Author Topic: AEV Gladiator Rubicon (Read 24081 times)

Flyin6 · « **Reply #450 on:** March 02, 2023, 02:18:51 PM »

Then came its big brother. Bye-Bye!

Flyin6 · « **Reply #451 on:** March 02, 2023, 02:20:23 PM »

Look at the room I now have to work with:

Flyin6 · « **Reply #452 on:** March 04, 2023, 04:12:25 PM »

Big news on the weight savings

I weighed stuff on a new electronic scale I just picked up.

Jack 8.7 It remains
rear seat small 35.2
Rear seat lg 54.1
small kit for top 12 oz
Seat bolts 1.0
Floor mats 4.1

Total weight savings = 95.2 lbs

Flyin6 · « **Reply #453 on:** March 04, 2023, 04:13:20 PM »

And here is a sketch denoting height differences between the AEV 2.5" and the Clayton 3.5":

Flyin6 · « **Reply #454 on:** March 04, 2023, 04:14:44 PM »

I pulled the seats. Next I removed the jack and this little kit used to store the top when it is off.

Flyin6 · « **Reply #455 on:** March 04, 2023, 04:16:16 PM »

I noticed a lot more noise without that rear seat, so I laid down some dynamat to quiet things back down:

Flyin6 · « **Reply #456 on:** March 04, 2023, 04:17:57 PM »

I do not want to drill a single hole if I don't need to. I needed some front mounts for the new flat floor, so I decided to just build off the four aft seat mounts.

Flyin6 · « **Reply #457 on:** March 04, 2023, 04:19:07 PM »

Then I decided I needed to mock-up the rear floor tray. I used some cardboard and got after it:

Flyin6 · « **Reply #458 on:** March 04, 2023, 04:21:12 PM »

That template got better and better with each fitting.

Next, I built up the two driver's side mounts from angle aluminum, riveting successive pieces together.

Flyin6 · « **Reply #459 on:** March 04, 2023, 04:23:28 PM »

The on to the passenger side. The pass side was different since the mounts are well recessed inside the seat overhang. I simply built an extension, angling it to follow the drop of the factory floor.

Flyin6 · « **Reply #460 on:** March 04, 2023, 04:24:35 PM »

Things were looking good so far. The new cargo floor fitted well

Flyin6 · « **Reply #461 on:** March 04, 2023, 04:26:44 PM »

Right next to where the rear seat bolted down on either side was a hole the exact perfect size to drop in a 1/4" nut-sert. This will now serve as the rear floor mount.

Flyin6 · « **Reply #462 on:** March 04, 2023, 04:32:48 PM »

With that done, It was off to the wood shop to build the new cargo(dog) floor.
The 4 x 4, 1/2" thick Baltic birch panel I selected was a bit too short. So after a bunch of measuring and fitting, I added a short section to the side to bring it out to full size.

With that done, I called it a day. Time to get ready for date night with a really pretty girl!

Bigdave_185 · « **Reply #463 on:** March 04, 2023, 05:13:18 PM »

Did the Duramax sell?

Flyin6 · « **Reply #464 on:** March 04, 2023, 08:51:36 PM »

Quote from: Bigdave_185 on March 04, 2023, 05:13:18 PM

Did the Duramax sell?

Not yet

Flyin6 · « **Reply #465 on:** March 05, 2023, 04:52:11 PM »

With the plywood glue cured, I did some more trimming to make it fit even better, then carefully drilled four holes through the panel into the mounts I had created earlier. I temporarily used screws to hold it in place

Flyin6 · « **Reply #466 on:** March 05, 2023, 04:53:11 PM »

Then I drilled the platform to 1/4" and the mounting pads to fit 1/4" Nutserts

Flyin6 · « **Reply #467 on:** March 05, 2023, 04:55:32 PM »

I took the panel over to my wood shop and cut out panels to access below. I used a track saw, but while I was pushing along the table suddenly moved causing me to mis-cut. I later repaired that with body filler.

Flyin6 · « **Reply #468 on:** March 05, 2023, 04:56:46 PM »

I glued some ribbing onto the bottom side then a flange for the doors to rest upon

Flyin6 · « **Reply #469 on:** March 05, 2023, 04:58:16 PM »

I then added some additional ribbing since this will be supporting the weight of a 130 lb dog, then added another ply over all the glue joints

JR · « **Reply #470 on:** March 05, 2023, 05:38:28 PM »

Back at it again, great. I even got notified of the new post!

That storage will come in handy. What about a jump seat back there just in case?

Flyin6 · « **Reply #471 on:** March 05, 2023, 08:06:19 PM »

Quote from: JR on March 05, 2023, 05:38:28 PM

Back at it again, great. I even got notified of the new post!

That storage will come in handy. What about a jump seat back there just in case?

So, you're saying tap talk is now working for you?
We made some changes to help improve TT functionality already.

JR · « **Reply #472 on:** March 05, 2023, 08:09:35 PM »

TT seems to be linking me up OK, was referring to regular site.

Flyin6 · « **Reply #473 on:** March 05, 2023, 10:23:16 PM »

Quote from: JR on March 05, 2023, 08:09:35 PM

TT seems to be linking me up OK, was referring to regular site.

Changes were made today. I need more input to see if we can home in on where the problem may be. I think it's in security. You have to run it at a higher level because of all the spam attacks these days, like over a thousand a day just here!

cj7ox · « **Reply #474 on:** March 06, 2023, 11:37:06 AM »

So, you saved 95lbs by removing stuff. How much does all the wood and aluminum you're installing weigh?

Flyin6 · « **Reply #475 on:** March 06, 2023, 01:35:18 PM »

Quote from: cj7ox on March 06, 2023, 11:37:06 AM

So, you saved 95lbs by removing stuff. How much does all the wood and aluminum you're installing weigh?

I haven't weighed it all yet, but I think it is going to come in-between 5 to 10 lbs.

Edit after finishing the project: Wow was I wrong...

Flyin6 · « **Reply #476 on:** March 06, 2023, 05:34:21 PM »

I thought I was going to finish this little project tonight, but when I checked the coating around 1600, I found a couple of "Light" areas, so I had to mix up some more Raptor and get after it again.

Out of the glue clamping, the parts looked good

Flyin6 · « **Reply #477 on:** March 06, 2023, 05:35:49 PM »

With a simple wipe down, I hung it and sprayed a whole bottle of Raptor liner on both sides and the lids too.

Flyin6 · « **Reply #478 on:** March 06, 2023, 05:37:01 PM »

That^^^^ had light spots where the coverage was not so good, so out came another bottle and I sprayed it all again.

Flyin6 · « **Reply #479 on:** March 06, 2023, 05:39:10 PM »

I may use some blocks to level it all up, or I may leave it with a slight tilt forward, haven't decided yet. I did get a good test and I can slide my seat back so far I can't reach the pedals with the floor installed, so that checks out.

And the cause for all this is just laying around wondering why all the fuss.

JR · « **Reply #480 on:** March 06, 2023, 06:14:21 PM »

Will you carpet it for the dogs?

Flyin6 · « **Reply #481 on:** March 06, 2023, 09:37:15 PM »

Quote from: JR on March 06, 2023, 06:14:21 PM

Will you carpet it for the dogs?

No...Dirt magnet.
When I carry dogs, I will install one of those dog hammock/isolation barrier things then toss a dog bed on top of that

Flyin6 · « **Reply #482 on:** March 07, 2023, 05:00:41 PM »

So I weighed it before installation. It came in at 19.6 which surprised me, I figured it for 10 lbs less.
That hardware was 1.4 for t tie-downs X 4 = 5.6
The dynamat was right at 6 lbs.

so the total weight for the cargo floor and sound deadening is 31.2 lbs

so I actually removed 63.8 lbs. from the truck. Not what I had hoped for, but I'll take it.

The truth will come in at the scales. I can now weigh it to see where it sits as a shell, mission-ready W/O cargo.

Flyin6 · « **Reply #483 on:** March 07, 2023, 05:02:24 PM »

I decided to add tie-downs so if I do add a cooler or something back there in lieu of a big dog, I have a means of securing it. I used threaded inserts for all attachment points.

Flyin6 · « **Reply #484 on:** March 07, 2023, 05:03:32 PM »

I temporarily held the jack down with a bungee cord.

Flyin6 · « **Reply #485 on:** March 07, 2023, 05:04:21 PM »

And here's some angles of the floor installed

Flyin6 · « **Reply #486 on:** March 07, 2023, 05:06:00 PM »

And with the cargo

Poor guy looks like I am taking him to the vet. He does not like going there!

JR · « **Reply #487 on:** March 08, 2023, 01:02:32 AM »

He just needs something to lay on.

Bigdave_185 · « **Reply #488 on:** March 08, 2023, 07:35:58 AM »

That fluffy face!

Sent from my iPhone using Tapatalk

oklawall · « **Reply #489 on:** March 08, 2023, 09:20:32 AM »

One of our two if you even start walking in the direction of my truck he runs over and sits by the door so he can go for a ride

Sent from my SM-N975U using Tapatalk

Flyin6 · « **Reply #490 on:** March 08, 2023, 09:24:11 AM »

Quote from: JR on March 08, 2023, 01:02:32 AM

He just needs something to lay on.

Yes...

I used these isolation carriers in the past, so one of those plus a dog bed on top.

Dogs want to stand up and look around a lot. But I have found that they can fall over easily and that could lead to injuries. I like them to lay down and just poke their heads out when going through the Micky-D's drive-through when I get quoffee. Funny but all the curvy roads around here tend to make them sick, so they end up laying down anyway!

Flyin6 · « **Reply #491 on:** March 08, 2023, 09:24:52 AM »

Quote from: oklawall on March 08, 2023, 09:20:32 AM

One of our two if you even start walking in the direction of my truck he runs over and sits by the door so he can go for a ride

Sent from my SM-N975U using Tapatalk

Same-same here...With all three!

Flyin6 · « **Reply #492 on:** March 08, 2023, 04:38:11 PM »

Today I installed the Mopar (Factory) brake controller.

This JT is rated to tow up to and over (in some cases) 7,000 lbs. That's double what the JL or JLU can tow, so this thing is a contender!

Well, sort of...If it only had some power...

The box is full of stuff. It's a straight-up install if you are factory equipped to tow. If not, I'd just avoid this mod. If you weren't factory equipped you are going to be running wires all the way to the back end and cutting into the factory harness.

Flyin6 · « **Reply #493 on:** March 08, 2023, 04:45:44 PM »

First I removed the top environmental and control panel.

It just snaps out so with gentle prying with the nylon prybars I had it out in 10 seconds.

Flyin6 · « **Reply #494 on:** March 08, 2023, 04:48:29 PM »

Next up I removed the panel right below. It snaps out after you remove a single screw

Flyin6 · « **Reply #495 on:** March 08, 2023, 04:50:16 PM »

Once that is removed, disconnect every connection until that unit is free.

Flyin6 · « **Reply #496 on:** March 08, 2023, 04:51:28 PM »

Keep gong you're not finished yet!

Flyin6 · « **Reply #497 on:** March 08, 2023, 04:53:23 PM »

At this point, that cluster of switches is free and set out of the way. Finally, remove the plastic trim piece located below the steering wheel.

Flyin6 · « **Reply #498 on:** March 08, 2023, 04:54:49 PM »

Now working with the free switch panel, I removed the factory 12 volt power receptacle because that is where the brake controller will be fitted.

Flyin6 · « **Reply #499 on:** March 08, 2023, 04:58:23 PM »

The MOPAR instructions are terrible. Just a series of pictures you are supposed to interpret. I had to resort to YouTube to figure out what Mopar people who, apparently cannot write, were trying to have me do.

So pretty much by experimentation and a bunch of test fitting I finally had my new switch mounted.