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  1. #1
    Join Date
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    Default Ironman: Prototyping

    I have finally gotten caught up with all of my orders for the first time in 2 years. Its an amazing feeling. I have been working on a ton of prototype Ideas for a while and I decided that I would share the pieces and parts here in the fabrication section because that is exactly all this is.

    I finished my P-type double shear track bar bracket tonight. I only wanted 3 parts and only 1 bend. The drawings will go to a laser guy later this week but here is my hand made P-type



    I use a miller 350P pulse Mig welder with a 3 part gas to keep the splatter to a minimum. I only do that stacked dime looking welding for my own personal parts. everything else gets a constant heat stitch type weld.



    The extra set of holes is for a cross bar going to the opposing side of the frame for extra stability.



    I think its important to do as few pieces as possible so I integrated the angle gusset into the lower support. This also allows for longer welds with less stopping and starting. The origin and termination of a weld is the most common fail point. Thankfully miller designed this machine with what they call background voltage, This eliminates cold starts.

  2. #2
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    Default Re: Ironman: Prototyping

    I didn't get to spend any more time on this today. but I hope to have more up for ya'll tomorrow night. I ended up spending the evening machining an anti sway setup for a local buggy. Who knew an old YJ sway bar could be turned down and put on a comp buggy
    Its fun to be building new and different stuff again

  3. #3
    Join Date
    Mar 2009
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    South TEXAS
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    Default Re: Ironman: Prototyping

    Beautiful welds.
    Hey bubba get your hand off my ass,

    Some days it is just not worth it to gnaw through the leather restraints.

    R.I.P. Brian 96_XJ Perrine 1990-2011

  4. #4
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    Default Re: Ironman: Prototyping

    Thanks Dude,
    I made the cross bar tonight but no pics yet I;m going to mod the bends a bit more before I show how it works I want extra clearance to work on all lifts.
    A-

  5. #5
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    Default Re: Ironman: Prototyping

    Here is the final cross member design. I also included the adjuster for the Monster track bar!!!!

    Side View

    Mtn Dew Cap Not Included LOL

    Cross member for Track Bar 1" solid


    I will do two different track bars for taller lifts and lower lifts for clearance purposes. This adjuster for the track bar (Not Shown) if for the lower lift track bar.

  6. #6
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    Default Re: Ironman: Prototyping

    I copied this out of the fabrication section so people could post up questions and feedback without having to be moderated.

    Wow this is nice! Until Andy told me (I didn't read) I thought this bar was the track bar!!!! It's just the brace!

  7. #7
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    Default Final product ready for testing.

    Here is the the bar in place on my 90 2 door



    side view:


    Final product.... word is Rene already claimed this set.




    I want to sell about 5 sets of these to guys to test out. I need about 250.00 for the kit. I will be selling them for around 300.00 once we know they are perfect.

  8. #8
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    Default Long arm cross member

    I have Finished Prototyping my cross member for my long arm system and Thought I would share a few pics with ya'll of the final product before I release them this weekend.



  9. #9
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    Default Re: Ironman: Prototyping

    Andy, I like how the center unbolts. This is a criteria I utilized when I made my own.
    230 hp 4.3L Chevy
    Built 4L60E with manual lockout
    Atlas 4 speed
    Griffin radiator
    On board air
    Warn 9.5ti on custom bumper
    7.5" RE front and bastard pack rear on custom long arms
    30 gal gas tank
    lockers
    And a bunch of other stuff

  10. #10
    Join Date
    Aug 2009
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    Hyrum, Utah
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    Default Re: Ironman: Prototyping

    i had a cross member that i made for my long arms, kind of like this. but man this one is way nicer. great job.
    01, Tera Flex 6" long arm kit, jks quick disco's,jks bar pin eliminators, Fox 2.0 shocks I won for 5 bucks, Tom woods Sye with rear drive shaft, Tera flex rear disc brakes, custom front bumper, customer rear bumper, rage roof rack. H4 head lights, k&n intake and cone, black steelies with 285x75x16 retreads, metal gas skid. Finally I have a nice jeep no more pos.
    .,=====o00
    //___l__,\____\,___
    l_--- \___l----[]lllllll[]
    _(o)_)___(o)_)--o-)_

  11. #11
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    Default Re: Ironman: Prototyping

    Yeah looks really clean. I like putting products like this on my Jeep.

  12. #12
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    Connecticut
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    Default Re: Ironman: Prototyping

    I am digging that crossmember.
    1999 XJ, 3" Skyjacker, 33x12.50 Cooper STT's, custom bumpas, dents

    1988 MJ, lowering in process

  13. #13
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    Default Re: Ironman: Prototyping

    Really like the xmember design! Great Work!
    1995 XJ SPORT 4.0L / AW4 / NP231 / 4" Homebrew Lift w. Hacked Fenders / Disconnected / 48" Jack / Bedlined Floor & Exterior / 33" Eldorado MTZ / Stock Axles / Twin Rack Lights / Custom Bumper with 8500LB Winch / Stiffys and a load of steel that needs to find a place on my heep.

    ______ooo
    / _/|_|_|\___\___
    |/ : \_|_|_/ : \ |iiii|
    ( _ ) _ ) . ( _ ) _ )

    Dirty to the C.O.R.E.
    Cumberland Off Road Enthusiasts

  14. #14
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    Default Re: Ironman: Prototyping

    Andy did you give any thought to building more of a boxed design? Connection not only of the bottom of the uni-body but up the sides? I'm sure if would be stronger, but is it necessary or at least a good idea?

  15. #15
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    Default Re: Ironman: Prototyping

    I have seen one or two that did that. Might interfere with rock sliders down the road.
    230 hp 4.3L Chevy
    Built 4L60E with manual lockout
    Atlas 4 speed
    Griffin radiator
    On board air
    Warn 9.5ti on custom bumper
    7.5" RE front and bastard pack rear on custom long arms
    30 gal gas tank
    lockers
    And a bunch of other stuff

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