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-   -   19?? CJ7 build thread (http://www.jeepforum.com/forum/f8/19-cj7-build-thread-491916/)

biker250 12-03-2007 10:49 AM

19?? CJ7 build thread
 
As most of you are very familiar with, when somebody asks what year your Jeep is, you smile and say "Which Part?" hence the question marks in the title...

I tried my best to wait until I was finished to do the build thread b/c if you guys are like me, it drives me crazy waiting months & months to see a completed project so I was going to try to post it all from start to finish but anxiety has gotten the best of me in wanting to share the project with the fellow gearheads so here we go....

Background: Got the Jeep almost 3 years ago for FREE! The guy couldn't get the 4.2 to bolt down in the engine bay & thought he had all kinds of stuff messed up so he said just take the thing minus the top & doors. $15 later for new motor mounts, the motor dropped right in!!! :2thumbsup:

A few hundred $$$ later (mainly for a radiator) I had a running & driveable mud buggy. A lot of mud & a few trees later, I had a broken frame rail (D. side where it turns up to go over rear axle) so in comes a $700 rolling chassis (minus engine & tranny) with 4" SL by Rough Country. When the body was being CUT off, it was apparent, a lot of work was in store to get it to bolt to the new chassis. All body mounts were disintegrated & nothing but rust existed. That brings us up to the current "build" which was to fix the body & get this baby goin again. First a few history pictures to prove that it was, indeed, once a mud buggy:



This is how i got it: No top, no doors, no windshield, no radiator, engine wasn't set in

http://i129.photobucket.com/albums/p...p/IM000015.jpg



First time out: The brown jeep is my girlfriend's dad's jeep....HE's the one that got stuck this trip :laugh:

http://i129.photobucket.com/albums/p...p/IM000080.jpg



Doin some muddin:

http://i129.photobucket.com/albums/p...p/IM000159.jpg



About to get really stuck in this crick:

http://i129.photobucket.com/albums/p...p/IM000158.jpg



G/f's dad lendin a hand:

http://i129.photobucket.com/albums/p...p/IM000174.jpg



The green? Jeep:

http://i129.photobucket.com/albums/p...p/IM000181.jpg




Time for the new chassis: Pullin the motor:

http://i129.photobucket.com/albums/p...esthething.jpg



Got the body off:

http://i129.photobucket.com/albums/p...dhismassey.jpg

biker250 12-03-2007 10:55 AM

Now fast forward to the present and I'll begin with the actual "build"



The day we got the new chassis under her...body is just resting on the frame

http://i129.photobucket.com/albums/p...p/IM000522.jpg


Grindin thru all the bondo only to find holes everywhere

http://i129.photobucket.com/albums/p...p/IM000260.jpg


This is gonna need fixed:

http://i129.photobucket.com/albums/p...p/IM000262.jpg


A cab support barely holdin on:

http://i129.photobucket.com/albums/p...p/IM000264.jpg


Fender wells are in sad shape:

http://i129.photobucket.com/albums/p...p/IM000266.jpg


Other really bad pictures:

http://i129.photobucket.com/albums/p...p/IM000254.jpg

http://i129.photobucket.com/albums/p...p/IM000246.jpg

http://i129.photobucket.com/albums/p...p/IM000265.jpg


After removing the roll bar, she's barely holdin together now:

http://i129.photobucket.com/albums/p...p/IM000267.jpg

http://i129.photobucket.com/albums/p...p/IM000268.jpg

biker250 12-03-2007 10:56 AM

Cutting out rotten chunks of metal:

http://i129.photobucket.com/albums/p...p/IM000269.jpg


Finally adding metal rather than removing:

http://i129.photobucket.com/albums/p...p/IM000270.jpg




Using metal I had laying around that's as thick as the steel used for the frame: :2thumbsup:

http://i129.photobucket.com/albums/p...p/IM000272.jpg


Who needs a radius for fender wells? Straight edges are so much easier...and more tire clearence:

http://i129.photobucket.com/albums/p...p/IM000276.jpg


Rocker panels that aren't goin anywhere:

http://i129.photobucket.com/albums/p...p/IM000277.jpg


Got the rear welded up solid...who needs a tailgate anyway?

http://i129.photobucket.com/albums/p...p/IM000279.jpg


P. Side floor cut out:

http://i129.photobucket.com/albums/p...p/IM000283.jpg


And then fixed:

http://i129.photobucket.com/albums/p...p/IM000284.jpg



Rear floor had to go:

http://i129.photobucket.com/albums/p...p/IM000286.jpg

biker250 12-03-2007 11:01 AM

Gutted the dash, wiring, heater:

http://i129.photobucket.com/albums/p...p/IM000288.jpg



Driver side rear fender cut out:

http://i129.photobucket.com/albums/p...p/IM000303.jpg



D. Side rear fender fixed:

http://i129.photobucket.com/albums/p...p/IM000305.jpg



Another view:

http://i129.photobucket.com/albums/p...p/IM000306.jpg



Fabbed in a little cubbyhole for tool bag, jerk strap, small cooler, etc....

http://i129.photobucket.com/albums/p...p/IM000308.jpg



Passenger side rear fender cut out:

http://i129.photobucket.com/albums/p...p/IM000309.jpg



Different angle:

http://i129.photobucket.com/albums/p...p/IM000310.jpg



Weldin up the last bloody fender:

http://i129.photobucket.com/albums/p...p/IM000314.jpg



Measure, Measure, Measure, Mark, Re-Measure, Re-Measure, Re-Mark:

http://i129.photobucket.com/albums/p...p/IM000319.jpg



Then cut:

http://i129.photobucket.com/albums/p...p/IM000322.jpg

biker250 12-03-2007 11:04 AM

Fixing the P. Side rear corner:

http://i129.photobucket.com/albums/p...p/IM000329.jpg



Weldin in the new corner:

http://i129.photobucket.com/albums/p...p/IM000333.jpg



Finished P. Side rear fender:

http://i129.photobucket.com/albums/p...p/IM000338.jpg



Mostly finished rear half of the tub:

http://i129.photobucket.com/albums/p...p/IM000339.jpg



Cuttin out some body mount plates:

http://i129.photobucket.com/albums/p...p/IM000343.jpg



This is where they're gonna go:

http://i129.photobucket.com/albums/p...p/IM000344.jpg



Cut:

http://i129.photobucket.com/albums/p...p/IM000345.jpg



Weld: It's that easy

http://i129.photobucket.com/albums/p...p/IM000346.jpg



Rear body mounts done:

http://i129.photobucket.com/albums/p...p/IM000348.jpg



Yea, that's a 3" body lift....not sure if I'm gonna keep it thatta way..may chop 'em so I have either a 1" or 2" lift to choose from:





Fabbin up a rear floor support/body mount piece:

http://i129.photobucket.com/albums/p...p/IM000370.jpg

biker250 12-03-2007 11:06 AM

Patching up some holes:

http://i129.photobucket.com/albums/p...p/IM000372.jpg


Makin seat brackets:

http://i129.photobucket.com/albums/p...p/IM000373.jpg



Won't be falling out in these babies:

http://i129.photobucket.com/albums/p...p/IM000375.jpg



Cut out D. Side floorboard:

http://i129.photobucket.com/albums/p...p/IM000379.jpg



Makin a piece to fix that floorboard:

http://i129.photobucket.com/albums/p...p/IM000380.jpg



D. Side floorboard done:

http://i129.photobucket.com/albums/p...p/IM000381.jpg



Flushmount taillight holes cut out...It's a good workout on the wrists

http://i129.photobucket.com/albums/p...p/IM000383.jpg



Fabbed up the last of the body mounts...finally!!

http://i129.photobucket.com/albums/p...p/IM000388.jpg

biker250 12-03-2007 11:09 AM

Finally gettin the body off for sandblasting:

http://i129.photobucket.com/albums/p...p/IM000408.jpg

http://i129.photobucket.com/albums/p...p/IM000409.jpg




Apparently, my welds are holding together...at least for now

http://i129.photobucket.com/albums/p...p/IM000410.jpg



Chassis beggin for some attention:

http://i129.photobucket.com/albums/p...p/IM000411.jpg



Locked & loaded for the sandblaster:

http://i129.photobucket.com/albums/p...p/IM000415.jpg



Weeeee little leak in the transfer case that I'm a gonna have to fix:

http://i129.photobucket.com/albums/p...p/IM000417.jpg



New tranny mount:

http://i129.photobucket.com/albums/p...p/IM000419.jpg

biker250 12-03-2007 11:12 AM

Body back from sandblasting:

http://i129.photobucket.com/albums/p...p/IM000480.jpg

http://i129.photobucket.com/albums/p...p/IM000482.jpg




Strenghtening rear body mounts:

http://i129.photobucket.com/albums/p...p/IM000484.jpg



Beefin' up rear floor:

http://i129.photobucket.com/albums/p...p/IM000485.jpg



Underneath tub after sandblasting:

http://i129.photobucket.com/albums/p...p/IM000486.jpg



Rear tub after sandblasting:

http://i129.photobucket.com/albums/p...p/IM000490.jpg



Firewall:

http://i129.photobucket.com/albums/p...p/IM000491.jpg



New motor mounts:

http://i129.photobucket.com/albums/p...p/IM000492.jpg



New bump stops:

http://i129.photobucket.com/albums/p...p/IM000493.jpg



Tranny/t-case after powerwash:

http://i129.photobucket.com/albums/p...p/IM000494.jpg

biker250 12-03-2007 11:17 AM

New water pump with fresh paint on that & thermostat housing to keep it from lookin like old water pump:

http://i129.photobucket.com/albums/p...p/IM000498.jpg



Bondo fiberglass:

http://i129.photobucket.com/albums/p...p/IM000503.jpg



More fiberglass:

http://i129.photobucket.com/albums/p...p/IM000504.jpg



More fiberglass:

http://i129.photobucket.com/albums/p...p/IM000505.jpg



Now before looking at the Bondo pictures, you need to realize my goal with the bondo or with the Jeep period is not to make it a show or original jeep by any means. I used the bondo just to smooth out some of the HUGE "elevation changes" created by welding on really thick pieces of steel to fix body panels.


First coat of bondo:

http://i129.photobucket.com/albums/p...p/IM000506.jpg

http://i129.photobucket.com/albums/p...p/IM000507.jpg



2nd coat of bondo:

http://i129.photobucket.com/albums/p...p/IM000511.jpg

http://i129.photobucket.com/albums/p...p/IM000512.jpg

http://i129.photobucket.com/albums/p...p/IM000513.jpg

biker250 12-03-2007 11:19 AM

Won't be needing the hood scoop anymore since all HVAC is gone:

http://i129.photobucket.com/albums/p...p/IM000518.jpg

http://i129.photobucket.com/albums/p...p/IM000519.jpg




3rd & final coat of bondo:

http://i129.photobucket.com/albums/p...IM000522-1.jpg



Dash re-design begins:

Dash before any work:

http://i129.photobucket.com/albums/p...p/IM000377.jpg


Cuttin out all the holes:

http://i129.photobucket.com/albums/p...p/IM000527.jpg


Fillin in with new metal:

http://i129.photobucket.com/albums/p...p/IM000528.jpg



Layin out all the pieces that will be goin into the dash:


http://i129.photobucket.com/albums/p...p/IM000529.jpg



Cuttin new holes:

http://i129.photobucket.com/albums/p...p/IM000745.jpg

biker250 12-03-2007 11:21 AM

Fittin new gas tank:

http://i129.photobucket.com/albums/p...p/IM000531.jpg



Finally made a decision on paint for the outside.....oh yea, the cheap & easy route :cheers2:

http://i129.photobucket.com/albums/p...p/IM000683.jpg





2 coats of primer:

http://i129.photobucket.com/albums/p...p/IM000701.jpg



Doin some carb work inbetween coats of primer:

http://i129.photobucket.com/albums/p...p/IM000692.jpg



The hood before re-painting:

http://i129.photobucket.com/albums/p...p/IM000693.jpg



The hood after some love from the sander:

http://i129.photobucket.com/albums/p...p/IM000703.jpg



More fancy paint work:

http://i129.photobucket.com/albums/p...p/IM000706.jpg



First coat of primer:

http://i129.photobucket.com/albums/p...p/IM000707.jpg



The tub off for "Lightning Liner" (Rhino Liner knockoff):

http://i129.photobucket.com/albums/p...p/IM000713.jpg

biker250 12-03-2007 11:24 AM

Skid plate problem took me most of a whole day to fix. Either motor needed moved back an inch or skid needed moved forward an inch. Decided to move skid forward an inch....it's not as easy as it sounds!

http://i129.photobucket.com/albums/p...p/IM000735.jpg



Fabbin up new mounts for the skid:

http://i129.photobucket.com/albums/p...p/IM000736.jpg


http://i129.photobucket.com/albums/p...p/IM000738.jpg



Skid plate done:

http://i129.photobucket.com/albums/p...p/IM000739.jpg



Sprayed undercoating on whole frame:

http://i129.photobucket.com/albums/p...p/IM000741.jpg



Tub back from "Lightning Liner" and installed on chassis:

http://i129.photobucket.com/albums/p...p/IM000747.jpg



Underside of tub:

http://i129.photobucket.com/albums/p...p/IM000754.jpg



Rear:

http://i129.photobucket.com/albums/p...p/IM000756.jpg




Just a lil tire clearance :D

http://i129.photobucket.com/albums/p...p/IM000759.jpg

biker250 12-03-2007 11:28 AM

Thought this was just a funny picture....it's the bellcrank and at one point, somebody put in that grease zerk & thought it a good idea to fill the whole thing with grease (yea, it's hollow) so when I put a rag in there & pushed it out, it came out lookin like one big turd. :rofl:

http://i129.photobucket.com/albums/p...p/IM000760.jpg



Test fittin grill & radiator:

http://i129.photobucket.com/albums/p...p/IM000761.jpg



Makin brackets to lower the radiator:

http://i129.photobucket.com/albums/p...p/IM000762.jpg



Notice the bracket welded to the radiator flange:

http://i129.photobucket.com/albums/p...p/IM000763.jpg



Radiator done...notice the middle of the radiator where you can see where the fan got into the radiator one time. Yea, that'd be the same tree that broke the frame & buckled the whole body....it was a bastard of a tree...but it was either take the tree or roll....and with no roll cage and no seatbelts with 4 people in the Jeep, I opted for the tree:

http://i129.photobucket.com/albums/p...p/IM000764.jpg



Front shot of grill after radiator has been lowered. Sometime, I'm gonna make some kind of guard to protect the bottom part of the radiator hangin below the grill:

http://i129.photobucket.com/albums/p...p/IM000765.jpg



Shot from the inside:

http://i129.photobucket.com/albums/p...p/IM000766.jpg



Painted firewall...used Krylong Rust Tough enamel...that stuff is awesome:

http://i129.photobucket.com/albums/p...p/IM000768.jpg

http://i129.photobucket.com/albums/p...p/IM000771.jpg

onesourcemike 12-03-2007 11:32 AM

This is great, keep them coming!!!

biker250 12-03-2007 11:33 AM

CB antenna mounted:

http://i129.photobucket.com/albums/p...p/IM000772.jpg



As she sits right now:

http://i129.photobucket.com/albums/p...p/IM000777.jpg







So that's about where I'm at now....I did get the base coat of paint sprayed on the tub last night and the hood also has a base coat (you have to pick & choose days warm enough to paint now that the snow is falling frequently).

I'm also in the middle of fixing the clutch linkage to work with the 3" body lift...not a big deal just a couple hours.

Still to do:
-) Run bypass hose from thermo housing to water pump since I have no heater
-) Finish clutch linkage
-) Finish dash
-) Wire engine compartment/gauges/radio/lights (I'm not using any wiring harness...making my own)
-) Install fenders & hood then finish paint job
-) Finish brake lines (from master cyl. to prop. valve) & bleed all lines
-) Install seats
-) Fill with fluids
-) Try to get it to start
-) Figure out what all problems I have & try to fix them :thumbsup:


Widely open to any suggestions. Please hold off on the 3" body lift putdowns...I know they're bad news but I'm not doing any serious trails, I just want the clearance. And the rollcage will be the next project....in good time.


The time now is 02:21 AM.

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