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Finishing up Overkill's Rear

Willys Prerunner
Posted October 14 2007 07:10 PM by Christian Hazel 
Filed under: Custom Jeep Projects, Jeep Enthusiast Culture, Christian Hazel

Just when I though all the tough stuff was done I discover the way I designed the rear really brought the suck. 


overkillpre2

Nah, I couldn't just go straight to the top of the framerail.  I had to be fancy and go through it to the rear bumper brace.  Not crazy hard, but when you're fighting for seconds here and there to work on junk a mildly complicated thing like this sucks precious time.  I started by shooting a 1-3/4-inch hole in the top of the framerail and oblonging it out with a carbide bit so the tube could go through at an angle.

overkillpre3

After bending a couple lengths of 0.120 wall DOM I notched the bottom to fit the bumper brace.

overkillpre4

With the bars in position I marked and measured where the upper end of the rear braces needed to be cut and notched.  It took a little while to get everything even and tight, but I finally got 'em burned in to the rest of the rear cage.  Down below the braces are welded both to the rear bumper braces and the top of the framerails.

overkillpre5

Finally, I finished up the rest of the framerail reinforcement triangulation.  The back end of this sucker is super rigid to say the least.  Now I can build the fuel cell mount and figure where I'm going to put the spare tire.  Then I'll build battery boxes and cargo areas.  I still don't know if I'll run a tailgate on this thing or not.  I like the look of a spare tire hanging out the back and it frees up a lot of space, but it just won't fit in my garage if I hang the spare out the back.  Tune in for more updates as they happen.

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