Dave's "S200KYS" Jimny 'laner Build...

mlines wrote: Dave,

I assume the cage is connected to the bumper which is connected to the chassis. In which case you need to watch out for body movement hitting the cage. The Jimny body moves a lot on its rubbers, I speak from the experience of mysterious banging noises from the car over rough ground (body hitting cage).

Rubber domestic door stop put to better use!

Hmmm, never thought of that... will do now though... door stops... another trip to B&Q then?

Thanks Dave.

Thanks for sharing Dave, always good to see those build pics that most of us forget until the job's done ...

Oooh, why's my build thread gone yella and pinned then?

Jimny-Dave wrote: Oooh, why's my build thread gone yella and pinned then?

Looks like you've been 'stuck' Dave ..... ..

Wednesday - my "day off in the week"... Well, most of the day!, I got into the shop at 6am and setup ready for opening at 7am, worked 'til 10am and then had time off until 3pm before I walk our dogs, shower and get back into the Post Office to relieve the missus at 4pm, so that left me 5 hours to crack on... my mate Alan arrived at ten to give me a hand too...



I started by welding some nuts to some washers...



And these then go on the bars that drop onto the rear bumper...



Tacked centrally in place...



And then welded round...



And then I drilled pilot holes through the joins in the two sections of the roof bars...



...and then drilled them out to 10.5mm, separted the two sections and drilled the inner holes big enough to take large 10mm nuts...



...and then welded them in...



... damn!, I got a blob of weld in the other side and had to lever it out with a big screwdriver, and then re-tapped the thread to make sure all the weld blob had gone...



With the two sections then bolted together we then again lifted the roof bars into place, and started planning the feet to attach it to the roof... some big washers and an offcut of tube with the profile on the end to match up to the roof bars was decided upon, but it then meant...



... painstakingly profiling the big thick washer to match the roofline! That took some time and lots of test-fitting to get them both matched to the roof's bodyline as above...



But that then gives us the lines I was after... Note the rear tubes to the bumper are temorarily (?) resting on poly bushes... I have bought some exhaust bobbins to go in this position, but we thought we might swap to the same bushes but in black, with a bolt coming up through from under the bumper and up into the end of the tube where the nuts were previously welded in...



So, there's the foot formed, it just needs welding up (which it has been, but it needs grinding and sanding to perfction before photos are shown!), and that will be drilled through, to...



... the inside of this very handy hole and grommet blank that Suzuki provided, so that the fastening will be hidden - eventually - behind this grommet...

More soon, but we're greenlaning in the Peak District / Derbyshire this weekend, so no progress then!...

Dave

Bit more today... managed to sneak out of the shop / Post Office for a few hours in the morning...

Won't bore you with loads of photos (for a change! ), so here's a summary... (all the photos are in my blog if you do want to see the step-by-step)...



All grinded and sanded ready for powder-coating, although the front windscreen mounts need fabricating first...

And I've made the waffle board mounts -



The back mounts are simple L-Shaped brackets that the waffle boards locate over and then push forward/under the bracket, and...



... locate over a simple bolt and spacer piece the same width as one of the square holes, and then a big washer and (stainless) wing-nut hold them in place...

Might seem the wrong way round to mount them, but...



I wanted them so that the could easily be lifted at the front to fold the soft-top roof to sit under the waffle boards which will provide some protection for the fabric roof...

I also drilled through the centre mounts ready for the bolts -



That will allow the mounts -



... to bolt through the B-pillar, where the serrated 3" washer will sit on a big rubber 'washer'.

Just got to get it back on the Jimny again (tomorrow?) and work out the front windscreen mounts...

Impressive Dave!

For the front mounts would they mount on a tab bolted to the bar that goes over the door window frame just under the lip of the front soft top ?

Gary

Yes, somewhere there...

I feel some cardboard templates coming on?

Just ordered some 80mm rubber washers off eBay for sitting between those feet and the B-pillar...

Finished the roof rails today!

Started by getting the rails back on again -



You can see there how the waffle boards cover the vinyl front roof section to protect it from trees...



After Gary pointed out that if I put brackets down to the windscreen's A-pillar, anything I hit might transmit forces down and crack the windscreen (Thanks Gary! :kiss: ), I decided to move the brackets back and secrete the under the vinyl roof -



There, when the soft-top is down you can hardly see the front brackets!

With it back on, if you look carefully, you can see it's strapped on, and has been taken and dropped off for powdercoating... and, as luck would have it, the job they were supposed to be doing tomorrow hasn't turned up, so I've hopefully jumped the queue and should get it back nice and quick!...



Will look quite subtle when it comes back in satin black?
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clever design Dave

look forward to seeing the finished pictures