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Dubai Hi-Tech / Refined Brute Build

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  • Dubai Hi-Tech / Refined Brute Build

    So I figure now is a good time to start the build thread on my Brute - the majority of the parts have finally arrived!

    First - an intro on what we have got planned - the whole goal is to make the Jeep much more user-friendly for longer trips. That means replacing the 4 jerry cans with an in-built second tank, more accessible cargo that can be better organised, and more comfortable cabin.

    The build will take a 2001 Wrangler and do the Brute conversion, with custom long arm suspension using MetalCloak parts. I'm already starting with on board air, air locker in the front, Ected in the rear, SwayLoc etc etc... And the 6-pak shocks will be complimented with King 2" gas bump stops.

    The refined part of the build - will be on two levels - firstly the interior is going to see quite a lot of leather and alcantara trimmings and a lot more noise insulation than it's ever had. Recaro seats may also be done too. The other refinements will be the expedition preparedness like the dual tanks with secondary pump, dual battery. The roof top tent. Also a swing-out tire carrier on a custom rear bumper. Taking the hard work out of it all.

    The HiTech aspect - it's going to have Garmin in-dash GPS integrated to the OBD-II system. Park sensors. Camera systems front / rear / underneath. Power Sunroof. Power drop down rear window. Power normal windows. Add to that radar based blind spot monitoring system. Already has power retracting running boards. Also some of the technology that will be used to make the parts - using scanning equipment and CAD to do the suspension pieces, design the roll cage, and make the rear bumper and cargo rack (and perhaps re-do the front bumper).


    And now some pictures!

    This is the Jeep as it stands today:



    Photoshop goal:




    Unboxing some parts!





    Should take a while to wear these bushings out



    Last edited by Laurie; 07-12-2013, 08:18 AM.
    2001 Jeep Wrangler Sport
    AEV Highline Fender Conversion
    AEV Brute Conversion Build Thread

    www.oman4x4.com

  • #2
    Gonna be awesome!!!

    Comment


    • #3
      Laurie, best of luck to you on your build! I know you will LOVE the completed project. Here is the one I am just finishing this week. Same color so maybe this will inspire you on... Good luck!

      Ben Hedrick
      www.BenHedrick.com
      HEDRICK Speedsports

      "Ive got a Jeep problem"
      2007 5.7L HEMI Sahara Unlimited - Sold
      2010 6.1L HEMI Rubicon Unlimited - Sold
      2011 6.4L (392) HEMI Rubicon Unlimited - Sold
      2002 4.0L AEV Brute - Sold
      2003 6.4L "Stroker" HEMI AEV Brute - Sold
      2005 4.0L SC AEV K9 Brute - Sold
      2014 345 HEMI Rubicon Xpo Adventurer
      2000 4.0L AEV 112 Long Wheelbase
      2006 4.0L AEV Brute Rubicon

      Comment


      • #4
        Ben - you tease! Thanks for the pic - looks great in red

        We're planning something a little different though - red with a hint of metallic / candy effect - should really pop in the sun
        2001 Jeep Wrangler Sport
        AEV Highline Fender Conversion
        AEV Brute Conversion Build Thread

        www.oman4x4.com

        Comment


        • #5
          Originally posted by Laurie View Post
          We're planning something a little different though - red with a hint of metallic / candy effect - should really pop in the sun
          I have NO doubts, that your build will be spectacular!!!!
          Ben Hedrick
          www.BenHedrick.com
          HEDRICK Speedsports

          "Ive got a Jeep problem"
          2007 5.7L HEMI Sahara Unlimited - Sold
          2010 6.1L HEMI Rubicon Unlimited - Sold
          2011 6.4L (392) HEMI Rubicon Unlimited - Sold
          2002 4.0L AEV Brute - Sold
          2003 6.4L "Stroker" HEMI AEV Brute - Sold
          2005 4.0L SC AEV K9 Brute - Sold
          2014 345 HEMI Rubicon Xpo Adventurer
          2000 4.0L AEV 112 Long Wheelbase
          2006 4.0L AEV Brute Rubicon

          Comment


          • #6
            Originally posted by Ben Hedrick View Post
            I have NO doubts, that your build will be spectacular!!!!
            Thanks! Means a lot knowing what you've built already!
            2001 Jeep Wrangler Sport
            AEV Highline Fender Conversion
            AEV Brute Conversion Build Thread

            www.oman4x4.com

            Comment


            • #7
              Oh I've been waiting for this build forever!!!! Can't wait to see how it turns out, especially the high tech!!!

              Comment


              • #8
                Can't wait to see how this one comes together, should be gorgeous!

                Care to share some of your ideas on transfer pumps and fuel setups? I'm still at a loss for how I want to plumb mine.
                98 Brute
                Portal-Teks/ARB's/RCVs/CTIS
                Brute and Highline Kit
                5.7 Hemi
                Getrag 238 6 speed
                Rubicon 241
                40" Toyo's/Hutchinson FC Wheels
                JK Unlimited Frame
                Blah Blah Blah

                97 F350 CCLB
                38" Toyo's on Hutchinsons
                Deavers/2.5" Kings/Long Travel Airbags
                ARB's/35 Spline Chromos

                05 XR650R
                Street legal and RTW prepped

                Comment


                • #9
                  Originally posted by Offroad Engineering View Post
                  Can't wait to see how this one comes together, should be gorgeous!

                  Care to share some of your ideas on transfer pumps and fuel setups? I'm still at a loss for how I want to plumb mine.

                  Yet to implement it but at the moment thinking to run it how they do on the Toyotas... dual tanks with dual fuel pumps with dual fuel senders. Flip a switch to alternate power from one pump to the other, and disconnect one sender and connect the other. May need to think about check-valves etc if the switched off pump itself doesn't stop the back-flow into the tank from the pressure created by the other one... that's the only real complication that I can see.

                  The idea is also to use two TJ fuel pumps too - so if one goes bad I have a spare. Immediately I can switch to the other tank and if I run that one empty I could swap the pumps on a trail fix if desperate...

                  Planning to do it using a Genright replacement enduro tank and then also use their fuel pump ring for the custom made tank mid-ship

                  All theory for now though
                  2001 Jeep Wrangler Sport
                  AEV Highline Fender Conversion
                  AEV Brute Conversion Build Thread

                  www.oman4x4.com

                  Comment


                  • #10
                    Frame is now cut! After the weekend it will be welded up again in its extended length, and then we worry about the tail section. After that, we throw axles and shocks under it and take measurements on where we will be placing the long-arm bracketry.



                    This is the cutting template - shows you where to section the frame. It's used on both sides, and you cut on the straight edge of the rear-most zig-zag holes.



                    This is the rear extension sub-frame - which includes the rear winch mount and the trailer hitch connector.





                    This is the alignment template for when it goes back together. It has the same holes as the cutting template and access holes for you to tack-weld it in place. This ensures the stretched frame is straight and correct.



                    This is the section of frame rail that will go in the extended part of the frame.



                    The cutting template clamped in place for the holes to be drilled.

                    2001 Jeep Wrangler Sport
                    AEV Highline Fender Conversion
                    AEV Brute Conversion Build Thread

                    www.oman4x4.com

                    Comment


                    • #11


                      The frame is now cut - and repositioned on the jack stands using the extension templates. They will then come off again while the inner reinforcements are put on. Then the extension pieces are loosley put in place, re-attach the extension templates and begin welding!






                      Some of you may notice no pictures of the interesting bit - when it gets cut - but there IS video and I'm working on it
                      2001 Jeep Wrangler Sport
                      AEV Highline Fender Conversion
                      AEV Brute Conversion Build Thread

                      www.oman4x4.com

                      Comment


                      • #12
                        Awesome. Nothing like cutting brand new parts in half!
                        98 Brute
                        Portal-Teks/ARB's/RCVs/CTIS
                        Brute and Highline Kit
                        5.7 Hemi
                        Getrag 238 6 speed
                        Rubicon 241
                        40" Toyo's/Hutchinson FC Wheels
                        JK Unlimited Frame
                        Blah Blah Blah

                        97 F350 CCLB
                        38" Toyo's on Hutchinsons
                        Deavers/2.5" Kings/Long Travel Airbags
                        ARB's/35 Spline Chromos

                        05 XR650R
                        Street legal and RTW prepped

                        Comment


                        • #13
                          http://www.youtube.com/watch?v=G4U4Mq3HbU0

                          Video of the Jeep frame being cut in half
                          2001 Jeep Wrangler Sport
                          AEV Highline Fender Conversion
                          AEV Brute Conversion Build Thread

                          www.oman4x4.com

                          Comment


                          • #14
                            Been a slow week as the build-room gets AC and extractor fans installed to help combat the 120+F temperatures here - but now making progress again.

                            The main chassis extensions are done - although a bit more welding to be done on the reinforcement plates tomorrow, then the tail section, bed mounts and then we will throw the axles under the frame with the new shocks, and standard control arms, and then start taking measurements to design the long-travel suspension. :-)

                            Frame with the extension done:



                            What join lines? Wish I had been able to stop by the shop and get some pictures before smoothing it out but was not able to...



                            External reinforcement plates. This will then be seam welded on the top and then the whole chassis will be flipped upside down and the same again for the lower side.

                            2001 Jeep Wrangler Sport
                            AEV Highline Fender Conversion
                            AEV Brute Conversion Build Thread

                            www.oman4x4.com

                            Comment


                            • #15
                              Latest Video instalment

                              http://www.youtube.com/watch?v=BtVQxPlEaM4
                              2001 Jeep Wrangler Sport
                              AEV Highline Fender Conversion
                              AEV Brute Conversion Build Thread

                              www.oman4x4.com

                              Comment

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