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Rear seat build

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Scratch View Drop Down
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    Posted: 13 Apr. 2023 at 11:22pm
I've been looking for a rear seat for a while now and I can't believe how much people want for an original.  Even a reproduction rear seat is more than I want to pay, and then to ship that big awkward thing adds even more cost, so I decided to try building my own.  I have 3 jeeps that I'll need rear seats for, and since I have a jeep from before and after the split, (serial number 77568)  I need an early, high back seat and 2 later full back seats.  The early bird gets the worm or something like that so let's start with the early one.

First I got some 14 gauge, 1" round tubing.  It cost me 23 bucks per 20' stick.  I used about 19' for this complete seat.  I picked them up in our suburban so I had the steel shop cut them in half so they'd fit.  This is 40 feet of it in 10 foot sections and according to my calculations, should be enough for two rear seats.




I've had this hydraulic tube bender for about 30 years.  I don't use it often but it happened to have the correct die for it so I gave it a try and it worked awesome for this!  By the way, I tried bending 16 gauge 1" tube and the bends looked horrible, so I used the 14 gauge.





I started by making the legs.  It's been a while since I bent anything with this thing and there are no markings for bends anywhere so I marked a bunch of 1" marks on the tubing then left plenty of room to cut off later and made my first bend. I then looked at the bend, and used my marks to figure out where I'd need to start each bend so I could make repeatable bends, I ain't the most intellergent feller out there, but I was able to figure it out.  
Then I needed to squish the end of the leg so it'd fit under the front leg socket.  I started to crank it down in my vise, then realized I have a 30 ton press so used that... It was much easier.





After the end was squished down, I brought it back to the vise and just using my hands, easily pulled in a nice 90 degree bend that I was very happy with.





Here's what it looked like after a few more flattening hits with the hammer and anvil and grinding a nice shape to it.




Next I made the bend for the rear leg and cut it to length.  By the way I was using the measurements from Jpet's drawings he posted a while back.  Thanks Jpet and all who helped him.





Then I made the other leg.




Edited by Scratch - 13 Apr. 2023 at 11:48pm
43 GPW 93487 Blk
44 GPW 230283 OD
46 CJ2A 50100 Tan
46 CJ2A 77632 Wht
47 CJ2A 141681 Grn
48 CJ2A 156240 Red/Yel
48 CJ2A "Lefty" 181341 Red
61 CJ5 123120 Tan
03 TJ Inca Gld
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scratch Quote  Post ReplyReply Direct Link To This Post Posted: 13 Apr. 2023 at 11:22pm
Next I started on the "seat" part of the reat seat.  Now remember when I had the steel shop cut those 20 foot tubes in half so I could fit them in my Suburban... I wish I would have them cut at the 11 foot mark.  I was about 7 inches short of being able to do this in one piece!  I wanted the seam to be in the front, just like the originals, but I couldn't do that so I did them in two pieces.  I can always make the cut where it's suppose to be later.  It was actually much easier to make this in two pieces anyways so it didn't bother me too much.

Here, you can see where I made my splices. 





And after grinding the weld with a flap wheel and using a DA sander, my seams disapeared.





Then I re-installed the legs, set the seat on top of them where it's supposed to go, then tack welded it in place.  I pulled it out to finish weld it and here's what it looks like.




I then tried it in a couple different jeeps just to make sure it didn't need any tweaking.


 



I also added the bottom bar.






Edited by Scratch - 13 Apr. 2023 at 11:51pm
43 GPW 93487 Blk
44 GPW 230283 OD
46 CJ2A 50100 Tan
46 CJ2A 77632 Wht
47 CJ2A 141681 Grn
48 CJ2A 156240 Red/Yel
48 CJ2A "Lefty" 181341 Red
61 CJ5 123120 Tan
03 TJ Inca Gld
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scratch Quote  Post ReplyReply Direct Link To This Post Posted: 13 Apr. 2023 at 11:23pm
Next I started to work on the back pan and brace.  (Thanks to Sean for his measurements on that) I drew it up then plasma cut it out from some 20 gauge steel.





I wanted to try this method of forming the corner flange, so I have this old harmonic balancer (maybe?) that has two different radius on it and tried it.





It worked ok, but I'm not really happy with it and I may end up redoing it.






Then I used my hole punch to make all my plug weld holes since I don't have a spot welder yet.




Next I welded the pan to the seat back, and finished off the welds with a 60 grit flap disk, followed by 80 and 120 grit on the  DA sander.







Edited by Scratch - 13 Apr. 2023 at 11:29pm
43 GPW 93487 Blk
44 GPW 230283 OD
46 CJ2A 50100 Tan
46 CJ2A 77632 Wht
47 CJ2A 141681 Grn
48 CJ2A 156240 Red/Yel
48 CJ2A "Lefty" 181341 Red
61 CJ5 123120 Tan
03 TJ Inca Gld
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Scratch View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scratch Quote  Post ReplyReply Direct Link To This Post Posted: 13 Apr. 2023 at 11:23pm
After doing all the plug welds and finishing them perfect, I forgot to fix my ugly corners in the pan.  I really don't like the look of this but I guess I'll leave it for now.  Hopefully, it'll get mostly covered anyways...






ugh...ly corner.





Next up was the brace so I cut out a piece and bent it to shape, then plug welded it in.  Forgot to get pics of that step.

I've heard one method for telling the difference between a repro and an original seal is the seam on the center front tube.  Thanks to a pipe cutter, I'll have the jeep police scratching their heads.



I've seen a pic on here of the seam, but I can't find it now.  I'd like to add the rivets, pins, screws or whatever they are.  If you have a good close pic of a seam and how its attached, please post it.



Edited by Scratch - 13 Apr. 2023 at 11:54pm
43 GPW 93487 Blk
44 GPW 230283 OD
46 CJ2A 50100 Tan
46 CJ2A 77632 Wht
47 CJ2A 141681 Grn
48 CJ2A 156240 Red/Yel
48 CJ2A "Lefty" 181341 Red
61 CJ5 123120 Tan
03 TJ Inca Gld
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scratch Quote  Post ReplyReply Direct Link To This Post Posted: 13 Apr. 2023 at 11:26pm
Then I cut out a piece for the bottom pan. This time, I did the radiused corners different.  I left the corner flange off and welded on a separate rolled piece to fit, just like a sheet metal patch.





They turned out much better!







I checked it for fit...





Then punched my plug weld holes.






I need to bring this pan over to my buddies house who has a bead roller.  I'll do that before I weld it in.



Edited by Scratch - 13 Apr. 2023 at 11:38pm
43 GPW 93487 Blk
44 GPW 230283 OD
46 CJ2A 50100 Tan
46 CJ2A 77632 Wht
47 CJ2A 141681 Grn
48 CJ2A 156240 Red/Yel
48 CJ2A "Lefty" 181341 Red
61 CJ5 123120 Tan
03 TJ Inca Gld
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scratch Quote  Post ReplyReply Direct Link To This Post Posted: 13 Apr. 2023 at 11:32pm
Finally I need to secure it to the floor.  The front legs are done, and I rebuilt my rear seat spring clips here: https://www.thecj2apage.com/forums/rear-seat-spring-clip-rebuild_topic51217_post522819.html?KW=rear+seat#522819






I had planned on buying new rear feet from Walck's as they were the only place I could find them, but with Carl retiring, it may take a while for KW to start selling his feet so I thought I'd try my hand at making a set.

I have oodles and scads of this 3/4" x 3/8" solid bar






First I made a mark at one inch from the end, and another mark at 3/4" from the end.  I used the drawings I found on here from Jpet and sean I think (thanks again guys) 





Then I found the very center of my where my chop saw hits, and made a shallow cut at the 3/4" mark.  It only needs to be 1/16" deep.  I did this on both sides so there was 1/4" of meat left between the cuts.







Edited by Scratch - 13 Apr. 2023 at 11:56pm
43 GPW 93487 Blk
44 GPW 230283 OD
46 CJ2A 50100 Tan
46 CJ2A 77632 Wht
47 CJ2A 141681 Grn
48 CJ2A 156240 Red/Yel
48 CJ2A "Lefty" 181341 Red
61 CJ5 123120 Tan
03 TJ Inca Gld
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scratch Quote  Post ReplyReply Direct Link To This Post Posted: 13 Apr. 2023 at 11:37pm
Next I used a 60 grit flap disc to lightly grind from the bottom of that cut to the front.  I did this on both sides.









Then I did the same grind from the bottom of the cut to the back one inch mark.  I did this on both sides.






Then I worked on the point, grinding on each side until I was semi happy with the point.









Edited by Scratch - 13 Apr. 2023 at 11:41pm
43 GPW 93487 Blk
44 GPW 230283 OD
46 CJ2A 50100 Tan
46 CJ2A 77632 Wht
47 CJ2A 141681 Grn
48 CJ2A 156240 Red/Yel
48 CJ2A "Lefty" 181341 Red
61 CJ5 123120 Tan
03 TJ Inca Gld
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scratch Quote  Post ReplyReply Direct Link To This Post Posted: 13 Apr. 2023 at 11:38pm
In this pic you can see the bottom of the chop saw cut right in the center there.






I used a round file on both sides until it went away.  That's when I knew when to stop.






With the mark gone, time to stop filing.






After that, I just lightly ground the correct profile for the spear point.  It was pretty easy to do.






Edited by Scratch - 13 Apr. 2023 at 11:58pm
43 GPW 93487 Blk
44 GPW 230283 OD
46 CJ2A 50100 Tan
46 CJ2A 77632 Wht
47 CJ2A 141681 Grn
48 CJ2A 156240 Red/Yel
48 CJ2A "Lefty" 181341 Red
61 CJ5 123120 Tan
03 TJ Inca Gld
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scratch Quote  Post ReplyReply Direct Link To This Post Posted: 13 Apr. 2023 at 11:41pm
Then, back to the CNC plasma table to draw up and cut out the round part of the feet.





And here is the completed foot!






Here it is setting in a scrap piece of 1" tubing.  I forgot how these were mounted so I'll have to look that up again and pin them in or weld them or whatever it's supposed to be.







All in all I had 23.00 in tubing and less than 20.00 in sheet metal.  And about 4 inches of steel for the legs.  Of course I did spend probably 8 hours on this thing so that's gotta be figured in too.  I like building things so I'll probably build a second one too, we'll see.



Edited by Scratch - 13 Apr. 2023 at 11:46pm
43 GPW 93487 Blk
44 GPW 230283 OD
46 CJ2A 50100 Tan
46 CJ2A 77632 Wht
47 CJ2A 141681 Grn
48 CJ2A 156240 Red/Yel
48 CJ2A "Lefty" 181341 Red
61 CJ5 123120 Tan
03 TJ Inca Gld
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Post Options Post Options   Thanks (0) Thanks(0)   Quote dasvis Quote  Post ReplyReply Direct Link To This Post Posted: 14 Apr. 2023 at 12:05am
Looks damn nice. 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote garcia63 Quote  Post ReplyReply Direct Link To This Post Posted: 14 Apr. 2023 at 12:36am
Great job! Thanks for the detailed build.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote otto Quote  Post ReplyReply Direct Link To This Post Posted: 14 Apr. 2023 at 12:40am
Great initiative to fill a need. 

Excellent craftsmanship Scratch! 
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If you can't get there in a Jeep, get a motorcycle!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote eestes1 Quote  Post ReplyReply Direct Link To This Post Posted: 14 Apr. 2023 at 7:08am
wow!
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You are a Bad**s!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote AKoller Quote  Post ReplyReply Direct Link To This Post Posted: 14 Apr. 2023 at 8:14am
This looks really good!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote rocnroll Quote  Post ReplyReply Direct Link To This Post Posted: 14 Apr. 2023 at 8:44am
.....Clap......


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impressive!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 14 Apr. 2023 at 9:26am
Excellent
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