Dave's la(te)st buggy build...

I then carried on...



Wheel off and supported with an axle stand, to get to the rear of the cab...



Some more CAD (Cardboard Aided Design! :laugh: ) with a Corn Flakes box (other breakfast cereal boxes are available! )



Holesawed a hole for the rear bed tube and slipped the template into place...



And then went right the way round banging the cardboard with a rubber mallet...? :blink:



So that I can see the groove, that's the shape I need!



Cut it out with "Manly Stanley" (Yup, most of the tools have names!) :lol:



And test fit our cardboard template...



Then pop that on top of the half piece of rectangular box section and draw round it... remembering that we need to cut and fold INSIDE the line so that it will fit into the rear of the body tub...



Like that...!



The bottom piece cut and trimmed to suit also...



Clamp, Weld, Hammer, Clamp, drink tea, repeat...



And we eventually end up with



Yup, happy enough with that...



Stand back and admire the matching sides...... and home for a shower and a Stella (together of course)... and tea and an evening with the fam'...Content in the knowledge that the other half of the rectangular box section is waiting to be trimmed and coerced into fitting into the top of the half door on Wednesday... :woohoo:

Like everything else once you've done it once it becomes significantly easier the second time round.

Lambert wrote: Like everything else once you've done it once it becomes significantly easier the second time round.

EXACTLY!

Started on the passenger door today -



The other half of the 4"x2" box section carefully measured, shaped and "bent" to the correct angles...



Some accurate measuring there if I do say myself :woohoo:



I was so happy with the fit and placement that I tacked it in place...

And then realised the welding gas was running out, so I went and fetched another bottle ready for Sunday



I returned with a new gas bottle and clamped the inside ready for Sunday too...

So just a half day today as I had other things to do, and it's "quite quiet" Wednesday as our eldest daughter is still with us working from home in my study above the garage...

More noise on Sunday though! Welding, grinding and sanding that door 'til I'm happy with it

The rocklobster side project now has it's own thread here

Meanwhile, this afternoon a carrier brought me these from JimnyBits -



TrailGear 26 spline front HD shafts!

Hmmm, this started out as a cheap and simple buggy build, whereby I took a Jimny with a basic suspension lift and big tyres with VVT diffs fitted to compensate for the new 29" tyre size... and changed the body to look like a buggy that I've been trying to build for years...

But, when recently tidying the store room in the shop, I cam across my LSD (limited slip differential) sitting on a shelf with it's sheared-off bearing carrier on the side... I had asked a well known Jimny gearing expert who can't be mentioned on this fine forum if he could fix it, but he said no So I put a shout out on facebook with photos of the damage to see if anyone else knew anyone that might be able to fix it... I then got a private message from a friend saying he knew of an expert welder / machinist that would be willing to have a look at it, and after seeing it, they think they can weld it and then machine it so that the bearing mount can indeed be salvaged...

So, with the LSD being a 26 spline unit, and probably requiring stronger shafts... enter Russ at JimnyBits to supply some TG HD shafts that will be up to the job, if and when the LSD comes back from repair from a friend-of-a-friend...

So... fingers crossed!

So the simple buggy may eventually go to having a rear lunchbox locker and rear TG HD shafts (already fitted), the rocklobster transfer box (seperate side project linked above) and a front LSD with 26 spline TG HD shafts in the front too!

I'll keep you updated,..

Hmmm... I'm mentioned previously that I'd like something to go here -



To hold ropes and my quick-link tree strop next to the spare wheel, and was thinking of a wire basket...?

I've just spotted this on another thread on here -



A fake Jerry Can with a hinged top!!!

I'll have a measure and see if that would fit, that would look ace if it will!!!