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Custom rebuild and redesign of Humvee / H1

GreatDaneHummer

Well-Known Member
Messages
994
Location
Chicago
I wanted to take some time and share a little about my crazy idea's and concepts that I am working on pulling together over the next year. I purchased my first H3 3 years ago or so and have been hooked on the Hummer brand ever since but with moving into a new place, student debt and a new wife that is finishing up her degree's the opportunity to formulate my dreams have been put on the back burner per say. Now has come the time where I can start to have a little fun in life so I started a small company called Skyfall Off Road. (Website will be up shortly)*

My goals for this company is to share some of my creations and designs with other people for use on their own trucks as well as offering additional normal accessories such as wheels, tires etc..

The first major project under the Skyfall Off Road name is the design and creation of what I would consider the next generation of Hummer H1's. If you could imagine what a modern 2017 H1 would look like this is what I am seeking. A large part of this project will be the heavy usage of Carbon Kevlar material to not just reduce weight but also to increase strength even higher without ever worrying about rust etc. My first Solid Works concept drawings have shown over an 800 lbs weight savings and I would predict this is still on the low end even using B4 ballistic glass. The design is based around a 2 door extended cab with the same dimensions as the current H1.

To start this project I purchased a 2000 Humvee from IronPlanet for cheap so I could start getting more familiar with the H1 design while at the same time I knew I would be stripping everything down to the bolts and rebuilding / redesigning most of the truck so to start with a civilian H1 would be very much a waste in my opinion. After some discussion with 3Hummers last night I changed around many of my initial ideas on the final product. Many would say bigger the better when it comes to tire size but a 37" tire keeps the center of gravity much lower providing a very stable platform and with a huge weight reduction off the top of the truck it will have far better handling characteristics.

The Humvee showed up on flatbed and was right away stripped down to nothing but a frame. The frame was picked up for sandblasting and powder coating. It is now completed and will be dropped off this weekend. The H1 body has been sand blasted after all the glass etc has been removed. Nothing more than a bare shell. From this the molds for the Carbon Kevlar will be created.

I have been doing some testing to see how many layers it takes to become as strong or better than the current H1 aluminum body. 8 layers is equal if not better than the aluminum depending on the location with 12 layers being the highest needed in any location. I will be using 15 to 17 layers depending on location to insure the strength is there. The complete make up of the structure I will hang on to for proprietary design elements but it has already been tested to hold up well against small arms fire without splintering or shrapnel on the interior. 1 of the (10) 7.62 AP rounds did penetrate clean through no different than the standard aluminum body H1 or Humvee. As B5 ballistics are not my target I was still impressed with the performance.

Power Train: Brand new crate motor 6.5 turbo 400T with 350HP and 700 ft lbs of torque put through a 6 speed Allison 1000 trans with a 2 wheel / AWD / 4 wheel drive transfer case. 6 Piston big brake kit, 12k half shafts and a custom designed radiator / intercooler / ac condenser stack with dual fans with carbon fiber shroud and more.

My goal is to be finished by 2017 Sema show and have 3 more being made within 6 months afterward.
 
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3Hummers

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10,515
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Central Texas
Yes, very interesting project. I told Cole to keep me posted on his progress. I also put him in touch with some resources that will hopefully be helpful to him.
 

GreatDaneHummer

Well-Known Member
Messages
994
Location
Chicago
Entire frame anodized and then powder coated. You ask why do both instead of just powder coating? Because you cannot get powder coating on the inside of the frame very well and this one was dipped to remove rust so it has an exposed inside that would rust again. The anodizing keeps the inside from rusting out while the combination of both on the outside keeps it strong against the midwest salt for a long time.

Powder Coating H1.jpg
 

GreatDaneHummer

Well-Known Member
Messages
994
Location
Chicago
Going with an Aluminum coating is a lot easier than doing the much more exotic actual direct anodizing with steel by using KOH and NaOH solutions but when you go that direction it is amazing to see the light purple color show up.
 

GreatDaneHummer

Well-Known Member
Messages
994
Location
Chicago
First major shipment of Carbon Fiber with my own blend of Carbon Kevlar (Spectra) is on its way! I am getting excited to start laying up actual finished layers. I am making 3x of everything to start with to minimize future setup expenses. Anyone familiar with working with Carbon Fiber will know the amount of time it takes to do things right vs. just being fast and quick. I am not using any prepreg product. All layers will be done by hand with my own make up of adhesives. This way I can insure consistent results and the absolute strongest bond available without producing any "soft spots".
 

LagunaH1

Well-Known Member
Messages
3,730
Location
Idaho
This sounds incredibly interesting!!!

I have from time to time thought about what one could do if one wanted to build an H1 equivalent using today's products and technologies.

I wish you the best of luck, can't wait to see how this progresses
 

GreatDaneHummer

Well-Known Member
Messages
994
Location
Chicago
So many reasons for the 6.5TD over the Cummins. The 6.5TD fits correct and is almost "drop in" ready for the H1 frame (not reinventing the wheel), cost and plus with dropping the weight so significantly down on the H1 you really don't need big power like the Cummins provides. At the weight I am aiming for it would be like putting a performance 6.5TD in the H3. 350 HP and 700 ft lbs of torque through a 6 speed transmission while keeping the H3's weight would be almost scary fast.

This is a 300HP version of the one I will be using.
https://www.youtube.com/watch?v=O233fuYBPuw
 
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GreatDaneHummer

Well-Known Member
Messages
994
Location
Chicago
Tell us again how you are going to market a H1 but can't do maint on a simple 3?

I have replaced the upper control arms, CV shafts, seals, lower control arms, steering rack, transfer case cross member, full exhaust, do my own oil changes, spark plugs, coil packs. Replaced the front and rear seals on my transfer case, replaced the front drive shaft, repainted my scratched up fender, replaced the rear bumper, replaced the brakes, new batteries, installed a snorkel, replaced the entire AC and radiator setup so really I don't know what the **** your talking about? The only thing I didn't do was rebuild the transmission and my dad and I did all the wiring of the SPOD for the lights as a fun father son project while he still can work on things. I have run my H3 on all the major trails in Colorado replaced a CV shaft on the side of a mountain and you say I can't do my own maintenance while you drive down snow covered roads and call it off roading? I don't know what your issue is but ANYONE on this forum that wants to take on a cool project with the Hummer brand then I am in all support of it, why are you not as an owner? What do you benefit by trying to put me down?
 
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3Hummers

Super Moderator
Staff member
Messages
10,515
Location
Central Texas
In many respects the H1 is simpler to work on than an H3. If you don't have all of the electronics to deal with that alone makes it easier for me. Bolt off and bolt on is easy. Running electrical issues, not so much for me.
 

Woodtick

Well-Known Member
Messages
801
Location
Ilanoid, UP MI
No snow in this pic. :corn: You should go back and read your posts from the last year. You talk in circles ? I hope I didn't make you feel sad inside? I'm a call it like you see it type a feller. image.jpgI'm down in Indy and I will be picking up a few things from CJ at Thor Parts. Let me know if you need anything ,no shipping costs.
 
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3Hummers

Super Moderator
Staff member
Messages
10,515
Location
Central Texas
I did not see the pre-edited posts but I will say that what someone posted about and their experience level from a year ago or more is totally irrelevant. I have seen absolute neophytes grow into off-road monsters in a short period of time. I could cite dozens of examples but case in point is 06 H3. When Chris first started running with us he was in a bone stock H3 and when people talked about lines he thought you were talking about the crease the dry cleaners put in his khakis. Now he has done his on SAS, installed motors, rebuilt t cases and done harder trails than most anyone on the forum. He has rebuilt numerous other rigs for other people. I would say that there are only a handful of people here that could hold their own with Chris on the trail or in the shop.
Cole is strapping on a big project. It will be a great learning experience for him and many of us that own and wrench on H1s. The H1 crowd are all very interested in what he is attempting and are supportive. I don't think any of us know exactly how it is going to turn out but I have attempted many projects that took twists and turns I did not expect. Learned something from everyone of them.
If the topic of this thread is not interesting to you don't follow it. If the OP is attempting something you can't do or you don't think he can do then sit back and watch with your mouth shut, otherwise they just might make you look foolish. I have watched many people on here pull off some amazing stuff. I am rooting for Cole and have put him in touch with some of the most knowledgable Hummer people in the country. I will help where I can but mostly am going to sit back and watch his progress and hope for his success.
 

scoreh3

Well-Known Member
Messages
1,024
Location
SoCal
I second what 3Hummers said and a good story to follow is Chris' 06 H3 , read some of his 1st posts and now look at him . He is an amazing young try and try again self taught fabricator . I say good luck to anyone that takes on a new project big or small.
 
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