Aussie Gray Rubicon

[Byrnesy]

Well lets just say this isn't my first rodeo. But I didn't think I would be doing a build just twelve months after I started my last.

Likely the same with our American cousins the used car market Down Under went bat shit crazy the last twelve months with COVID. And after seeing a lot of change, with many people loosing their employment and businesses I considered myself lucky to work on through the hurt. I see know that my decision to get back into the Power Generation Industry 15 years ago has paid off handsomely. But I am not so smug as to take that for granted and after buying and building my dream truck I had a opportunity to move it on and lower my debt by $15000 and still be able to get into a brand new Gladiator Rubicon.

I bought one of the early ASV converted RAM1500 Laramie and had kitted out with a RSI Canopy, a custom built fridge slide and single draw, dual battery system, 35s a two inch lift and what is likely the best full Performance Exhaust system in the world for the 5.7lt Hemi in the Rams ,a Beaudesert Exhausts Performance System. After a Dyno tune, with 35s fitted it was turning out 287 rear wheel horsepower, up from 234 and peak torque going from 668Nm to 746Nm. But the big difference was the torque off the line from 0kmh going from 188Nm to 550Nm.

So it was no small task selling the RAM that cruised with ease towing 1.5 tonnes to step back to the Gladiator. Not to mention scarring the shit out of a few boy racers off the traffic lights from time to time.

I test drove one and was pleasantly surprised at the leap years of refinement in the Gladiator over my 2010 CRD JKU. And the Pentastar and auto worked well together. So the decision was made, a deposit placed, the planning and research began.

The plan was to pare back this build in comparison to the RAM and make the absolute most of the the 700kg load of the Gladiator here in Australia.

I guess I should say that my main uses of this and all my fourbies is accessing public and private lands for hunting, now with my eight year old son and overlanding. Check out here for his first 'successful hunt with Dad.

My first concern with the Gladiator was internal comfort having come from the RAM and having owned a JKU. hence right after I made the deposit I ordered the Hotheads Headliners Premium kit with Sound Assassin for the Gladiator.

I fitted this on New Years eve. And WOW the cab is so much quieter, the sound from the stereo much improved. And with the most humid summer on the east coast of New South Wales I can remember in my 51 laps of the sun, the insulation property of the liner is massive with the AC on auto cutting right back after about 6 minutes of operation. Likely one of the best after market options for a Jeep.

Given the dealer 'rape' charges for aftermarket accessory I have had a Hayman Reese Towbar fitted along with a Redarc Tow Pro Elite by a place that has tinted my windows and been in operation for over thirty years, a still family run business called Altapac. Who have recently moved into the 4WD accessory fitting business. Great service and workmanship. For the American readers to give a perspective on cost it was $2199AU to tint the front two windows with the best matching color tint and apply a clear UV cut film over the rear five windows already tinted. Plus supply and fit the tow bar and the RedArc brake controller.

Ill continue on with my plans in a day or two.

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[Sazabi19]

Welcome and nice to see someone from down under. It'll be nice to see a different perspective coming from your neck of the woods. It's nice to hear that the truck is large enough inside to fit you guys and your gravity belts. Also, your toilets spin the wrong way :P

 

[Byrnesy]

Given the lower load mass on the Gladiator, Down Under, and the increasing indications that various state police will likely start road side weighing 4WDs under the guise of 'compliance' but more likely from revenue raising driven by our nanny state elected politicians and then combine that with how quickly accessory weights add up I am taking a super hard look at the mass of anything I add to Aussie Grey.

The first requirement was a canopy. Three options Alu-Cab, RLD and RSi. All great looking products but the weight. anywhere from approx 140 pounds to towards 200 pounds, ball park 90 odd Kg.
And I guess I should outline why a canopy. Well it provides a large volume of weatherproof storage, a extra degree of security (although nothing is impenetrable from the determined arsehole) and when hunting direct out of my vehicle with my son he has a dry place to sleep with a sense of security.

This was was the biggest and most frustrating decision with heaps of research and phone calls and some great points made by members here. Then I switched tack.

What if I used my trade skills and built a aluminum canopy frame infilled with security door mesh and covered with canvas or the like? So, sketching a design and looking at materiel masses I was looking at about 28Kg to 32kg or 60 to 70 pounds complete. We will see how that ends up.

This depended on two factors; me getting a Spool Gun for my MIG and be able to weld the stuff , and my tube bender being able to effectively bend the 1" OD tube.

A length of tube later and I was committed.

The photos are up till last night the 18th of January.

TBC and thanks for the interest.

 

[Mac Attack]

Given the lower load mass on the Gladiator, Down Under, and the increasing indications that various state police will likely start road side weighing 4WDs under the guise of 'compliance' but more likely from revenue raising driven by our nanny state elected politicians and then combine that with how quickly accessory weights add up I am taking a super hard look at the mass of anything I add to Aussie Grey.

The first requirement was a canopy. Three options Alu-Cab, RLD and RSi. All great looking products but the weight. anywhere from approx 140 pounds to towards 200 pounds, ball park 90 odd Kg.
And I guess I should outline why a canopy. Well it provides a large volume of weatherproof storage, a extra degree of security (although nothing is impenetrable from the determined arsehole) and when hunting direct out of my vehicle with my son he has a dry place to sleep with a sense of security.

This was was the biggest and most frustrating decision with heaps of research and phone calls and some great points made by members here. Then I switched tack.

What if I used my trade skills and built a aluminum canopy frame infilled with security door mesh and covered with canvas or the like? So, sketching a design and looking at materiel masses I was looking at about 28Kg to 32kg or 60 to 70 pounds complete. We will see how that ends up.

This depended on two factors; me getting a Spool Gun for my MIG and be able to weld the stuff , and my tube bender being able to effectively bend the 1" OD tube.

A length of tube later and I was committed.

The photos are up till last night the 18th of January.

TBC and thanks for the interest.

Given the lower load mass on the Gladiator, Down Under, and the increasing indications that various state police will likely start road side weighing 4WDs under the guise of 'compliance' but more likely from revenue raising driven by our nanny state elected politicians and then combine that with how quickly accessory weights add up I am taking a super hard look at the mass of anything I add to Aussie Grey.

The first requirement was a canopy. Three options Alu-Cab, RLD and RSi. All great looking products but the weight. anywhere from approx 140 pounds to towards 200 pounds, ball park 90 odd Kg.
And I guess I should outline why a canopy. Well it provides a large volume of weatherproof storage, a extra degree of security (although nothing is impenetrable from the determined arsehole) and when hunting direct out of my vehicle with my son he has a dry place to sleep with a sense of security.

This was was the biggest and most frustrating decision with heaps of research and phone calls and some great points made by members here. Then I switched tack.

What if I used my trade skills and built a aluminum canopy frame infilled with security door mesh and covered with canvas or the like? So, sketching a design and looking at materiel masses I was looking at about 28Kg to 32kg or 60 to 70 pounds complete. We will see how that ends up.

This depended on two factors; me getting a Spool Gun for my MIG and be able to weld the stuff , and my tube bender being able to effectively bend the 1" OD tube.

A length of tube later and I was committed.

The photos are up till last night the 18th of January.

TBC and thanks for the interest.

Looks good...I think. Knowing that you follow the Southern Cross and we follow the North Star, sometimes things can appear to be ass-backwards or back-asswards...depending upon how you view the world, in either case anyone that eats Vegemite and thinks its good...well, you don't know good food or you're just hard...Welcome Aboard, Bubba.

 

[Byrnesy]

Thanks Mac Attack. Not a huge lover of Vegemite but every now and then a light spread on hot buttered toast is the bomb.

Talking of the Southern Cross Im trying to find someone, Etsy or elsewhere that can do a JT Fuel Flap decal of the Eureka Stockade Flag or the Gadsden Flag.

 

[pixeldecals]

Talking of the Southern Cross Im trying to find someone, Etsy or elsewhere that can do a JT Fuel Flap decal of the Eureka Stockade Flag or the Gadsden Flag.

I can help you with that for sure!

 

[Byrnesy]

Earlier on in the week I had time to fit the front bumper.

I don't know what its like in ole US of A but it is almost impossible out here to find the weights of accessories listed on manufacturers websites. So ask and you are met with 'Oh I don't know, we don't get asked that much .'

Just goes to show how one of the young blokes at work ended up with his very lightly modified Toyota Landcruiser Prado , (dual battery, fridge and slide, single draw and ARB steel Bull bar with brush rails) weighing in at 2.96 Metric Tonnes. Surprised the crap out of him.Luckily he purchased a 3.5T GVM upgrade per-registration.

This bar I have to thank a very good mate for his suggestion, Offroad Animal.

The quality of this bar is very good, simple to install and the factory fog light even suited the supplied brackets. I'll likely replace the factory foggies later.

For everyone's info, and yes apparently Offroad Animal is availble in the USA (one owner is American) I removed 16kg of plastic and steel and installed 25Kg of new bar, bolts and brakets.

 

[Byrnesy]

I can help you with that for sure!

Let me know what you need. Maybe we take this to PMs and discuss.

Happy to support a Forum member.

 

[Sazabi19]

At least here in the U.S. on most sites I've seen show the weight of parts, especially bumpers and the like that are heavier. That's weird that it's not really a thing for you guys. You'd think they'd know at least the shipping weight to give you a rough idea of worst case scenario.

 

[Byrnesy]

At least here in the U.S. on most sites I've seen show the weight of parts, especially bumpers and the like that are heavier. That's weird that it's not really a thing for you guys. You'd think they'd know at least the shipping weight to give you a rough idea of worst case scenario.

A few show shipping weights.

 

[Byrnesy]

Latest update...

Well, just to give readers a 'view' of what COVID related issues are like Down Under I was essentially left with no choice to get the COVID vax. I will state that I was not a anti-vaxer but was hestiatant given the rapid development, approvals and introductions. I would have likely had it in in twelve to eighteen months given I do want to travel internationally and it would possibly required in those destinations. And that time frame would have given more time to shed light on efficacy and side-effects.

But my employer had other ideas. And the job I have, a Power Plant Operator is extremely well paid, and very rewarding given the great crew I work with. And it simply could not be replaced with another as there isn't anything like it. Their stance was " We are not forcing you to have it but you cant come on site unless you are vaccinated" freaking sniveling corporate weasel words. It s a bit hard to operate two 720MW Coal Fired Turbo-Generators from the home office.

So mid January I had the first Astra shot and that laid me flat for three days.
Nine days later I come down with CoVID and loose another three.

It was now a race to get the canopy cage finished as I was booked into to have the cover done on Monday just [passed, which I re-scheduled due to isolation requirements till today. Which is pushed out till tomorrow because of a blow out in his work load.

So with two massive days in the shed cutting, grinding and MIG welding in 34 deg C and about 90% RH its been tough. I hate the humidity.

But the delay has been a benefit as I have been able to finish it off properly, less the gas struts on the rear door, and do a few additions for another idea I had on the canopy roof. More to come on that.

This is the first aluminum welding I have done since I completed Welding Training at Technical College in 1994 and that was TIG. Well I have come to the conclusion MIG welding Aluminium is the most difficult of all welding. Some of it wasn't the prettiest and a bit of post weld grinding was required. But structurally it is much stringer than I imagined, I can stand on the top center of it with very little flex.

Overall Im very happy with the results thus far with the total weight of the cage , uncovered coming in at 28.5Kg or a shade under 63 lb.

During last week my front mud flaps from RokBlokz turned up. A great product but they weren't straight forward to fit. And that is not Rok Blokz fault. The Rubicons in Australia have the same slider as the US but don't have the high line front guard. Something that I may have overlooked, though not sure on that. Any way great result in the end.

Early start tomorrow so here's some images.

TFR

 

[Mac Attack]

Latest update...

Well, just to give readers a 'view' of what COVID related issues are like Down Under I was essentially left with no choice to get the COVID vax. I will state that I was not a anti-vaxer but was hestiatant given the rapid development, approvals and introductions. I would have likely had it in in twelve to eighteen months given I do want to travel internationally and it would possibly required in those destinations. And that time frame would have given more time to shed light on efficacy and side-effects.

But my employer had other ideas. And the job I have, a Power Plant Operator is extremely well paid, and very rewarding given the great crew I work with. And it simply could not be replaced with another as there isn't anything like it. Their stance was " We are not forcing you to have it but you cant come on site unless you are vaccinated" freaking sniveling corporate weasel words. It s a bit hard to operate two 720MW Coal Fired Turbo-Generators from the home office.

So mid January I had the first Astra shot and that laid me flat for three days.
Nine days later I come down with CoVID and loose another three.

It was now a race to get the canopy cage finished as I was booked into to have the cover done on Monday just [passed, which I re-scheduled due to isolation requirements till today. Which is pushed out till tomorrow because of a blow out in his work load.

So with two massive days in the shed cutting, grinding and MIG welding in 34 deg C and about 90% RH its been tough. I hate the humidity.

But the delay has been a benefit as I have been able to finish it off properly, less the gas struts on the rear door, and do a few additions for another idea I had on the canopy roof. More to come on that.

This is the first aluminum welding I have done since I completed Welding Training at Technical College in 1994 and that was TIG. Well I have come to the conclusion MIG welding Aluminium is the most difficult of all welding. Some of it wasn't the prettiest and a bit of post weld grinding was required. But structurally it is much stringer than I imagined, I can stand on the top center of it with very little flex.

Overall Im very happy with the results thus far with the total weight of the cage , uncovered coming in at 28.5Kg or a shade under 63 lb.

During last week my front mud flaps from RokBlokz turned up. A great product but they weren't straight forward to fit. And that is not Rok Blokz fault. The Rubicons in Australia have the same slider as the US but don't have the high line front guard. Something that I may have overlooked, though not sure on that. Any way great result in the end.

Early start tomorrow so here's some images.

TFR

Great work! Unique! This rig in the US....people are gonna think you have dogs in the bed...or...some may think you're a human smuggler. I would think...the food is in the bed and you're keeping the children (crumb snachers) at bay. Enjoyed working with the AZ/NZ folks in Beirut, Pakistan and Afghanistan...a different view on solutions. Thanks.

 

[Byrnesy]

Great work! Unique! This rig in the US....people are gonna think you have dogs in the bed...or...some may think you're a human smuggler. I would think...the food is in the bed and you're keeping the children (crumb snachers) at bay. Enjoyed working with the AZ/NZ folks in Beirut, Pakistan and Afghanistan...a different view on solutions. Thanks.

It takes all sorts to come up with different solutions.
And it takes open minds (like parachutes they only work when they are open) to consider the merits of other peoples ideas. I got this idea from 'The Road Chose Me' . I just developed and like to think I improved on his.

I think it was you that said you will never stop a determined thief in my post about Alu-Cab or RSi.

So thank you for tilting my frame of reference encouraging me to look else where.

 

[Byrnesy]

So yesterday afternoon I picked up the canopy from the men at Charlestown Canvas, local to me.

Their feedback was that the construction of the cage was one of the best jobs they'd seen and were surprised at how light and strong it was.

And they have worked their magic, Thanks Brett and Eli, and I'm supper happy.

All up this canopy cost me a shade under $1900 in total and weighs in at 30.5kg or 67 pound.

 

[Byrnesy]

Been a while but progress is continuing.
Given a plan to tour the Victorian High Country later this year and the monumental amounts of rain we are having on the east coast of Australia I dived in and purchased a AEV Snorkel whilst they were available in Australia.

Very happy with another excellent product from AEV. Easy fitment and good instructions. Although I did deviate slightly from the instruction in that I added Sikaflex 252 under the A pillar mount as ta buffer for movement and sealing.

Currently working on the rear storage box and it is coming along nicely. Im using a aluminum composite product to keep the weight down, more on that latter.

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