Comanche Pre-runner Build

[Tan Comanche]

This is the last plate for the cab. Done.



Gnarly and slightly absurd desert shackles are welded and plated. Along with a bastard pack of six leaves.



Model 20 truss...legit.

More to come!

 

[Tan Comanche]

The truss is welded up and installed. The limit straps are tacked in. The lower shock mounts are "there". was short some 3/8's tabs so it will be finalized next week after a run to midnight 4x4.



This is a pic of the spring plates I used. The metric ton model 20 axle tubes are big enough (~2.75") that I robbed these plates off a 14 bolt and they fit without modification.



This is a teaser of the upper shock mounts. You'll see the rest next week.







Now for some tech. I know this tread has t been very in-depth for tech mostly because everything has been a one-off, but that should change as some of the major fab work comes to a close.

This is the disk brake swap I did for the 20. It utilizes ZJ rotors (5 on 4.5), front calipers from a 73-84, 1/2 ton, Chevy 4x4 and a custom bracket which I plasma'ed. It was surprisingly simple to make and quite compact; it fits in aluminum 15" wheels. With an in-cab portioning valve I think it will provide pleasing results.

 

[ChrisO]

Awesome build. Love the fab work, Atta boy!

 

[Tan Comanche]

Thanks chrisO and others for the positive feedback!

It was a big night...



Lower shock mounts finalized.



Disk brake brackets were burned in. You can also see the shape of the bracket in the pic.



Rear upper shock mounts are done! The triple bypasses are in position as well. Here is a couple of different shots of the mounts.

 

[Bart]

Lots of progress. Nice welds.

 

[Tan Comanche]

Burned in the bump cans and swaybar.



This isn't a very good picture but it's a roller!! This is at full droop on both ends. It is cycling 17" front and rear, at the straps. Had to modify some of the link brackets, due to binding, when the coilovers were in. The motor is being finalize right now and will likely be shoehorned in in two weeks. Till then...

 

[Tan Comanche]

Time for an update!



Nerf bars have four ribs that go down to a lower "subframe". The rockers were cut out and this is tacked in every couple of inches. The plan is to have a disposable piece that extends out further from this nerf bar running parallel with it.



Here is another shot of the substructure.



The B pillar goes through the floor and attaches to this rib, which is tied in in multiple places.



The A pillars is a similar story. Here you can see the A pillar coming through the floor and to a cross rib, which is welded to the unibody/nerf bar and then has another support that runs down the the crossmember.



Here is another angle of the crossmember. There are three bolts per side holding the x-member in. On the back side there is the lower tube substructure that has two bolt flanges on it to allow for extra support and removal of the x-member.



Another pic. It should take a good beating.

 

[Tan Comanche]

Bump cans for the rear were decided upon. The section of frame Comanche frames are pretty strong so it was notched for the can and tacked in.

I still need to do some plating behind the bumps because the model 20 disk calipers were contacting the frame at full bump. So it was clearanced for them.



Another pic.

 

[ChrisO]

Lookin' good! When finished, what are you gonna do with it (other then have serious fun?), race it (BORE?) or ???

 

[Tan Comanche]

Lookin' good! When finished, what are you gonna do with it (other then have serious fun?), race it (BORE?) or ???

Well...I don't know what is going to happen, I'd love to see the car in a series. It has been overbuilt to handle racing conditions. To race it would need an additional door bar in the cage to meet spec. Aside from that, it should pass.

The car is going back to the customer and his plans are to have a multipurpose desert machine. It has to be able to haul two dirt bikes, camping gear, tools, dog, etc. and get there FAST! I'm running out of real estate for everything.

 

[BuzzyB]

I think I know what I'll do with this fantastic build Matt is orchestrating......Hold it WFO and steer!

 

[Tan Comanche]

Today was a day to button up a bunch of odds and ends. All the plating was welded up.



It is kind of hard to see but the frame is boxed in and the bump cans are burned in. There should be ample clearance for the disk calipers now.



He is a different angle of it. It is recessed an inch from the edge of the frame. Then welded to the bump can and the frame. It strengthened that section nicely.

Motor is being finalized this week and shoehorned in next week. Till then...

 

[deepthinker]

It looks great!

 

[Tan Comanche]

The heart of the beast is finally installed! It is a Chevy 4.3L bored .040 over, RV cam, flat-top pistons, etc. It is mated to a 700R4 with Kevlar bands, corvette servos and 'the works'. The motor mounts are cut out of 1/4" plate and burned into the frame where it was reinforced.







Rear mounts sits right on top of the crossmember in a poly bushing.



This is what it looks like from the underside.



This is a picture looking down the panhard bar toward the frame-side mount. It fits right between the oil pan and the pulley; has a 3/4" clearance at full bump. This should allow for some adjustment in the link length and castor.

 

[ChrisO]

I like it! Being 2WD, approx. how long will the rear drive shaft be? (Much longer than if a T-case was hanging off the back!) Keep postin', I love this build!
I found this pic on the interweb a few years back. It too is ultra cool!

 

[Tan Comanche]

I appreciate the good feedback ChrisO!

The driveline is exactly 60" from center to center. I don't anticipate any binding throughout the whole cycle with that kind of length. The plan is to run a slip yoke. At ride height the axle pinion is pointed down 1* and the transmission output is up 1* degree.



Tonight I worked on the exhaust...but ran out of parts. Should be finished up next week. I'll post up then.

 

[Tan Comanche]

It has been awhile since I posted. A lot has even done recently...



Exhaust is finished up, bathed in high-temp black and wrapped for literal and figurative coolness.



Summit sells really neat 2 into 1 pipes. Super clean and easy. Suggested.



Side exit exhaust, a must when running with a back window.

 

[Tan Comanche]

Quick release steering wheel is in.


The splined section was welded onto a 1/2 ID x .120 piece of DOM and then the whole assembly was tig'ed onto the jeep steering shaft.



Also cut out this adjustable bracket to support the steering column. It allows for an inch of horizontal and vertical movement...not a lot ,but just enough to fine tune the steering position.

 

[Tan Comanche]

Nerf bars are finalized. Note the grippy tread, it comes in 4' lengths for ladders. Cut it to length and slide it over 1.25 DOM...flawless fit.



Got the light bar and roof rack put together. I'll let the pics do the talking.







This is how it sits as of last night.

 

[ChrisO]

Great idea. I like the quick release wheel on the stock column. Keeps the electrical simple. Also, the adjustments, nice touch. Keep the posts coming, good job!