Doors & Windshield for Rocky

[Bob R1]

02/12/2026
The Windshield Frame and Inner and Outed Rubber Trim for around the glass was dropped off at Glass Plus this morning when they opened at 8:30 AM.
After getting the Windshield installed I will run the Roxor in to Anthony's Shop to have the Roll Bars tied into the YJ Windshield Frame. He has a Tubing Bender and should be able to get the roll bars sorted out.

Next is a game plan change. I have a buddy that works at a fabrication shop. I have talked with him, and what I plan to do is make a Filler Piece out of wood to go between the Fortress Roof, and the Top of the YJ Windshield filling in the approximately 4 Inch Gap between the Roof and Windshield. I should be able to work out the exact size and angles using wood for him to replicate in steel in the Fabrication Shop, complete with end caps. He Stubby Bumper-ed my 2013 MOAB JK's American Expedition Vehicles front Bumper for me a few years ago. He does great work, and is a perfectionist.

Once this is done I will be ready to work on getting the YJ's Half Doors installed on the Roxor. With luck Cody will be up for this project also.

I did manage to get the Wiper Switch popped out this morning. I am still waiting on my Rocker Switch Pro's Switches to arrive.

I did some research on the factory Light Bar Wiring today. I bought and installed the factory Light Bar Switch shortly after buying Rocky in 2024. Doing some research today I learned that the factory Light Bar Switch is wired through a Fuse Panel Relay and is ready to just plug in the (Missing Relay) to be use-able. I believe that I located the wiring to connect to the light bar under the dash.

I looked over the factory Light Bar Wiring that plugs in to the Light Bar Switch. It has FOUR Wires. It should only need TWO wires to provide Power to the Relay. Power In and Power Out to the Relay. I am wondering if the extra TWO Wires might be for back lighting when the Relay is installed in the Fuse Box. I may need to start a post on this to find out.

Bob R

 

[Bob R1]

02/15/2026
I goofed off yesterday, and went to a Gun Show in West Plains Missouri. ZERO work on the Roxor. I did however pick up a Rivet Nut Installation Tool at Harbor Freight. I also rounded up my Electric Die Grinder, and my Cutter set that I had previously bought to work on the Roxor. Luckily the Die Grinder and cutter bits were easy to locate.
I did manage to pick up an old 40X Remington Walnut Target Rifle Gun Stock as well as an HS Tactical Gun Stock also for a short action Remington at the Gun Show. It rained all day, so the Gun Show was more enjoyable than working in the shop.

WINDSHIELD
My plan for today. After Church my plan is to enlarge the bolt holes in the Windshield Hinges. The front bolt holes are pretty good. The side bolt holes will need enlarged to get the bolts in. Two of the holes only need a little work. The holes closest to the Door Mounting Hinge are off enough that I cannot see any of the bolt hole in the Roxor. I plan to have the Windshield bolted in place when I am done today.
EDIT Windshield Installed. The bottom side bolt holes on the Roxor were too far out of Jeep Specifications to elongate the windshield hinge and get bolts installed.

WIRING
Next up for today will be splicing the wiring going back to the Rear 6 LED Flood Lights, LED Interior Light mounted on the Roll Bar, and the 12 Volt Receptacle mounted on the Bulkhead to power my Sprayer and Seeder. I will also probably run the wiring for a Front Light Bar to be installed at a later date. If you recall the reason for cutting the wiring, was that I had the wiring routed up the Drivers Side Roll Bar through a drilled hole in the Cowl. The original installation of the wiring worked fine with the Fortress Windshield which mounts in front of the Cowl. The Jeep YJ Windshield mounts on the Cowl, so the wiring needed re-routed from under the dash, to a location behind the drivers seat. I am planning on running the wiring from under the dash to behind the seat, going under the door opening. I am planning on Friction Taping the Wiring Bundle.
Now that I have determined that the Factory Roxor Light Bar Switch is Back Lit, I am planning on using it. I will need to install a 5 Pin Relay in the fuse box, and extend the factory wiring on to the back, where it can be routed back forward on the Horizontal Roll Bar to connect to the Light Bar.
Since I now have the ON/OFF Wiper Switch popped out, I can go ahead and button the Dash Panel back into place. I am still waiting on the Two Speed Windshield Wiper Rocker Switch, however I can install it later. I do need to scratch my head a little today and decide exactly how to run the wiring from the Wiper Switch to the Wiper Motor.
EDIT Completed. I ended up routing the factory YJ Windshield Wiper Wiring around the left edge of the dash using the Roxor Dash Bolts and Nylon Wire Clamps. The factory Wiring Plug ended up at the bottom edge of the dash.

ROLL BAR CONNECTION
I am off work Tuesday, and it is supposed to be a beautiful WARM Day. My game plan is to drive Rocky in to Houston, MO. to Teem Tire (Muffler, Tire and General Repair Shop) and have Anthony connect the Horizontal Roll Bars to the YJ Windshield Frame. I have new Heavy Duty End Plates (Weldable) to bolt to the Windshield Frame. Anthony has had off road Jeeps for years, he is all over fabrication work on a Jeep. He also owns a Tubing Bender to bend the roll bar ends to the correct angle. Planning to repurpose Roll Bar tubing from either the Front Roxor ROPE, or the Horizontal Roll bars from the YJ. I cut the YJ Roll Bar's off just in-case I needed the tubing.

I will close for now and probably do some planning on todays work while staying clean before Church.

Bob R

 

[Bob R1]

02/20/2026
Today I was working on wiring the Wiper Switch. I ended up using TWO Five Pin Relays, one for Hi-Speed Wipers and one for Lo-Speed Wipers.
My Rocker Switch Pro Switch has 10 Pins. The pins across from each other on each end are Hot and Ground for the Indicator Lights. I have the Lower Indicator Light jumper-ed to come on with the Ignition, like my other rocker switch's. I have the top Indicator Light wired to come on when I put the Wipers on Low. I am at a stand still until morning when my other Plug for the 5 Pin Relay shows up at NAPA. I decided using a Factory Plug on each Relay was probably a better plan than having Four Spade Connectors on each relay, that could be pulled out much easier. I mounted the Relays side by side on a plastic Octagon Box Cover, then cut it down around the relays. I left the upper hole in the cover in place to zip tie the relays up out of the way.

I still need to verify the Wiper Motor Wiring. That should not be a big deal. Connect the Ground Wire, then put power to the Wiper Motor Wires, and see which wire powers up Lo and which wire powers up Hi on the motor.

Change from my above plans. I now have the guy who has fabricated parts for my Jeep Jk MOAB on board to do the fabrication work. My NEW Fabricator/Welder is scheduled to meet me Sunday after Church to weld the Roll Bar End Connector into the YJ Windshield Plate, and the Factory Horizontal ROPES. I have the roll bar connector pieces cut out and ready to weld in place. With luck they will make a good Grab Handle to assist getting in Rocky. I will also have him shorten the front of the factory ropes and cap the end to keep wasps out of it. The rear tubes are to far forward with the YJ Windshield in place. With the Front of the factory ROPES removed, the Horizontal Tubes extend past the windshield frame a small amount requiring them to be shortened probably Two Inch's on each side. I am using a 1-5/8 Fender washer with Three 1.5" Fender washers behind it with a 5/16 Bolt that will end up sticking out of the front of the Roll Bar for the Cap. The three 1.5" washers will go inside the Roll Bar as a stiffener. We will weld the bolt in place as a potential mounting location for a Roof Bracket.

After we get the Roll Bar connected up, I can work on designing the Filler Plate to go between the top of the Windshield and the Fortress Roof. The top of the Windshield Frame measures 1.5 Inches wide. My plan is to fabricate the Filler Plate out of a 2" X 4" Board first to get the angles worked out. Then have the Fabricator make one from sheet metal using my pattern. Much cheaper to work the angles out using a cheap 2x4 board.

I put the drivers side Jeep Half Door on a while ago. I will need to install Nut Zerts for the Lower Hinge. The Lower Hinge, Hinge Bolts Nuts on the Roxor are not installed in the correct location for the Jeep YJ Half Doors to mount up. I will also need to get Counter Sunk, Flat Head Torque Screws for the Windshield Hing Side Screws, or the doors will not mount up.
Looking like the door opening will need moved back approximately Three Inches or so for the doors to close. I will also need to add probably 1-1/2 Inch of filler plate under the doors.
I will also need to reroute my Wiper Motor Wiring. What I discovered was that the Jeep Door comes almost all the way to the Left Row of Switch's. I was using the Left side dash bolt's to hold the wiring clips. The wiring would end up interfering with the door installation. Better to find this out today, than after I get the Wiper Motor all wired up, then have to regroup and move it later.

With luck I will have the Wipers up and running tomorrow. I will hold off on installing the Nut Zerts, and let the Fabricator decide what we need to do.

Bob R