AP's 5 Speed WJ Build - Page 15 - JeepForum.com

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post #211 of 1162 Old 04-01-2010, 10:29 AM Thread Starter
AgitatedPancake
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As of yesterday I took the heads out to a local machine shop that knows these 4.7's inside and out. They are inspecting the heads, and repairing/updating as necessary. Today I hope to get the clutch pedal assembly and master cylinder knocked out. That's a big hurdle, once I have that done I'll be way happy. After that I'm plannin on a mock install of the block and tranny so I can start working on the new (or modified) crossmember and working on the shifter location in the floor)






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01 WJ 5 Speed Claytons LA's, 36" Iroks, 35 spline 9" rear, Custom Ruffstuff 60-9" front axle.
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post #212 of 1162 Old 04-01-2010, 09:04 PM Thread Starter
AgitatedPancake
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So I did a LOT of work on the clutch pedal today. I actually ended up using the toyota brake pedal and bracket instead of the clutch pedal, it worked out WAY better. The pivot tube is probably 3" long, the pedal mounts to the right side of the tube and the arm that's going to push the MC will be on the left side, essentially shifting the clutch pedal a few inches to the right! Modified all the bracketry and welded it up. It looks right at home in there hahaha





Clutch release position:


Aaaaand on the floorboard. Don't worry, that's not how the brake pedal is staying

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01 WJ 5 Speed Claytons LA's, 36" Iroks, 35 spline 9" rear, Custom Ruffstuff 60-9" front axle.
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post #213 of 1162 Old 04-01-2010, 09:05 PM
Shinobi
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u are one mad crazy man ... Can't wait to see it finished !! keep it up man


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post #214 of 1162 Old 04-01-2010, 09:18 PM Thread Starter
AgitatedPancake
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Haha well this became way more of an undertaking than I thought when I first began. It started with the radiator failure and rebuilding the front end...did that and discovered the tranny was completely gone (instead of partially lol). I pulled that to start the 5-speed swap, and decided to pull the motor because of how close I was already. With the motor out, I decided it was the best time to put new valve seals in. Well we ended up having to take off the heads, when we noticed it looked like the heads could need a little machine lovin'.

Talk about a snowball effect lol! Luckily I can keep making progress on different parts of the project as the engine is on hold

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01 WJ 5 Speed Claytons LA's, 36" Iroks, 35 spline 9" rear, Custom Ruffstuff 60-9" front axle.
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post #215 of 1162 Old 04-02-2010, 12:51 AM
ratmonkey
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just some friendly advice, up your wire speed a tic or slow down a hair, getting a little undercut on some of those welds.

and clean the metal.


i know i can put out some bird turds when i'm in a hurry though. lol.

'97 zj 5.2, some stuff, some other suff, and some things that even work sometimes.

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post #216 of 1162 Old 04-02-2010, 01:09 AM Thread Starter
AgitatedPancake
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haha I see the undercut your speaking of, on the left side correct? Yeah I was trying to fill a gap and put way too much heat into the bracket and it started melting back. That's what I get for welding this basically sheetmetal bracket with .035 wire lol. I'm trying to burn through it so I can use the spool of .025 I have waiting to go in. Also, I wire wheeled the area I welded beforehand, it's just hard to see the transition from the rust to the shiny

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01 WJ 5 Speed Claytons LA's, 36" Iroks, 35 spline 9" rear, Custom Ruffstuff 60-9" front axle.
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post #217 of 1162 Old 04-02-2010, 01:25 AM
ratmonkey
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i'd suggest some sanding discs instead of the wheel next time.

like i said, i don't always make the nicest looking stuff, but at least it's what i'm paid to do in my "day' job.

'97 zj 5.2, some stuff, some other suff, and some things that even work sometimes.

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post #218 of 1162 Old 04-02-2010, 09:35 AM Thread Starter
AgitatedPancake
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Fair enough, thanks for the advice man! I don't think I'm ever going to have to worry about this bracket failing, but it's always good to know how I can do better

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01 WJ 5 Speed Claytons LA's, 36" Iroks, 35 spline 9" rear, Custom Ruffstuff 60-9" front axle.
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post #219 of 1162 Old 04-02-2010, 05:26 PM Thread Starter
AgitatedPancake
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I did enough tinkering today to keep my mind churning about how to mount the MC. I don't like that POS factory bracket, I think I'm going to build one. It's badass, the MC itself just twist locks into that black bracket. Makes it WAY easy to remove and modify.

I haven't really shown decent pictures of the clutch pedal setup, so here some are. I added the pushrod today (from the yota MC).


And this pic with the MC. The part in my hand is actually going to be tipped up unlike I have it in the pic. It's going to work perfectly between getting a good centered throw of the pushrod and clearance between the MC and inner fenderwells.

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01 WJ 5 Speed Claytons LA's, 36" Iroks, 35 spline 9" rear, Custom Ruffstuff 60-9" front axle.
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post #220 of 1162 Old 04-02-2010, 09:20 PM
FortCollinsZJ
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Quite an undertaking Greg. The whole project is looking great! Oh, and so are the welds, don't read too much into a critique from a guy who posts welds like this, (taken from his thread)



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post #221 of 1162 Old 04-04-2010, 03:10 AM
ratmonkey
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Yep. That machine sucked bunghole for stick welding. We've since replaced it at work. That and I'm a terrible stick welder when using under 5/16" Rod. I am significantly better with a wire feed or mig welder, most of the time.


I don't always make the greatest welds and never have claimed to. But I can armchair qb with the best of them.

Fczj, I've seen your tube work too.

I'm not getting in a pissing match here. I had pertinent advice and provided it. His welds look good other than the plating not being fully removed before burning.

'97 zj 5.2, some stuff, some other suff, and some things that even work sometimes.

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post #222 of 1162 Old 04-05-2010, 05:45 PM Thread Starter
AgitatedPancake
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Got the master mounted today! Little more work and it'll be time to burn it home and do a final pedal install! I ended up scrapping all of that stock bracket except for the actual clip-in part for the MC.







I got the brake pedal pad on for all you haters too. Startin to look like factory components haha!


Up underneath the dash, almost had to relocate the hood cable and that other line (rear washer I think?)


AND...my heads are done at the machine shop

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post #223 of 1162 Old 04-05-2010, 06:34 PM
GraKee99
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Great work!

I was thinking, the master cylinder is right where the emissions box on 99 and I think 00. This might not be possible on mine, NOOOO!

Brian

WJ, WK, CJ5


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post #224 of 1162 Old 04-05-2010, 06:53 PM Thread Starter
AgitatedPancake
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Lol I have that evap box unbolted right now. I'm going to have to put it somewhere...hrmm

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01 WJ 5 Speed Claytons LA's, 36" Iroks, 35 spline 9" rear, Custom Ruffstuff 60-9" front axle.
Build Thread:
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post #225 of 1162 Old 04-05-2010, 06:58 PM
GraKee99
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I was wondering where it went, I thought they didn't change it till 03 and 04 to the back. Makes perfect sense now. Looks like it is still possible.

Brian

WJ, WK, CJ5


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