"Deh Cockaroach" Build - JeepForum.com

 
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post #1 of 12 Old 08-27-2011, 11:05 PM Thread Starter
Finnly56
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1985 CJ7 
 
Join Date: Jan 2010
Location: Coalhurst
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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post #2 of 12 Old 08-28-2011, 11:32 AM Thread Starter
Finnly56
Registered User
1985 CJ7 
 
Join Date: Jan 2010
Location: Coalhurst
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
Finnly56 is offline  
post #3 of 12 Old 08-28-2011, 11:37 AM
Imped
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2004 TJ Wrangler 
 
Join Date: Feb 2008
Location: Indianapolis
Posts: 20,294
Thornbirds.

OlllllllO
Float Test Build
IndyORV
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post #4 of 12 Old 08-28-2011, 10:18 PM Thread Starter
Finnly56
Registered User
1985 CJ7 
 
Join Date: Jan 2010
Location: Coalhurst
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.

"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  
post #5 of 12 Old 08-28-2011, 10:52 PM Thread Starter
Finnly56
Registered User
1985 CJ7 
 
Join Date: Jan 2010
Location: Coalhurst
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
Finnly56 is offline  
post #6 of 12 Old 08-28-2011, 11:47 PM
sprezie
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2004 WJ 
 
Join Date: Apr 2011
Location: springs
Posts: 25
nice rig to have to "start" with!!!
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post #7 of 12 Old 08-29-2011, 12:31 PM Thread Starter
Finnly56
Registered User
1985 CJ7 
 
Join Date: Jan 2010
Location: Coalhurst
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
Finnly56 is offline  
post #8 of 12 Old 08-30-2011, 05:14 PM Thread Starter
Finnly56
Registered User
1985 CJ7 
 
Join Date: Jan 2010
Location: Coalhurst
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
Finnly56 is offline  
post #9 of 12 Old 08-31-2011, 09:10 PM Thread Starter
Finnly56
Registered User
1985 CJ7 
 
Join Date: Jan 2010
Location: Coalhurst
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
Finnly56 is offline  
post #10 of 12 Old 09-03-2011, 11:19 AM Thread Starter
Finnly56
Registered User
1985 CJ7 
 
Join Date: Jan 2010
Location: Coalhurst
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
Finnly56 is offline  
post #11 of 12 Old 09-18-2011, 10:13 AM Thread Starter
Finnly56
Registered User
1985 CJ7 
 
Join Date: Jan 2010
Location: Coalhurst
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
Finnly56 is offline  
post #12 of 12 Old 09-18-2011, 10:18 AM Thread Starter
Finnly56
Registered User
1985 CJ7 
 
Join Date: Jan 2010
Location: Coalhurst
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  
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