you have excellent fit up with a decent sized weld and complete joint penetration. Incorporating the shackle anchor into the frame mount ensures a solid pulling point with out the worry of the weld failing. Thank you for your patience. I'm working as fast as I can to get this out before wheeling season.
Respectfully GIJoe
Thread Starter
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Overlanding
Joined: May 2013
Posts: 18
Likes: 3
Update
Well, the front bumper is built. Waiting to get it back from the powder coaters. The roof rack is coming along slowly. The basket is built just working on the mounting feet.
The Rear bumper is next. I have the shell cut out but need to take the old one off to work out the mounting bracketry.
The steering skid plate is finished and awaiting powder coating.
I am on the fence about the steering skid or HD steering and Trac bars. I had some weld-in inserts made for HD bars waiting for AB to send the Balljoints.
Frame sliders are on hold until I can figure out how to get the box tube to follow the bottom of the body line ( and ideas?)
Axle guards are drawn and a working model is made but I need to move it over to RADAN for the laser to cut.
Rear control arm sliders are drawn but look a bit bulky so I need to re-work the material to get a better product.
I also had time to draw the transmission skid. I found some crude pictures of a product that is billed as a transmission guard. I cut one out of some scrap aluminum sheet and it fits perfectly under my transmission and transfer case. Not sure if this is 5MT specific but if it fits why not.
I was in an accident last week that re-assured my decision buy a land rover. I was rear ended at an intersection by an off duty police officer. He was driving a chevy aspen and his plastic bumper and grill just about exploded. His car was un drivable (smashed in the radiator). The land rover dosent even look like it was hit. The responding officer had difficulty believing I was hit.
So in the coming weeks I'm going to need some help. Im building these parts to fit my land rover and it dawned on me some of the dimensions might be different as the model years progressed. As the plans get ready for release ill need some people to do some quick measurements to verify they don't need re-work before release. Like inter frame spacing and such. Anyone who can provide solid accurate numbers get first release. I have a 94 discovery. so if you chose to participate please indicate the year and condition of your truck in the PM (including any modifications pertinent to the measurements)
As always, thank you for your patience.
gratuitous progress shots.
some of these photos are not complete. In one the brush guard is just sitting on the bumper.
I start my modeling in either autodesk Inventor or Solidworks. The FEA is done in a third party software. After the part is modeled and FEA I transfer the flat patterns to OMAX or RADAN for cutting. Its a convoluted process but it works
Respectfully
GIjoe
The Rear bumper is next. I have the shell cut out but need to take the old one off to work out the mounting bracketry.
The steering skid plate is finished and awaiting powder coating.
I am on the fence about the steering skid or HD steering and Trac bars. I had some weld-in inserts made for HD bars waiting for AB to send the Balljoints.
Frame sliders are on hold until I can figure out how to get the box tube to follow the bottom of the body line ( and ideas?)
Axle guards are drawn and a working model is made but I need to move it over to RADAN for the laser to cut.
Rear control arm sliders are drawn but look a bit bulky so I need to re-work the material to get a better product.
I also had time to draw the transmission skid. I found some crude pictures of a product that is billed as a transmission guard. I cut one out of some scrap aluminum sheet and it fits perfectly under my transmission and transfer case. Not sure if this is 5MT specific but if it fits why not.
I was in an accident last week that re-assured my decision buy a land rover. I was rear ended at an intersection by an off duty police officer. He was driving a chevy aspen and his plastic bumper and grill just about exploded. His car was un drivable (smashed in the radiator). The land rover dosent even look like it was hit. The responding officer had difficulty believing I was hit.
So in the coming weeks I'm going to need some help. Im building these parts to fit my land rover and it dawned on me some of the dimensions might be different as the model years progressed. As the plans get ready for release ill need some people to do some quick measurements to verify they don't need re-work before release. Like inter frame spacing and such. Anyone who can provide solid accurate numbers get first release. I have a 94 discovery. so if you chose to participate please indicate the year and condition of your truck in the PM (including any modifications pertinent to the measurements)
As always, thank you for your patience.
gratuitous progress shots.
some of these photos are not complete. In one the brush guard is just sitting on the bumper.
I start my modeling in either autodesk Inventor or Solidworks. The FEA is done in a third party software. After the part is modeled and FEA I transfer the flat patterns to OMAX or RADAN for cutting. Its a convoluted process but it works
Respectfully
GIjoe
Last edited by cgoffroad; Feb 28, 2015 at 05:18 PM.
Looks good the only change I might make would be a thicker main hoop on the brush guard. That's personnel preference though.
Nice work!
The roof rack basket looks amazing exceptional work on that.
Nice work!
The roof rack basket looks amazing exceptional work on that.
Last edited by ArmyRover; Feb 28, 2015 at 11:15 PM.
Thread Starter
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Overlanding
Joined: May 2013
Posts: 18
Likes: 3
I made several versions of the brush guard in 1 inch, 1.5 inch and 2 inch diameter .120 wall DOM. The one pictured is 1.5 inch .120 wall DOM. For weight to strength the 1.5 inch seemed best. I did not test different sizes for the main hoop though, interesting idea.
That basket will be the death of me. Twice the bailegh tube notcher almost ate my hand. We keep it outside in a shed and I didn't give the roughing bit time to warm up and it shattered. Scared the living crud out of me.
Thanks
Joe
That basket will be the death of me. Twice the bailegh tube notcher almost ate my hand. We keep it outside in a shed and I didn't give the roughing bit time to warm up and it shattered. Scared the living crud out of me.
Thanks
Joe
