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Unread 08-28-2011, 12:05 AM   #1
Finnly56
Registered User
1985 CJ7 
 
Join Date: Jan 2010
Location: Coalhurst, Alberta
Posts: 20
"Deh Cockaroach" Build

1985 CJ-7 Renegade
Engine: SBC 400 from '77 or '79 Truck
Trans: Ford Top Loader from '69 Mustang
T-Case: DANA 20 from '79 CJ
Front Axle: DANA 44 3.73 gears from '78 Scout
Rear Axle: DANA 44 3.73 gears from ???
Tires: 38.5" Thornbird
Wheels: 15" M/T Classics


I actually started this build/rebuild in August '09 when I bought the JEEP, I've been very regularly visiting the forums for a long time now to get ideas and advice on a whole bunch of different issues I have come across and I would like to say a really big "THANK YOU" to everyone that I have mooched information off of!

I have been slowly tearing it down and rebuilding it with the equipment that came on it. Most of it is what I want on my dream JEEP but as I got deeper and deeper into tearing it down I figured I'll use this one as my daily driver mostly and build my hardcore JEEP after, with EVERYTHING I want on it !
The PO was in the middle of building this one himself, but decided he only "needed one JEEP" He had a very nice CJ-6 that he's keeping and just sold his CJ-5 a week before.






The day of arrival




Parts and spare parts.


T-Case binding off the front yoke, and the Skid plate with a huge chunk taken out of it.


T-Case in need of some new seals


No transmission cover and a scabby hole for the shifter to poke through. I tore it apart before i thought to give it a try to see what it's like to shift. It sits pretty close to the drivers seat, I hope I just have to get an offset handle rather then trying to move anything else around.


Fenders off


There was a rats nest of wiring through out the entire JEEP it took a while for me to straighten things up just to take them out.


__________________
"Deh Cockaroach" Build
'85 CJ-7, 400, FTL, D20, Dana 44 F/R, 38.5" Thornbirds... Rebuilding
'85 CJ-7, 258, T5, D300, WARN 8274 winch, 33" BFG A/T... Donor patient
2013 JK Rubicon
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Unread 08-28-2011, 12:32 PM   #2
Finnly56
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1985 CJ7 
 
Join Date: Jan 2010
Location: Coalhurst, Alberta
Posts: 20
separated tub and frame


tub off


leaky power steering and T-case


Transmission and 1 Head off


The skid plate with a huge piece missing right down the centre line of where the mount is bolted, there was very little support through it.
__________________
"Deh Cockaroach" Build
'85 CJ-7, 400, FTL, D20, Dana 44 F/R, 38.5" Thornbirds... Rebuilding
'85 CJ-7, 258, T5, D300, WARN 8274 winch, 33" BFG A/T... Donor patient
2013 JK Rubicon
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Unread 08-28-2011, 12:37 PM   #3
Imped
Web Wheeler
 
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2004 TJ Wrangler 
 
Join Date: Feb 2008
Location: Indianapolis
Posts: 19,669
Thornbirds.
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OlllllllO
Float Test Build
IndyORV
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Unread 08-28-2011, 11:18 PM   #4
Finnly56
Registered User
1985 CJ7 
 
Join Date: Jan 2010
Location: Coalhurst, Alberta
Posts: 20
They look like a really awesome tire for 4wheeling, but they're not going to hold up too much for me because I have a lot of highway miles I have to travel to get to any good wheeling places around me. I'm thinking about getting a good set of tires for the highway and then swapping tires for the weekend just not to let the Thornbirds go to waste! I'll see how it goes.
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"Deh Cockaroach" Build
'85 CJ-7, 400, FTL, D20, Dana 44 F/R, 38.5" Thornbirds... Rebuilding
'85 CJ-7, 258, T5, D300, WARN 8274 winch, 33" BFG A/T... Donor patient
2013 JK Rubicon
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Unread 08-28-2011, 11:52 PM   #5
Finnly56
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1985 CJ7 
 
Join Date: Jan 2010
Location: Coalhurst, Alberta
Posts: 20
I had to redo the seals on the heads so while they were apart I gave them a good cleaning.
Dirty


CLEAN


There was a really thick film of grime and sludge below the intake when I took the top end apart. So i'm scrubbing the entire engine inside and out, without taking too much apart. I used HVAC Tin tape to seal off all the holes that I didn't want water to get into and used my garden hose to get out a "POOP" load of sediment, and other stuff that was inside the water jackets and passages.


And after I was done and dried off I gave the crank a quarter turn and blew the tape and also my ears apart LOL.


Valves, seals, and heads all back on.
__________________
"Deh Cockaroach" Build
'85 CJ-7, 400, FTL, D20, Dana 44 F/R, 38.5" Thornbirds... Rebuilding
'85 CJ-7, 258, T5, D300, WARN 8274 winch, 33" BFG A/T... Donor patient
2013 JK Rubicon
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Unread 08-29-2011, 12:47 AM   #6
sprezie
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2004 WJ 
 
Join Date: Apr 2011
Location: springs, colorado
Posts: 25
nice rig to have to "start" with!!!
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Unread 08-29-2011, 01:31 PM   #7
Finnly56
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1985 CJ7 
 
Join Date: Jan 2010
Location: Coalhurst, Alberta
Posts: 20
I definitely lucked out finding this one! Not everything is in great shape tho. Ya it has all the equipment on it, but I've found a whack load of stripped/ broken/ missing bolts and hardware. I figure the PO stuck all the parts together with a bit of dress up parts just to get rid of it.
__________________
"Deh Cockaroach" Build
'85 CJ-7, 400, FTL, D20, Dana 44 F/R, 38.5" Thornbirds... Rebuilding
'85 CJ-7, 258, T5, D300, WARN 8274 winch, 33" BFG A/T... Donor patient
2013 JK Rubicon
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Unread 08-30-2011, 06:14 PM   #8
Finnly56
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1985 CJ7 
 
Join Date: Jan 2010
Location: Coalhurst, Alberta
Posts: 20
T-Case all apart. new seals going in.


Sealed up and ready for paint.


This is the temporary patch job I did on the skid plate that came with DEH COCKAROACH, but I swapped it with the other JEEP I have for now until I build my own later.


__________________
"Deh Cockaroach" Build
'85 CJ-7, 400, FTL, D20, Dana 44 F/R, 38.5" Thornbirds... Rebuilding
'85 CJ-7, 258, T5, D300, WARN 8274 winch, 33" BFG A/T... Donor patient
2013 JK Rubicon
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Unread 08-31-2011, 10:10 PM   #9
Finnly56
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1985 CJ7 
 
Join Date: Jan 2010
Location: Coalhurst, Alberta
Posts: 20
I noticed this a while ago but just got around to taking pictures of it. I have to get the pinion angle changed on the front D44 but the spring perch on the passenger side sits right on the housing and the outside U-Bolt doesn't sit very square. Is that ok sitting like that or should I grind more out of the diff to square it up, or would that take away too much strength? And there is also a hole drilled through one of the ribs on the diff, would that effect the strength that much as well? When I get the pinion angle changed I may have to oval out the hole in order to have the U-Bolt fit through again.



__________________
"Deh Cockaroach" Build
'85 CJ-7, 400, FTL, D20, Dana 44 F/R, 38.5" Thornbirds... Rebuilding
'85 CJ-7, 258, T5, D300, WARN 8274 winch, 33" BFG A/T... Donor patient
2013 JK Rubicon
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Unread 09-03-2011, 12:19 PM   #10
Finnly56
Registered User
1985 CJ7 
 
Join Date: Jan 2010
Location: Coalhurst, Alberta
Posts: 20
Engine out


Everything separated


Frame ready for cleaning and POR 15 on the inside.
__________________
"Deh Cockaroach" Build
'85 CJ-7, 400, FTL, D20, Dana 44 F/R, 38.5" Thornbirds... Rebuilding
'85 CJ-7, 258, T5, D300, WARN 8274 winch, 33" BFG A/T... Donor patient
2013 JK Rubicon
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Unread 09-18-2011, 11:13 AM   #11
Finnly56
Registered User
1985 CJ7 
 
Join Date: Jan 2010
Location: Coalhurst, Alberta
Posts: 20
My new YORK, all cleaned up and resealed.
__________________
"Deh Cockaroach" Build
'85 CJ-7, 400, FTL, D20, Dana 44 F/R, 38.5" Thornbirds... Rebuilding
'85 CJ-7, 258, T5, D300, WARN 8274 winch, 33" BFG A/T... Donor patient
2013 JK Rubicon
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Unread 09-18-2011, 11:18 AM   #12
Finnly56
Registered User
1985 CJ7 
 
Join Date: Jan 2010
Location: Coalhurst, Alberta
Posts: 20
Frame painted.


Base coat on engine.
__________________
"Deh Cockaroach" Build
'85 CJ-7, 400, FTL, D20, Dana 44 F/R, 38.5" Thornbirds... Rebuilding
'85 CJ-7, 258, T5, D300, WARN 8274 winch, 33" BFG A/T... Donor patient
2013 JK Rubicon
Finnly56 is offline   Reply With Quote Quick reply to this message
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