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  #1  
Old 12-14-2009
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Number7 Number7 is offline
(George)
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Jeep WJ On-Board Air/Dual Battery Mounting Frame
Kristoffer needed to figure out how to mount dual batteries and an air tank in the spare tire well of his WJ along with an access panel to the gas-tank sending unit. Diane and I needed some major work done on our computer, so we swapped projects.

I started by fitting pieces of 3/4" plywood opposite each other in the wheel-well.


I glued the plywood down with elastomeric roof putty. Notice where I used tin-snips to cut a hole for access to the gas tank sending unit. This will be the foundation for the steel mounting frame.


This is the dual-battery / air tank mounting frame starting to take shape:


Two of these babies are going in:



Starting to fit the mounting frame into the wheel well:



Completed mounting frame fitted into the wheel well:


Tabs were welded to the frame corners and then screwed into the sides of the wheel well.


More . . .
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George & Diane
'00 TJ 2.5L LowOutput w/5 spd.
4" Teraflex Longarm w/ 33" MT's
4:88 Gears / Super 35 Rear
Dana 30 Front w/ Warn Hubs
TeraLow 4:1 T-Case
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Last edited by Number7; 12-14-2009 at 07:00 PM.
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Old 12-14-2009
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Default Re: WJ On-Board Air/Dual Battery Mounting Frame
I used webbing material and elastomeric roof coating to seal the wheel well and form an access opening for the sending unit:





All the sides are formed, and a thin piece of sheet metal is placed over the sending unit to be used as an access hatch:


I webbed and coated over the access hatch; a knife will need to be used if access is required:


Several coats of elastomeric roof coating were applied to seal out exhaust fumes and the elements. The coating also made everything completely rattle-proof!


Now thekdude has a great mounting place for his air tank and dual batteries. Kris will continue the project from here.

George
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George & Diane
'00 TJ 2.5L LowOutput w/5 spd.
4" Teraflex Longarm w/ 33" MT's
4:88 Gears / Super 35 Rear
Dana 30 Front w/ Warn Hubs
TeraLow 4:1 T-Case
OX Lockers


Every Dog Has His Day!
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Old 12-14-2009
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(Kristoffer) (K1KRS)
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Default Re: WJ On-Board Air/Dual Battery Mounting Frame
thanks again George, it came out great!

i'll post up plenty more info on the project once i get back into it after the holidays!

i have the compressors, air tank, 1 battery, all my air fittings/lines/etc, battery cables and connectors, and i just got a few of these guys to help routing the big battery cables: http://www.offroadtrailtools.com/sho...t_detail&p=295

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Old 02-12-2010
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theksmith theksmith is offline
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Default Re: WJ On-Board Air/Dual Battery Mounting Frame
full writeup for the dual batteries and on-board-air is over here: http://www.offroadpassport.com/forum...read.php?t=427
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Old 09-02-2013
ultimo ultimo is offline
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Default Re: WJ On-Board Air/Dual Battery Mounting Frame
Hi this is my first post I would like to make the same holes above for the fuel pump access and also the holes on the side where the wires come in/ go out.

How can I get started

1) How do I acertain where exactly the pumps and lines are? How not get a hole going without hitting the tank or snipping the wires accidently?

2) For the holes where the wires come and go, is there anything behind there I might drill into?

Thanks for you help.

JT
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Old 09-03-2013
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Default Re: WJ On-Board Air/Dual Battery Mounting Frame
Look at the first post and pic 1 and 2 show the location of the fuel pump. Use a cutting wheel on a 4 inch grinder to get started and then use a good pair of tin snips. DO not drill! George
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George & Diane
'00 TJ 2.5L LowOutput w/5 spd.
4" Teraflex Longarm w/ 33" MT's
4:88 Gears / Super 35 Rear
Dana 30 Front w/ Warn Hubs
TeraLow 4:1 T-Case
OX Lockers


Every Dog Has His Day!
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Old 09-03-2013
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Default Re: WJ On-Board Air/Dual Battery Mounting Frame
Originally Posted by ultimo View Post
2) For the holes where the wires come and go, is there anything behind there I might drill into?
i'm guessing you mean for my dual battery part? i used the vertical indentations in the tub area as a reference, i actually came a little close to some of the evap and fuel lines, so do be careful. best thing to use in situations like this is a step-bit aka uni-bit so you only push through 1/4" or so on the first small hole and don't go flying into something farther behind where you are drilling, you can get a cheap version of them at harbor freight.

as G said, don't drill down though towards the tank though - usa a dremel or small air cutoff, or carefull grinder action.
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Old 09-03-2013
ultimo ultimo is offline
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Default Re: WJ On-Board Air/Dual Battery Mounting Frame
Thanks....! Not sure if I dare to drill down if there is so many ??s behind Will try the uni-bit option though...
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