Jeep Wrangler TJ - AEV Brute Conversion

With the rear cab section removed, we hoisted the body off the frame so we could access the frame area where we'll cut and add the extension. The fuel and brake lines that secure to the driver-side framerail were also removed. AEV provides extended brake and fuel lines with the kit.

With the cutting jigs clamped in place, Mel drilled holes for the self-tapping screws that will hold the jigs in place for marking, cutting, and welding. The jigs will also help align the frame extensions side to side. Note that the rear-suspension control arms were also removed from the Rubicon Express crossmember. We'll relocate the rear control-arm mounts using RE brackets in part three of the buildup.

With the cutting jigs removed, we scribed a cut line along the sides and top of the framerails to ensure that the cuts would be straight around the perimeters of the framerails.

When we were happy with our cut line, we used a Sawzall to cut both framerails.

With the framerails cut, the front half and rear half of the TJ were separated.

We cut the cab mounts from the forward frame section. The mounts will be repositioned and welded back on to support the cab closeout assembly.

Mel welded the frame sleeves in place in the forward frame openings. AEV also supplies sleeves for the rear frame openings.

The 24-inch frame extension was fitted in place over the sleeves, and the front and rear halves were joined.

Before welding the extensions in place, Mel measured both sides of the vehicle to make sure they were consistent and on par with the figure AEV indicated in its detailed instructions.

The cutting jigs were then bolted back in place to snug the halves together and hold them in place. After final measurements to ensure all was happy, Mel used a tack-weld to hold the extensions in place.

After the jigs were removed, Mel applied the final welds, making multiple passes to ensure ample penetration.

After the seams were fully welded and ground flat, the provided fish plates were secured to the inside of the framerails and stitch-welded in place to help reinforce the extension area.

Mel cleaned up the pork chop to receive the cab closeout assembly, particularly where we'll apply spot-welds for the cab closeout attachment. We also used a body hammer to reshape the areas tweaked while removing the rear cab section.

The cab closeout was easily fitted over the pork chops and aligned with the guide holes at the top of the waterfall. The door strikers were installed to help determine proper placement and hold the closeout in place.

Mel measured across the cab at the door openings at multiple locations to make sure the figures were consistent with those noted before cutting the cab sides. We'll continue the buildup of our Brute conversion in next month's issue. The entire series will also be posted on www.4wdandsportutility.com.