AEV Brute Conversion - Part 3: Cut and Weld to Completion

With a straightedge along the length of the bed mounts, Mel measured from the straightedge to the center crossmember to determine consistency side-to-side. We performed multiple measurements repeatedly before welding anything.

With the forward bed mounts still only tacked, we set the bed atop the mounts with 1-inch body spacers in place to match the cab height. The built-in bed crossmembers offer threaded holes for bed attachment.

When we were pleased with the fitment of the bed, Mel completed the finish-welding to the forward bed mounts and the rear frame assembly. He made multiple passes over the weld bead to ensure good penetration.

We were somewhat concerned that our Poly Performance rear coilover suspension conversion would interfere with the mounting of the bed assembly, but it proved to be only a slight issue. Though we were able to reroute the line to the remote reservoir, we will likely change out the fittings so the line can run under the bed instead of sticking into the wheelwell.

With everything welded up, we still took a lot of time making sure the bed was straight from all angles and that the bed lines matched the cab lines. Even after all of our measurements, we still shimmed one corner of the bed at the mount to achieve the most even fit.

We attached a straightedge to the framerail and measured the distance up to the cab mounts to ensure all four mounts were accurately placed. Once we liked their position, they were welded to the frame.

The Brute kit accepts the factory fuel tank, but we decided to increase capacity by installing a 19.5-gallon Crawler Extreme fuel tank from Gen-Right. Like all Gen-Right fuel tanks, the Crawler Extreme tank is constructed from 1/8-inch-thick aluminum alloy and is installed in a heavy-duty, 3/16-inch-thick, foam-lined skidplate. The tank is secured using stainless steel straps, and it features factory Mopar rollover valves and an internal baffle design to reduce fuel movement within the tank and keep it near the pickup. The tank also accepts the stock Jeep fuel pump, fuel sensor, and related components.