Project Scratch-Built Scrambler

131 1010 Scratch Built Scrambler Front Passenger View

There is a point in a project build when the reality of finishing the rig is so close that driving it down the road could be just a week or two away! Our Scratch-Built Scrambler is starting to look, feel, and roll like the Jeep we've been designing for the last few years. We even made a trip to the Department of Motor Vehicles to have it registered as a custom-built vehicle, which was also a major endeavor in patience and time.

Looking for a good coating to cover the interior of the Aqualu aluminum Jeep body, we hooked up with Rhino Linings and had the entire inside of the tub shot with the spray-on bed and body liners. Rhino Linings are a high-quality spray-on liners that work incredibly well at protecting surfaces and as sound-deadening material while also making for a nonslip/skid surface. We are extremely happy with how the linings turned out.

The guys at Overkill Engineering have done an incredible job reworking the Scrambler's rollcage and suspension. The four-link front suspension was redesigned and changed to a radius arms, and the cage was reworked to incorporate the seat mounts, which are also tied into the frame. This finally gave us the ability to securely mount the Mastercraft Baja RS seats we ordered up a number of years ago.

Since this is a scratch-built Jeep, a number of small components like hinges, seals, and cables were needed. We spent a lot of time thumbing through our favorite Omix-Ada/Rugged Ridge catalog and ordered many parts that will add the finishing touches to the Jeep.

With the temporary operating permit from the DMV taped to the front windshield, we hope to have the new/old Jeep on the trail quickly-the end of this build is near, and we can see the light at the end of the tunnel!

Rhino Linings is a super-tough spray-on liner that's impervious to liquids like fuel and oil. It's also available in a number of colors that will complement many vehicles. Three types of liners are available: HardLine, TuffGrip, and SolarMax. We had the tub of the Scrambler shot with TuffGrip since it is a little softer and more pliable than the other sprays. We felt this liner would make the interior easier to maintain and help keep things like coolers and toolboxes from sliding around.
Rhino Linings is a super-tough spray-on liner that's impervious to liquids like fuel and o
The entire surface area that's going to be sprayed needs to be sanded and primed. After this prep the area that needs to be kept intact needs to be taped off. The sprayed-on polyurethane polyurea elastomer is shot on at high temperatures but dries to the touch in seconds and fully cures in 24 hours. This is a very low VOC spray that's even approved by the FDA as a food grade material and surface.
The entire surface area that's going to be sprayed needs to be sanded and primed. After th
The spray forms a flexible and resilient bond to metal, fiberglass, and wood. It has great resistance to chemicals such as oil and fuel. The TuffGrip will make the tub of the Scrambler easier to maintain and clean. We can simply hose it out for cleaning. We had the lining sprayed with Rhino's UV protection spray to protect and maintain the color and surface texture of the lining. The lining will also help keep the interior of the Jeep cooler and deaden sound.
The spray forms a flexible and resilient bond to metal, fiberglass, and wood. It has great

To get 37-inch-tall tires under the rear wheelwells, Travis Kirkman at Overkill lengthened them 5 inches and cut the outer openings so the tires won't rub at full stuff. Cutting the opening and welding them back in place was done before the tub was shot with Rhino Linings. After the cutting, welding, grinding, and spraying, we couldn't tell where the wheelwells were extended.
To get 37-inch-tall tires under the rear wheelwells, Travis Kirkman at Overkill lengthened
The guys at Overkill fabbed this heavy-duty crossmember out of 1/4-inch plate steel. The crossmember also features a built-in transmission mount and recessed area for the transfer case.
The guys at Overkill fabbed this heavy-duty crossmember out of 1/4-inch plate steel. The c
The front radius arms and rear four-link suspension arms now mount to the heavy-duty crossmember. This removed the control arm pockets from the inner framerails where they interfered with the exhaust headers and didn't leave much room for travel. Removing the control arm pockets will also make running the exhaust from the 5.9L Dodge magnum engine out the back of the Jeep much easier.
The front radius arms and rear four-link suspension arms now mount to the heavy-duty cross

The Scrambler's seat mounts were tied into the rollcage with 11/2x0.120-inch DOM tubing. Both the seat mounts and the cage are attached to the frame. This provides excellent protection and safety in the event of a rollover.
The Scrambler's seat mounts were tied into the rollcage with 11/2x0.120-inch DOM tubing. B
We fitted the Jeep with MasterCraft's Baja RS reclining seats. The suspension seats are extremely comfortable and provide the same protection as MasterCraft's full-fledged race seats. We have found that the seats alleviate driver fatigue over long hauls, and reclining provides excellent comfort while we're cat napping at highway rest stops.
We fitted the Jeep with MasterCraft's Baja RS reclining seats. The suspension seats are ex
MasterCraft made us a rear seat for the back of the Scrambler, which turned out exceptionally well. The seat was designed to fit between the rear wheelwells, and its feet will bolt directly to the tub floor.
MasterCraft made us a rear seat for the back of the Scrambler, which turned out exceptiona

The MasterCraft seats are designed for the Jeep CJ, YJ, TJ, and Unlimited and for the Ford Bronco, Toyota Land Cruiser, and Toyota Tacoma. The seats fit perfectly in the Scrambler, and we were able to squeeze a 10-inch-wide Tuffy Security console between them. The console provides secure storage, which is great for a Jeep with a soft top, and it offers a comfortable armrest.
The MasterCraft seats are designed for the Jeep CJ, YJ, TJ, and Unlimited and for the Ford
We needed a number of hard parts like door hinges, grille lights, and hood hold-downs. Rather than use old rusty worn-out parts scavenged from a junkyard, we ordered the components from Omix-Ada. We were surprised at the amount of hard-to-find and original replacement parts the company offers.
We needed a number of hard parts like door hinges, grille lights, and hood hold-downs. Rat
The parts from Omix-Ada, such as the tailgate hinges and cables, fit perfectly. The new parts also saved us hours of cleaning up old parts like hinges while trying to get them to operate smoothly.
The parts from Omix-Ada, such as the tailgate hinges and cables, fit perfectly. The new pa

SOURCES
MasterCraft Safety 9335 Stevens Road Santee CA 92071 800-565-4042 www.mastercraftsafety.com	Rhino Linings 9151 Rehco Road San Diego CA 92121 858-450-0441 http://www.rhinolinings.com
Tuffy 25733 Road H Cortez CO 81321 970-564-1762 www.tuffyproducts.com	Overkill Engineering Nuevo CA 888-225-0243 www.overkilleng.com
Omix-Ada 460 Horizon Drive Suite 400 Suwanee GA 30024 770-614-6101 www.omix-ada.com	Aqualu 435 Neave Court Kelowna AK 888-765-6714 www.aqualu.com