Ugly Betty - TJ Magnum V8 Conversion and more - Page 40 - JeepForum.com

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post #586 of 746 Old 01-18-2014, 02:13 PM
Rubicon0311
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I say make inners....always a pain trying to clean out the engine bay.

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post #587 of 746 Old 02-12-2014, 04:18 PM
tyjreid
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Jason, I've know you've discussed it before but, when you wired your speedo did you us the two wires from the dodge plug and a 5 volt supply from the ecu?
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post #588 of 746 Old 02-12-2014, 05:58 PM Thread Starter
Jason
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I don't remember, so that means it must have been straight forward.

All the speed sensor is is a 5V, ground, and signal to the PCM. I seem to recall that I had to wire in all the jeep stuff from the fire wall back (Neutral sense, speedo, fuel level) into the Dodge harness.

"Ugly Betty" Build - 97 TJ 5.9 Magnum / 46RE Swap

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We're men! We don't need no stinkin directions!
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post #589 of 746 Old 03-07-2014, 08:32 AM
silvertub2000
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Awesome job!, I wanna do similar swap, you should swap axles out with the dodge lol be a cool rig
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post #590 of 746 Old 04-11-2014, 10:31 AM Thread Starter
Jason
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Welllll... Since the weather is getting better, and my travel has settled down a little bit, I've been doing a little work on the ol' girl. I have many other projects that have been waiting all winter, so I won't be able to make serious progress here, but some is better than none. I also may try to move, and this Jeep might get sold at the same time, so everything is kind of up in the air at the moment. But, on to the progress:

The turn signal stalk never worked right. Turning the steering wheel wouldn't cancel it in one direction, and the other direction didn't really work at all. I finally replaced that yesterday. I know this seems minor, but it was terribly annoying.

Last year I scored a windshield to replace my very cracked one. It was so bad that the wiper blades got tore up and it wouldn't clear the windshield in a rain. Yuck. I also needed sun visors, so I asked for the whole frame which ended up being very clean rust-wise. The guy that pulled it had trouble with the bolts and torched them out. I used my impact driver and they came free pretty easy.



Since I won't likely see the bottom of this windshield frame again, I shot some primer on it and under the hinges to prevent rust. There was a tiny bit of rust that I sanded off by hand. I am going to use my existing hinges, which were also in good shape. Just needed a little touching up.


"Ugly Betty" Build - 97 TJ 5.9 Magnum / 46RE Swap

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post #591 of 746 Old 04-15-2014, 07:46 PM Thread Starter
Jason
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Windshield and frame were successfully replaced. It was great to have functioning windshield wipers.

I drove it today. A few observations:

- I haven't started it in a few days. It cranked extra-long, then puffed a bit of smoke out of the tail pipe when it finally started. Ran fine after that.

- It was windy. The hood was flopping around a lot. It's held down by a bungee cord and the factory safety latch. Passing gravel trains made the hood jump enough to make me nervous. I need to engineer a permanent latch, like pronto.

- The shocks are super craptastic. I won't replace them, but I noticed them clomping around in front while I drove it today.

- I still enjoy romping around in this little *****.

"Ugly Betty" Build - 97 TJ 5.9 Magnum / 46RE Swap

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post #592 of 746 Old 07-27-2014, 04:01 PM Thread Starter
Jason
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my travel has settled down a little bit
Famous last words, I suppose. I've been on the road every other week, then trying to catch up with house work and other normal things when I'm home, so little Jeep work has done. This work project should end in September, so hopefully I will be around more.

I did build some inner fenders, mostly to hold the stuff under the hood (fuse box, coolant overflow, etc.)



I'm still not happy with these things, but I continued to massage them until they were acceptable. They are painted and ready to go.

I finally cut the holes for the flush mounted tail lights:



I started sanding and prepping for paint. The black color on this Jeep was some rubberized or textured paint. Soft and cuddy; hard to sand off. I also found a little rust when sanding. These things will need to get patched:


"Ugly Betty" Build - 97 TJ 5.9 Magnum / 46RE Swap

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post #593 of 746 Old 07-30-2014, 05:43 PM Thread Starter
Jason
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Got that rust hole patched up. Just need to touch it up a little and should be good to go.

"Ugly Betty" Build - 97 TJ 5.9 Magnum / 46RE Swap

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post #594 of 746 Old 08-01-2014, 07:19 AM Thread Starter
Jason
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- It was windy. The hood was flopping around a lot. It's held down by a bungee cord and the factory safety latch. Passing gravel trains made the hood jump enough to make me nervous. I need to engineer a permanent latch, like pronto.
So, "pronto" means 3-4 months in my world. Got some hood pins the other day. Putting the fenders on today to align everything and installing the hood pins today.

"Ugly Betty" Build - 97 TJ 5.9 Magnum / 46RE Swap

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post #595 of 746 Old 08-12-2014, 08:43 AM Thread Starter
Jason
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Updates:

- Hood pins are finished. The strike plate is chrome, and I'm not happy with it. I wanted to paint it to match, but I think it will get scratched up by the cotter pins. Maybe powder coat would work better?

- Found another hole to patch. Tons of dirt and **** behind. (No wonder it rusts...)



- Instead of patching another hole on the tub (under the tailgate hinge; shown in pic a few posts above) I decided that would be a handy place for some reverse lights. I tried cutting with a hole saw but the metal was too week to hold the centering bit. So that leaves me with the dilemma of cutting a somewhat round hole without a hole saw. You can see in the pic below where my saw walked and started cutting above where I wanted it.

This was my solution:

I've measured that my plasma cutter will cut about 3/16" from the edge of the tip, so whatever guide surface that I use needs to be 3/16" away from where I actually want the cut. So I found a smaller hole saw and stuck it to the tub with a magnet, and used that as a guide for my hole. I forget my calculations, but that left my hole 1/8" smaller than it needed to be. I just filed the rest out so the light would fit.

-Remember the black color on the body was some textured, rubberized stuff, so I sanded it all off. Decided that I didn't like the texture of the white paint either, so I sanded that all off too. Not real interesting work, but here's an in progress pic:



- After I got all the sanding done, I got on to spraying primer. I only have a cheapie HF gun for spraying, but it's worked surprising well thus far. My first batch I mixed was way too thick (but recommended by the data sheet), and I spent a lot of time sorting out the gun settings and mix ratio. After much experimentation, I ended up tripling the amount of reducer to get it to lay nicely. I also only have a paint tip which probably didn't help.

Since my gun was flinging some serious primer boogers all over the place, I sanded all the panels down again with 320 grit and once it was all smooth I shot another coat of primer. This one came out much better since I had the mix correct. The primer on the hood cracked (likely my fault for laying it too thick and/or moving the hood while it was wet. And there is a spot where I leaned on the Jeep. Those two areas need some attention, but after that I should be able to hit it with some color.



Then, I went fishing:


"Ugly Betty" Build - 97 TJ 5.9 Magnum / 46RE Swap

Quote:
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post #596 of 746 Old 08-14-2014, 06:26 AM Thread Starter
Jason
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Here's some of the cracks on the hood. It peeled on one spot, and the primer remained soft to the touch. Tells me there's an adhesion problem somewhere. The bottom 1/4 of the picture was unsanded (you can see it's rough) and the top part was sanded. Going to strip it and start over.



Meanwhile, I wet-sanded the primer on everything else with 320 grit again -- got it really smooth. Burned through in a few places, so I touched them up. Clean, clean, clean. I didn't want to fuss with my junky gun that I sprayed the primer with, so I bought a newer, nicer gun.

Everything else is now in color:



The paint laid well right off the bat. Came out very well with little orange peel. There are a few specs of dust in it here and there, and it sagged on the passenger side due to a combination of poor light and inexperience.

"Ugly Betty" Build - 97 TJ 5.9 Magnum / 46RE Swap

Quote:
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post #597 of 746 Old 08-18-2014, 11:07 AM Thread Starter
Jason
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Finally got the hood looking nice, then sprayed. I rolled it out of the garage so it can bake in the sun a bit. The camera doesn't even pick up the retina-searing color of this thing.


"Ugly Betty" Build - 97 TJ 5.9 Magnum / 46RE Swap

Quote:
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We're men! We don't need no stinkin directions!
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post #598 of 746 Old 08-18-2014, 07:03 PM
milemarker01
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Awesome job!! Nice to see some progress.
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post #599 of 746 Old 08-19-2014, 08:49 AM Thread Starter
Jason
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Thanks. It's nice to see this thing moving forward a bit.

The transmission pan has been dripping a bit of fluid for a while. It's gotten worse over time, so I am starting to look into that. It was wet above the pan, so I think the culprit is the fill tube. I pulled it out and tried to reseat it in its gasket. Re torqued the pan bolts too. Letting it sit overnight to see if there are any new drips. If not, then the fill tube was the culprit. I'll re-fill and see if it still leaks after that. If so, I'll replace that fill tube seal. I would have just replaced it, but the parts stores don't have it and I'd have to order from a dealer.

"Ugly Betty" Build - 97 TJ 5.9 Magnum / 46RE Swap

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We're men! We don't need no stinkin directions!
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post #600 of 746 Old 09-01-2014, 12:19 PM
Poodah
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Jason I am currently in the middle of a 5.9 swap into a tj. I have read your whole thread and it has been an awesome reference. I have a question about cruise control. My jeep currently does not have cc. The donor dodge ram does. My question is did you include cc into your build? If so how did you handle the wiring?
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