This week I've been working on my tube fenders. Didn't have a pipe bender, tried getting away with a makeshift one out of an old caliper and bottle jack, just crimped the pipe. Moved onto some black pipe and had a couple pieces bent up at the local machine shop. Didn't go with a flare just incase I go with narrower tires down the road when these are burnt off. Haven't built the inner fender walls yet, was going to use the ones from the old fenders but I looked this afternoon and there's not much left. I like the look, just have to get the other side done and I can start taking it apart for sandblasting and painting. I'm sure there is much more welding to be had when I get it flipped. But we'll cross that bridge when I come to it.
Went back and forth several times trying to decide how to make the inner fenders so they didn't look boxy or tweaked. Looked again at the old inner fenders and decided to start with them. There was enough there that I could cut out the rusted parts and weld in new steel where needed. They came out great, still more welding to do and some gussets to put in.
Had some time tonight to cut in my break lights and back up lights. I went with a flush mount, less to tear off out in the woods. They're LED's that I got from eariler.com, tractor supply sold them too but this place was way cheaper. Backup lights could have been smaller but I like the look and I'll be able to see what I'm running over... The gro it has a nice look and they fit great.
Had some time over easter to put in the fuel fill and moved it to the side. didn't have room to put it in the back with the new tail lights plus it always collects dirt and mud in the back right behind the tire.
Also had to replace the indented panels under the windshield they were starting to rust out.
That was it for the top time to flip it over and work on the bottom and then the frame. Don't have enough room in the shop for both the frame and the tub so the frame went outside until I can get the primer on the tub. Once that's done I'll put the tub in a shed near by and work on the frame.
You're doing a great job! Very meticulous! Did the CJ5 have so many body mounts, or were you afraid the tub would fly off? I dont know how many are supposed to be there, but that looks like a lot!
Well I thought it was a lot too but the new bushing package came with 5 on each side, I think it looks ridiculous because I'm using the 66 frame which stays narrow and I'm using the measurements from the 79 frame which has the mounts out 7" and the 79 frame widens in the back. I did look and there are still a few of the old mounting points on the frame that I'll cut off. The other interesting thing is that the bolts measure 7/8" which seems like a lot of bolt to hold down a tub especially with that many points of contact. I've been roughly going off of this blueprint someone posted and have found a few places online.
Well... I haven't updated this in a while. Due to the fact that I work at a summer camp and nothing exciting has happened with the build. I have however had a few weeks to work on it since our season has ended and I found some pics that I hadn't posted since Feb. So I'll try and get a few up with some commentary. .
Amazing work on the tub. I don't think I've seen someone completely rebuild the back half from sheet metal pieces yet
Did you do a cost of materials you put into rebuilding the tub? I'd be curious how it compares against replacing it with a used tub
I bought $400.00 in steel and that includes the local machine shop bending the two back corners for me, probably $100.00 in mig wire and $?.?? in grinding wheels. I didn't have a plasma cutter and didn't want to heat up that thin metal so I used cut off wheels on a 4.5" grinder to make all my cuts.
I've been painting and installing, painted all the running gear, frame, engine, tub.
Sandblasted the frame, and running gear before I painted it. Made a homemade sandblaster out of an old propane tank and some ball valves. Picked up a dead mans nozzle from harbor freight, 20 bucks later you've got a sandblaster.
I'm using paint from Tractor Supply, glossy black and the tub will be IH Red. Don't really like the look of chrome on the jeep so I'm going to keep it pretty simple, red and black.
Had to replace the seal on the tranny and the pilot bushing, seemed someone had forced something at some time. When I pulled it apart the pilot bushing fell out in pieces so I checked the bearing in the tranny and replaced the main seal.
installed the fuel tank (new poly), break lines and fuel lines.
Pulled the tub back in, primed and painted the bottom then got a few guys to help me set it on the frame.
Put a little bondo on the parts that weren't quite straight... but for the most part there was just a thin layer near some welds. The back got the most, due to a seam and probably the most support and heat.
Shot it with grey filler primer and wet sanded
Shot it with red oxide primer and wet sanded X2
A guy dropped off a HVLP sprayer with its own 3 stage turbine, said he didn't know how to use it... Told him I did so now its mine. That worked out well, sprays great.