CJ windshield frame, Crusty style

CrustyJeep · Jun 27, 2006

OK I finally got around to starting on a from-scratch windshield frame for the crusty old CJ. The requirements for this thing are:

1) Tree proof forward and reverse, and able to withstand at least a mild roll.
2) Have actual glass, because it needs...
3) Windshield wipers.
4) Must resemble a stock CJ frame.
5) Oh and, it must not look ghetto

I decided to go with a bolt in unit, meaning it will use the stock windshield hinge mount thingies. It will be bolted hard to the cage in at least three locations. The plan is to have the glass installed with modern windshield glue, not a rubber gasket.

I decided to use a chunk of box tube for the bottom piece, and a chunk of 1.5"x.120" DOM for the top and sides, bent to vaguely match the cage.

A trip to the local steel yard got me a piece of 2"x4"x.120" box tube. Four inches is too tall, and three would be too short... So I'll have to rip the bottom 3/4" or so off and the reinforce it a bit.

CrustyJeep · Jun 27, 2006

After a few hours of measuring and cutting, basically copying the (remains of) the old stock frame, I got the wiper hardware installed and working

The oval access holes are one inch longer than stock. Because the box tube has a smaller inside depth than the stock frame, I needed longer access holes to allow the wiper tie rod to slide into place. That means I can't use the stock plastic plugs. Big whoop

TreeClimber · Jun 30, 2006

CrustyJeep said:
A trip to the local steel yard got me a piece of 2"x4"x.120" box tube. Four inches is too tall, and three would be too short... So I'll have to rip the bottom 3/4" or so off and the reinforce it a bit.

Glen,

It really looks like a neat concept, and I think it'll be sweet when done. Why is the "three would be too short" statement.... The pics look like you could actually shave an inch off, but you state "rip the bottom 3/4".... Are you really that tight on the last 1/4 inch?

2nd question, is that since you've already assembled this, and are going to trim it down on the bottom, are you going to bevel the bottom edge so that it tilts the windshield back, or are you planning on welding the 'glass cage' at an angle?

The reason is I like the idea enough that I've actually thought of doing this also.

Tony

CrustyJeep · Jul 1, 2006

TreeClimber said:
2nd question, is that since you've already assembled this, and are going to trim it down on the bottom, are you going to bevel the bottom edge so that it tilts the windshield back...?

Yes, exactly. 25 degrees inclination is what I have in mind. I forsee a bit of wrestling with the band saw to get a rip fence (or whatever the hell you'd call it on an upright band saw) setup

So without having made the final measurements yet, I think the rear side of the box will be less than three inches high, but the front will be taller. I'm going to cut it as low as possible without causing problems with the wiper stuff.

CrustyJeep · Jul 5, 2006

Not much gets done when you get to go wheeling instead

Today I ripped some of the bottom of the frame off. This could have been done with a straight edge and a plasma, but I don't have plasma, so band saw it is.

This lightened it up considerably, but also took away a lot of rigidity. I will need to add some material back in to give it back some of its box shape and strength.

Hip · Aug 8, 2006

CrustyJeep said:
Please don't :rb: up my design by sticking it on your heep :flipoff:

Man I can see I will have to make some pretty heavy threats to hopefully get this thread CLEANED OUT, JON:flipoff:

or finish the darn thing and post pics... did i tell you i fully tested mine a few weeks ago. tested sat.

CrustyJeep · Aug 9, 2006

I have no plans for any sort of standard top. I may toss a piece of aluminum up there, or talk Mary into sewing a custom bikini top.

CrustyJeep · Sep 18, 2006

OMFG I worked on the windshield frame :redneck:

The frame itself has taken shape. After a few passes in the bender, I got the bends just right to snap right into the frame bottom. I got it mounted and tabs installed. The tabs on the sides are right in the area where most of the tree contact happens, so the force of rubbing a tree should be transfered directly to the cage with very little deflection in the frame itself. The tab on the top keeps it from flexing side to side. Four bolts, and the frame can swing down like normal.

Bends done, ready to get trimmed and welded to the frame bottom...

The welding about half done, mounted, and tabs installed.

TreeClimber · Sep 18, 2006

Looking pretty good Glenn.

What'd you plate the bottom of the rectangular tube with?
Plans for glass/lexan installation?

CrustyJeep · Sep 18, 2006

TreeClimber said:
What'd you plate the bottom of the rectangular tube with?
Plans for glass/lexan installation?

It's open on the bottom, with five or six small pieces of 1/8" strap to kindof hold it all together.

I've changed my mind on glass installation, I now plan to put it in with a gasket like stock. I will weld in a flange (1/2" wide I guess?) and have a glass place cut a custom windshield and install it for me, with a custom gasket. It will be glass, and the wipers will work

Hip · Sep 19, 2006

CrustyJeep said:
It's open on the bottom, with five or six small pieces of 1/8" strap to kindof hold it all together.

I've changed my mind on glass installation, I now plan to put it in with a gasket like stock. I will weld in a flange (1/2" wide I guess?) and have a glass place cut a custom windshield and install it for me, with a custom gasket. It will be glass, and the wipers will work

i was able to use the stock gasket i just removed a little to make it fit the new smaller glass.

lookin good glen.

CrustyJeep · Sep 29, 2006

More progress

I finally got the windshield flange done and the finish work done. It's ready to get blasted, sealed, primed, and then it goes to the glass shop for custom glass. Then the wipers go in and I get to wheel the piss out of it

The corner pieces going in. I cut these out of 1/8" plate on the band saw. The rest of the flange is made of 1/8" x 3/4" strap. The entire flange is stitch welded in (except the bottom corners, I continuous welded them for strength), so I will have to use a body sealer to keep the water from *pouring* around the flange. I inset it by 1/2" from the outer surface, about the same as the stock frame.

The hot nasty work with grinders and welder finally done, ready for bead blasting and sealer. I am really tired of windshield frames right now :haha:

boxboy · Sep 29, 2006

Hey look at you! you got off your ass and did something :Good:

So who are you getting to blast and seal it?

CrustyJeep · Sep 29, 2006

boxboy said:
So who are you getting to blast and seal it?

Me :flipoff:

My brother's super duper dry air system + my crappy HF media blaster = tasty goodness

The only thing I won't attempt myself is the glass work.

TreeClimber · Sep 29, 2006

Glen,
Have you thought about powder coating it instead? Buddy of mine has been doin' some on his stuff, and it's not that spendy.
T

CrustyJeep · Sep 29, 2006

TreeClimber said:
Have you thought about powder coating it instead? Buddy of mine has been doin' some on his stuff, and it's not that spendy.

Powder coat is awesome, right up until you rub it off on a tree. I can touch up primer or paint, but not powder coat. I refuse to use it for pretty much anything on this POS.

This is what I bought to seal the gasket lip. What would happen to this stuff in a PC oven?

TreeClimber · Sep 29, 2006

CrustyJeep said:
This is what I bought to seal the gasket lip. What would happen to this stuff in a PC oven?
http://multimedia.mmm.com/mws/mediawebserver.dyn?6666660Zjcf6lVs6EVs66Sbmpc7rrrrQ-

And I'd talk to your windshield supplier. They use a black 'goop' to bond in most newer windshields (unlike the rubber gasket you've got) that is incredibly strong. I'd consider just bonding the glass into place, with enough 'goop' to also seal that gap.

CrustyJeep · Sep 29, 2006

TreeClimber said:
And I'd talk to your windshield supplier. They use a black 'goop' to bond in most newer windshields (unlike the rubber gasket you've got) that is incredibly strong. I'd consider just bonding the glass into place, with enough 'goop' to also seal that gap.

That was my first plan, but I have since become paranoid that bonding the glass would make it too "structural", and I don't think a piece of glass would fair too well against hard rubbage or a roll when the frame flexes.

OTOH, Hip's windshield floats in a gasket and he has real world proof that it can withstand a roll, even with rocks involved

Brian H · Sep 29, 2006

CrustyJeep said:
That was my first plan, but I have since become paranoid that bonding the glass would make it too "structural", and I don't think a piece of glass would fair too well against hard rubbage or a roll when the frame flexes.

OTOH, Hip's windshield floats in a gasket and he has real world proof that it can withstand a roll, even with rocks involved

I would like to see this real word proof.

Hip · Sep 29, 2006

yep i cant seem to post the picture...

rolled hard onto the lid at the big rock at walker valley. landed on the front clip/hood and the top of the windshield frame. i closed my eyes cause i was sure the glass would get busted and i just put it in about two weeks before. took it like a champ.

http://www.nw-wheelers.com/forum/showthread.php?t=112&page=3&highlight=rollover

there is a picture in this thread