2021 JLU @horst_jlu BUILD

[srbadenhorst]

Hey guys,

So thought I'd start a thread on my build for my personal 2021 Jeep JLU.

I am a South African Mechanical Engineer based in the UAE who has access to some awesome tools which allows me to build my own stuff. I also happen to have an open innovation centre across the road from me which has a CNC mill, lathe, and a bunch of other lekker tools which I plan to learn to use and utilize. Having all the resources accessible to me I thought I may as well start using them.

I needed something to start building for and as I have a large interest in cars and working in the industry for several years, I went that route. I researched various vehicles available to me in the UAE the Jeep JLU seemed to be the best option with regards to ease of parts to manufacture. Jeep really did well to make designers lives a bit easier and it is also a very popular brand if I plan on selling some stuff at a later stage.

I am crammed on time so will post updates when ever I get a gap.

Ideas and input would be appreciated.

Cheers

@horst_jlu

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[srbadenhorst]

The base.....

2021 Jeep Wrangler JLU Sport.

Jeep came with the following:

Teraflex 2.5” lift kit
Falcon SP2 2.1 shocks
KMC Wheels 17” XD series wheels
BFG KO2 35” tires

Bonnet decal and spare wheel cover were removed immediately

 

[srbadenhorst]

Initially I thought that SEMA garage had access to JLU CAD files but turns out only up until 2017 models. Luckily I had a FARO arm available to do some scanning. First time using one of these and took a bit of trial and error but got it right.

Black cloud looks like a mess but it saves so much time when designing.

 

[srbadenhorst]

First thing I decided to build is a rear drawer system, give the JLU more organized space for tools and camping gear.

I had a general idea of what I wanted and worked towards that. 2 drawers 150mm high, 400mm wide and 600mm deep, enough space to get larger items stored away and utilize the depth of rear. A loadable platform with options to mount tie downs (I carry toolboxes which slide all over, strapping essential). Additional storage just behind the rear seat for the jacks and wheel spanners, won't be using the rear tub as I have other plans for the space.

My biggest thing was I wanted it to look pretty "stock", fit the vehicle tightly and look "factory".

This is what I came up with.

I mounted the drawers directly to the floor with cross members in the rear, keeping the carpet in (I find it looks a bit neater) and added a loading platform on top with anchor point cut outs to use standard cargo rings. The whole unit fits nice and tight with the interior panels.

Everything is made from 1100 3mm aluminium.

 

[ExpeditionBuilds]

First thing I decided to build is a rear drawer system, give the JLU more organized space for tools and camping gear.

I had a general idea of what I wanted and worked towards that. 2 drawers 150mm high, 400mm wide and 600mm deep, enough space to get larger items stored away and utilize the depth of rear. A loadable platform with options to mount tie downs (I carry toolboxes which slide all over, strapping essential). Additional storage just behind the rear seat for the jacks and wheel spanners, won't be using the rear tub as I have other plans for the space.

My biggest thing was I wanted it to look pretty "stock", fit the vehicle tightly and look "factory".

This is what I came up with.

I mounted the drawers directly to the floor with cross members in the rear, keeping the carpet in (I find it looks a bit neater) and added a loading platform on top with anchor point cut outs to use standard cargo rings. The whole unit fits nice and tight with the interior panels.

Everything is made from 1100 3mm aluminium.

Nice work Shannon!

https://www.youtube.com/channel/UC5HJ5REOo6XbFuakJem6TTw


-Steven

 

[srbadenhorst]

Next up, rear cargo shelf.

I went with the tube and sheet metal design. Shelf utilizes the same cut outs for the cargo rings as the drawer system and added a laser cut 3mm neoprene top to reduce noise and movement when it is loaded.

Keeping the white colour to fit the car.

 

[srbadenhorst]

A tail gate table was next on the cards.....

I like the use of a Molle panel and zero cables so I worked around that.

Mounting to the OEM tail gate, needed to change out one of the original M8 bolts to get enough thread to use a M8 nut.

Finished up and installed. Went with the stainless top, will go with a wooden version at some stage, I like the look.

I used "quick latches" for locking and stainless shoulder bolts for hinging.

 

[mushroomax]

Wow, that neoprene trick on the rear cargo rack is a brilliant idea. How much weight do you think the rear tailgate table will hold by avoiding the "traditional" cable route? Admiring your design and craftsmanship for sure.

 

[srbadenhorst]

Wow, that neoprene trick on the rear cargo rack is a brilliant idea. How much weight do you think the rear tailgate table will hold by avoiding the "traditional" cable route? Admiring your design and craftsmanship for sure.

Well the fasteners would have to pull out of the tailgate mounting points before the table would give way for sure. I do get a bit of flex in the main panel when pressure is applied, nothing a gusset in the rear wouldn't fix. A lot easier to install than the cables in my opinion, neater look too.

 

[srbadenhorst]

I have a long trip planned through Saudi Arabia and need extra fuel and water storage. I went the Rotopax route to fix both problems.

I decided to mount the fuel/water cans to the outside like I have seen on some other vehicles, awesome way to save space inside or on a roof rack.

 

[srbadenhorst]

For added storage and somewhere to mount some lights I decided to go ahead with a roof rack. I mainly like the look of the setup and thought if I have 4 people in the car for a trip the added storage would work out well. I've bought 6x 7 inch spot lights that will be mounted up front. The 2 outer lights are adjustable left/right/up/down and the 4 center adjustable up/down.

Fabrication pics, parts gone into powder for black grit coating.

 

[mushroomax]

That fixture table is money. How are steel prices over there?

Great work as always

 

[srbadenhorst]

That fixture table is money. How are steel prices over there?

Great work as always

I pay the equivalent of $120 for a sheet of 3MM - 2.4M x 1.2M 1100 series aluminium, if that's anything to compare to. Tubing I actually bring in from South Africa as there is no one here that bends it properly and it costs me a ton. It's a nightmare.

 

[srbadenhorst]

Roof rack and lights mounted....

Can still get the freedom panels on and off which I was worried about. Next up I need to wire everything up.

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