Our yellow Jeep Brute conversion...
Our yellow Jeep Brute conversion is nearly complete. Here, it's shown before the paint and bodywork, with the bed assembly and fiberglass half-cab top in place. The completed Brute project will be featured in the Oct. '07 issue of 4WD&SU.
The installation of AEV's Brute conversion kit on our yellow Project TJ is well under way. Off Road Evolution owner Mel Wade and his crew attacked the project at full speed in order to meet our two-week deadline, and as the drop-dead date rapidly neared it was looking more and more like we'd be on the road to Moab for the Easter Jeep Safari right on schedule.
In last month's installment of the AEV Brute conversion, we lengthened the frame 24 inches using the company's frame-extension kit and were preparing to join the new cab closeout assembly to the forward body section. For this month's coverage of the buildup, we finished welding up the cab closeout, installed the rear frame extension, and mounted the new bed assembly. Once all of the components were in place, we readied the vehicle for paint and bodywork and hauled it to 1 Day Paint & Body in Downey, California. Check out the photos and captions for the nitty-gritty, and check back next month as we reveal our Project Yellow Brute in its finished form.
With the stock rear body section...
With the stock rear body section removed, all that remained was the factory rollbar hoop with the inner body pork chops where the door-striker plates secure. Before the cab-closeout assembly was fitted in place, Mel sanded all of the surfaces where welds would be applied.
Before we mated the closeout...
Before we mated the closeout to the forward body section, we drilled holes along the edge of the closeout so spot-welds could be applied to secure it to the stock body section.
The cab-closeout assembly...
The cab-closeout assembly was fitted in place and located over the pork chops using the door-striker plates.
Mel also drilled holes in...
Mel also drilled holes in the cab sides so they could be joined by spot-welding each side to the provided cab-side backing plates
The doors were test-fitted...
The doors were test-fitted on the cab, and Mel adjusted the strikers as needed to create the best fit.
The J-rails we removed from...
The J-rails we removed from the rear tub section were cut to fit the closeout assembly and then welded in place and ground flush so we could fit the top.