Go Back   Jeep Garage - Jeep Forum > Jeep Platform Discussion > Grand Cherokee - WK > Technical Tips/DIY/How-To

Join Jeep Garage Today
Reply
 
Thread Tools Display Modes
 
  #1  
Old 09-13-2012, 02:16 PM
Member
 
Join Date: Aug 2012
Posts: 11
Thanks: 0
Thanked 0 Times in 0 Posts
Rep Power: 725
tahoelabdad is on a distinguished road
Garage
Under body shield-Filling the gap between radiator and swaybar

The project didn't take very long, only about 4 hours total.

As mentioned in an earlier post, the need to do this was due to there being so much space between the radiator and engine which allowed snow/mud/muck to get up and into the electric cooling fan which shortened the life of the motor (especially with the 3.7)

After replacing the fan twice, I thought it time to do something about it.

Initially, I thought a simple shield would suffice, so I used a piece of aluminum and bolted it in:


However, while doing this, I realized there's still a lot of space on the sides, so I thought I'd fab up a full shield. I chose to keep the aluminum piece in and built around it, but this can be done on its own.

The material used:
1- sheet of 1/8" foam insulation
2- packages of fiberglass cloth
1- can resin/catalyst
1- pack mini rollers (and handle)
1- can acetone for clean-up



Not pictured:
Painters Tape
3M adhesive spray
Thin cardboard
Masking Tape
RTV Sealant
Paint Brushes
Spray Paint
Sandpaper

I started by measuring and cutting the foam to fit in the space and used file folder cardboard to make the sides of the form, and covered it with painters tape:


I measured and cut 2 pieces of the fiberglass cloth to fit, and sprayed one of it and the form with adhesive. Note that the adhesive shouldn't be put on too thick to allow the finished piece to be removed more easily. I taped the egdes of the cloth to keep it from sagging with the resin.


Not pictured: I cut out the cloth around the front air-dam mounting tabs and filled it with small patches of cloth off the Jeep.

Using the mini rollers, I applied the catalyzed resin to saturate the cloth. I allowed the first coat to cure to tacky and applied a second layer of cloth followed by another coat of resin.
I put on 2 more coats of resin and allowed it to cure overnight.

I removed the fiberglass piece, cleaned all of the tape off it and the Jeep and started finishing it:


I put 2 more layers of cloth/resin on and an additional 2 coats of resin.

Once it was all cured, I put a light scuff on with 400 grit sandpaper and painted it using Krylon Satin Black.

I put a thin bead of black silicone RTV sealant around the front edge and sides and using the bolts holding the air-dam (and the piece I installed earlier) I bolted it into place.

Here's the final unit installed:




From above:



It should be noted that in my case, I used the aluminum plate previously installed to hold the unit in place. I used metal strapping to make clamps that loosely wrapped the sway bar, which could also be applied to the unit on its own.
The sides are not firmly mounted, but are adhered with the RTV. If I had a smaller Dremel or angled drill, I would have screwed it into the sheet-metal, but it's mounting is pretty substantial.

I also drilled a couple holes in the front of the piece to allow for drainage should any water still get up inside.

I built this over two days and spent a total of 4 hours on the build (not including cure times) and actually drove around with the uncured unit for a bit!

I'm not concerned about the final appearance, but if so desired, the unit could be finished with body putty for a smoother finish, but that seemed like too much work for something that only me and my mechanic are going to see!

I spent $25.00 total on it.

Let me know your thoughts and questions!
__________________

__________________
Reply With Quote
  #2  
Old 09-13-2012, 03:04 PM
SvenskaJeepGuy's Avatar
Let's Roll
My Jeep: 2005 4.7L WK
 
Join Date: Dec 2009
Location: Scranton PA
Posts: 13,083
Thanks: 139
Thanked 162 Times in 152 Posts
Rep Power: 1255316
SvenskaJeepGuy has a reputation beyond reputeSvenskaJeepGuy has a reputation beyond reputeSvenskaJeepGuy has a reputation beyond reputeSvenskaJeepGuy has a reputation beyond reputeSvenskaJeepGuy has a reputation beyond reputeSvenskaJeepGuy has a reputation beyond reputeSvenskaJeepGuy has a reputation beyond reputeSvenskaJeepGuy has a reputation beyond reputeSvenskaJeepGuy has a reputation beyond reputeSvenskaJeepGuy has a reputation beyond reputeSvenskaJeepGuy has a reputation beyond repute
Garage
Re: Under body shield-Filling the gap between radiator and swaybar

nice work!
__________________

__________________
Reply With Quote
  #3  
Old 09-13-2012, 04:52 PM
suzieque's Avatar
Senior Member
My Jeep: 2008 3.0L WK
 
Join Date: Jul 2009
Location: Canada
Posts: 1,224
Thanks: 0
Thanked 9 Times in 9 Posts
Rep Power: 3085
suzieque is a name known to all
Re: Under body shield-Filling the gap between radiator and swaybar

my wk has a stock plastic shield between the radiator support and sway bar. did your stock piece get removed?
__________________
2008 WK "S" Limited bright metallic silver, 5 speed W5J400 transmission, June 18/2008 build, 213RE rear differential with 3.73 axle ratio, 245/60R18 Goodyear Fortera tires, NV245 transfer case, 3.0L CRD.
Reply With Quote
  #4  
Old 09-13-2012, 06:00 PM
Member
 
Join Date: Aug 2012
Posts: 11
Thanks: 0
Thanked 0 Times in 0 Posts
Rep Power: 725
tahoelabdad is on a distinguished road
Garage
Re: Under body shield-Filling the gap between radiator and swaybar

Our WK came from Enterprise Car Rental and was as bone stock as could be! We bought it in '08 with only 2200 miles on it for less than $10K so it was a bargain. I have more time than money right now, so building things like the shield was kind of fun.
I looked through the Mopar lists and aftermarket but couldn't find an existing piece, so decided to build my own.
__________________
Reply With Quote
  #5  
Old 09-13-2012, 09:55 PM
suzieque's Avatar
Senior Member
My Jeep: 2008 3.0L WK
 
Join Date: Jul 2009
Location: Canada
Posts: 1,224
Thanks: 0
Thanked 9 Times in 9 Posts
Rep Power: 3085
suzieque is a name known to all
Re: Under body shield-Filling the gap between radiator and swaybar

Quote:
Originally Posted by tahoelabdad View Post
Our WK came from Enterprise Car Rental and was as bone stock as could be! We bought it in '08 with only 2200 miles on it for less than $10K so it was a bargain. I have more time than money right now, so building things like the shield was kind of fun.
I looked through the Mopar lists and aftermarket but couldn't find an existing piece, so decided to build my own.
That's cool, some serious off readers don't like the stock plastic shield and put in a metal piece, that is what I assumed at first that you were doing.
__________________
2008 WK "S" Limited bright metallic silver, 5 speed W5J400 transmission, June 18/2008 build, 213RE rear differential with 3.73 axle ratio, 245/60R18 Goodyear Fortera tires, NV245 transfer case, 3.0L CRD.
Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Similar Threads
Thread Thread Starter Forum Replies Last Post
Catch can filling too fast ? Snow4Lif3 Troubleshooting/Problems 7 11-04-2012 10:55 PM
Filling gap between radiator & motor tahoelabdad Technical Tips/DIY/How-To 4 09-13-2012 03:16 PM
V6 Intake Shield? ajs800 Engine Performance/Intakes/Exhausts 8 01-18-2012 08:26 AM
GAP Insurance rustyosaurus Grand Cherokee - WK2 - 19 01-06-2012 11:01 AM
Air suspension filling question jp467 Trouble Shooting/Problems/Service 1 04-20-2011 05:00 PM

Powered by vBadvanced CMPS v3.2.3

All times are GMT -5. The time now is 09:27 AM.


Powered by vBulletin® Version 3.8.8 Beta 4
Copyright ©2000 - 2014, vBulletin Solutions, Inc.
Copyright 2012 - JeepGarage.Org
The Jeep Grand Cherokee Owners Community