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  #1177  
Old 05-21-2013, 01:40 PM
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Re: Omelet's Build Thread!

Finally, I was so close! Now I pressed the snorkel against the Jeep good and tight to make sure this was where I wanted it before going any farther. I liked it so I only needed to adjust the template slightly using the outline I did before as a reference, and tape it down again.




Then I pulled the snorkel off, used a punch to mark the center of the bolt holes, and started drilling. I drilled them slightly larger than they needed to be so I wouldn't have any trouble getting all three to line up. Then I cleaned up the back side of all the cuts.




It was finally time to remove the tape and get the snorkel mounted with all the hardware.




First thing I did was place the snorkel on the Jeep and secure it with the A-pillar bracket.




Then put the weather strip back in place.




And made sure the door would still close




I plan to take it back off and paint the bracket and bolts black so they blend in.




I did a great job making the template, lining it up, and drilling the holes, because all three bolts went in no problem! Once they were all securely fastened here is how it looked.




It doesn't fit like a glove, but it definitely fits better than I was expecting. I thought I was going to NEED to whip out the bondo and fill in all the spots where it didn't sit flush and had huge gaps.




The hood does touch it when it's up, but that's not a problem. It also sits a little high so there is a gap over the top of the hood, but that was necessary. If I would have brought it down any more the bottom of the snorkel wouldn't have lined up with the fender where it flares out. Which would have made mounting more difficult and there would have been more noticeable gaps around all the sides. So I can live with the gap on top, and if not then I will whip out the bondo




Now for some different angles. The light was failing so the quality isn't that great.












This is just phase one! Phase two will be actually plumbing it into the filter box which I hope to get to here soon. Also, for anyone wanting to do this same thing I did keep the painters take intact and plan to make a template that I can mail off to anyone interested. That way most of the guess work is out of it. You will just need to line it up on your fender using the contours, and drill away That is at a small fee
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  #1178  
Old 05-21-2013, 01:45 PM
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Re: Omelet's Build Thread!

(13 APR 2013)

Time to make a couple of updates to the build!

For the past few months I have been working with OTRATTW to get some custom switch covers for the Bison. Well last week I finally received 4 of them!!!




I got one for the the 40" on the roof (Roof Light Bar) One for the 20" in the Matrix (Bumper Light Bar) One for the D2s in the grill (Amber Trail Lights) And one for the 20" mounted on the rear of the Gobi (Backup Light Bar)




Once I got the old covers off (which was a snap since they sent me a removal tool for FREE!!!) here is how my switch panel looks now during the day:




And here is a night shot:




I am SO excited to finally have these! The custom covers really complement the Bison's interior and they just look awesome! I had to get on their FB page and thank them with this simple pic




So for all you guys who would like the same type of cover, just shoot them an email or call asking for the WK covers. You can have the text say whatever you'd like
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  #1179  
Old 05-21-2013, 01:47 PM
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Re: Omelet's Build Thread!

Next up was the AEV EGR module. I have been running a modified SL now for over a year without the module. I got into the habit of hitting the ESP button upon startup every time. It was a simple thing to do and worked most of the time, however I was still getting ESP activation in some turns especially while breaking. It wasn't the end of the world, but I am trying to get the Bison to be as problem free and reliable as I can before leaving it in the hands of the wife for a while. So I decided to finally spend the money on the module. I placed an order throw Kolak (of course ) and once AEV finally got around to making it, the module showed up at my door.




I intend to activate the one touch flash feature, but haven't gotten around to doing it yet. For now I installed the module into the steering wiring, but have yet to use it to reprogram the Jeep for the one touch flash.






Now that I have had it installed for about a week I can say I do enjoy it. Not having to hit the ESP button is nice although I some times still hit it out of habit I have had the ESP still activate while driving around, but it's not as often as before and doesn't seem to be as severe. This should help the wife have a little more piece of mind!
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  #1180  
Old 05-21-2013, 01:48 PM
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Re: Omelet's Build Thread!

Oh yes I also put my JKS #2001 back onto the Jeep! They don't extend quite as far as the SL links, but they will do for now.






For those who don't know about these, the post gets screwed into the sway bar and then you drill out the aluminum piece in the other end large enough to get the factory top bolt through.

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  #1181  
Old 05-21-2013, 01:49 PM
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Re: Omelet's Build Thread!

(14 APR 2013)

I have been living with a horribly worn and disgusting steering wheel for the past couple of years now. So I finally decided to stop by an upholstery shop that I drive by every day on my way to work and back I chose a recycled leather that was as close to the factory wheel color as possible. I picked it up a day later and paid $95! It wasn't the best upholstery job I had ever seen, but for half the price most other guys were paying I like it.






Since I had already paid for a yard of leather, they also covered the center arm rest and only charged me $45.






The color isn't a perfect match to the factory sand color, but it will do for now. I still plan to get a set of SRT or S-Limited seats and have them reupholstered. I was planning on a saddle brown but I found a cocoa color that I think I like even more.




I figure if I get the seats, steering wheel, center arm rest, and E-brake handle covered in the cocoa leather, then it should all blend nicely with the tan/brown interior!
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  #1182  
Old 05-21-2013, 01:50 PM
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Re: Omelet's Build Thread!

So last weekend I had quite the ordeal when I was trying to swap over to my off road set of 35s. I went to remove my front passenger tire and one of the lug nuts wouldn't come off. Come to find out the lug was just spinning! So after trying a couple of simple tricks I came to the realization that I was going to have to drill it out. I was not very thrilled about doing this, but you have to do what you have to do. After quite some time and a couple of broken gits I finally got the nut off!!!






It wouldn't have been the end of the world since JK moabs are so cheap, but I was able to save the wheel from sustaining any damage.




I was so excited to have that over with! Luckily I have a couple of spare 1.25" spacers laying around for times like this. So I started loosening the nuts holding the spacer on when one of them didn't want to turn. I even tried heating it since they were installed with loc-tite, but it just wouldn't give. That's when the unfortunate thing happened, the socket spun and the nut rounded I boy was I mad! Now we were in a real pickle. Once getting a socket on it was a lost cause, I tried welding a socket to the nut but that didn't work. Then after debating any remaining options, we decided to get out the grinder and dremel and start removing the metal around the nut. I thought maybe if I had more space to weld that I could make that idea work better.




I guess my welding skills (or lack there of) with my little unit just weren't that great, because that didn't work either. So we decided to keep grinding until we could get some pliers on the nut and muscle it loose.




Then finally after grinding for far too long, we were able to get a pair of visegrips on it and break it loose!






I placed an order with Bora for a new set of 1" spacers, but in the mean time I installed one of the spare 1.25" ones I had. I had recently swapped out the cheaper lug nuts I had been running for a set of Gorilla nuts which could have been the issue, but I can't be sure. Unfortunately the Gorilla nuts are still on the rear, so we will see how that goes when the time comes to switch back to the 295s. I am now looking for a quality set of nuts that won't break the bank so I don't have to keep using my old one. I am just really hoping the rears come off without any issues.
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  #1183  
Old 05-21-2013, 01:55 PM
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Re: Omelet's Build Thread!

(25 APR 2013)

One of my 35s was looking a little weathered so I wanted to swap it out. I hunted around locally but only found ones from guys asking way too much ($700 each!!!). SO I started looking around else where and found a guy online selling two of them. I didn't really need two, but he gave me a great deal on the pair that I couldn't pass up. Unlike the last set of five I got these two are new! Once I got them I swapped out the one that was iffy and the next worse one.








Since these are new, you can see the difference in the grooving between it and the mud cut under it and then the dirt cut under that.







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  #1184  
Old 05-21-2013, 01:57 PM
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Re: Omelet's Build Thread!

(26 APR 2013)

So I have been wanting to do a type of side exit exhaust for some time now. I have been thinking up different ideas and seeing what others have done (mostly Baja/PreRunner rigs) trying to figure out exactly what and how I wanted to accomplish it. The main benefit to doing this is to move the tailpipe from under the bumper where I keep smashing it into the bumper every time I go wheeling. The other reasons are because I think it would look and work awesome and I haven't seen any one do it yet on a WK let along most Jeeps. I really liked how the Zone Comanche in the Ultimate Adventure turned out (I have always wanted to build one and I love what they did with this one) so my plan was to do something similar.




I also wanted to get a new longer resonator installed. So I figured I would swap out my old 3" x 8" reso for a new 3" x 12" reso while I was at it. First thing to do was to cut out the old one and get the new one in and see what kind of space I was dealing with.






The plan was to get it as high up as possible to accommodate further bumper mods later on. There is a pinch weld back there that I decided to cut and fold up to create more room and also a mounting point.






Now for the fun part! I had to figure out exactly where the pipe was going to be coming out at. Once I figured that out I masked the area off and found the center. Then I brought out the drill and the massive hole saw again






Oh boy! This time I used a 3.5" hole, figuring I was going to use a 3" pipe this would give me some wiggle room.




Oh look, the reso!




Now that I had the hole cut I needed a bezel. I used some aluminum I had laying around and cut the center hole using the same 3.5" saw, then made another circle 1" out from there at 5.5" and cut it with a jigsaw.




If you noticed the pipe will be coming out of the bumper along a crease, so I had to bend the bezel to match. I didn't want to just use my hands and bend it in half because the crease isn't a sharp angle, it's more of a gradual bend. So I decided to place the bezel between to 4x4s, grab one of my sledges, and using the wider side of the handle push down creating a gradual bend. After a couple of tries slowly bending it more and more, it was perfect and matched the crease in the bumper very nicely!




For the tip I used a section of 3" pipe that was made with a slip on end. The pipe it's self is 3" but one of the ends is about 3.25". So I decided to use the wider end as the tip. That would still give me a little room around the outside between the bezel. It would be tight but I didn't want a huge gap. Then because it would eventually turn black anyways, I painted to tip flat black.






Next up was to figure out the mount. I didn't want the tip wiggling around inside of the hole so I planned to use the pinch weld and bolt the tip to it for stability. I planned to use a type of band clamp to couple the tip ti the reso, so all I needed to do was to make a mount to go from the clamp to the PW.






Once the paint dried I mounted it up. Then all it needed was some fine tuning once the bezel was in place.







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  #1185  
Old 05-21-2013, 01:58 PM
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Re: Omelet's Build Thread!

Now for the finishing touch, the bezel! I lined up the bezel with the hole and marked off where I wanted to the rivets to be.




After using a center punch, drilling a pilot hole, and widening each hole for the size of the rivets it was good to go.




Now I am not very experienced with riveting so maybe it is the aluminum rivets or maybe I just suck at doing this, but I had 3 rivets that snapped the stem off at the end instead of inside the rivet like they are supposed to.




So I had to get out the dremel and cut them flush the use a small drill bit and counter sink them so they looked the same as the others. That turned out ok, maybe it is just my OCD (or CDO if you'd prefer it in alphabetical order )




After getting the bezel buttoned up, I just had to adjust the exhaust tip and tighten everything down. Now for the finished pics!!!












In the end it turned out pretty much how I was envisioning! It is up high enough for my future plans and out of harms way while wheeling. I will drive it around for the next few day and see if it settles at all, because I might need to adjust it a little. I am undecided on whether to leave the bezel unpainted or I might decide to take it off and paint it graphite to match other parts of the Jeep, then reinstall it leaving the rivets silver. I'm just not sure how well the paint will hold up to the heat. The other thing I might try to knock out it filling in the gap where the exhaust tip used to be with a painted piece of plastic so it doesn't stand out. I plan to trim the bumper when I get home so I will just end up cutting it back out, but if it annoys me enough within the next week I might just do it.

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  #1186  
Old 05-21-2013, 02:02 PM
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Re: Omelet's Build Thread!

(28 APR 2013)

Since I have already let the cat out of the bag on FB and I am not sure I will have time to finish this up before I leave, here is a little sneak peak into one of my new super secret mods...


I placed an order for a set of Rigid lights a while back not knowing they have never actually made any and that it would take so long for them to make a set for me. I received one of them in the mail on Fri so I started getting to it!




I ordered a set of SRM2 Amber Specter Diffused lights in black. These little guys put out just over 1000 lumens with a 60 degree beam and I bought them through Kolak for a killer price!














Now the plan is to use them in my headlamps in place of the forward facing amber running/signal light. Not that anyone around where I live knows what a blinker is or how to use one, but I feel like mine are not bright enough in certain conditions. I like to be visible while driving around, but I don't like to run my headlights all the time. Amber is such an easy color to see in every type of weather or light. I like using my D2s as running lights, but they are not strictly legal on the road to have on. Even though I see guys using them as fog lights all the time, I don't what my wife to get pulled over and have to explain why there are amber lights inside of my grill on! SO the plan is to paint these guys chrome and mount them in the headlamp like so...

Here is the supplied mounting hardware:




I installed the hardware with the mount facing to the rear as far behind the light as possible:




Removing the clear lens from the bottom pocket where the amber light is, you will see the main hole that the bulb comes in through and one just above it:






I ran the wire through the top hole and installing the light up-side-down inserting the mounting bolt through the main rear hole:




Then I grabbed a fender washer I had laying around and used the supplied nut to mount the light firmly in the housing:










That is as far as I have gone so far, but once they are painted chrome they will blend right in. And they fit great!!! I have been researching chrome paint, since all the local stores sell is a silver paint with a chrome flake. That doesn't really cut it as it look ok, but it is NOT chrome and doesn't allow the light to blend in perfectly with the chrome reflector. I am leaning towards Paz Stix Mirror Chrome, but we will see Once this is done I am also planning on buying and painting a white LED set and using them in the taillights to replace the 7W Cree bulbs I have back there
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  #1187  
Old 05-21-2013, 02:18 PM
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Re: Omelet's Build Thread!

Well I think that is about it for now. I started a couple things before I left so I will have to get those finnished up once I get home. But for now at least we are up to date
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  #1188  
Old 05-22-2013, 06:40 AM
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Re: Omelet's Build Thread!

Wow, that is one impressive update mate. Thought you had run out of things to update on this, but you proved me wrong.
How are you off for compression length on the new longer rear shocks seeing they look around 1.5" longer at full compression?
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