Well it's been a little while since I last posted a progress. I'm now officially in month 2 of my build. Overall, I feel like I've accomplished quite a bit although through mostly short increments. I’m taking into considerations two facts:
1. I’ve never done anything remotely this in-depth.
2. I’m only working in the evenings from 8 to midnight.
Here are a few pics of the progress. As always, if you see something strange, feel free to comment. I don't care who's reading this-- you've got to know more than I do!
I got the Classic Tube pre-bent, stainless brake lines run with the Crown extended brake lines going to the front discs and rear drums.
I wanted to run the brake and fuel lines through the eBrake bracket with a rubber grommet like motiv8ya did on his Ghetto Fabulous 79 CJ7 build
but that didn't quite work out for me. The lines were just too stiff and bulky.
Misc. Brake and Fuel Line frame mounts.
I installed the brake proportion valve without a hitch and then noticed that the large rear connector is either the wrong size or needs an adaptor to fit the brake line. Anyone have any thoughts on this?
Crown Extended Brake Lines-- Good quality stuff!
Brake lines - Hard line through frame to extended, braided stainless lines.
Rear brake line and mount.
I finally got the axles put back in place. I’ve got the old Dana 30 axle mocked-up in front for the time being. I've got a Dana 44 from an FSJ but I need to pick it up from a friend who's been kind enough to loan me some garage space. I'm not sure what'll be involved in getting the D44 front to fit, so the D30 will suffice for mock-up.
The rear D44 looks good. It's mocked-up and in-place for now. I'll need to remove it and clean/paint it and then reinstall it. I also got the leafs, shackles, bushings and shocks all replaced and/or painted and mostly assembled. The only issue I ran into was a problem with the square u-bolts on the D44 rear spring mount. I had to order replacements due to the existing being badly stripped. I couldn’t, for the life of me, find an exact replacement. The only square u-bolts I could find were 3” too long (10" overall). They’ll have to do. Can I trim these bolts without ruining them?
I got the fuel tank and skid prepped and coated with POR-15. New sending unit, o-ring, gaskets and hardware too. Found 2 old sending units in the bottom of the tank! Spares, I guess. ;-)
Got the motor further buttoned-up but after reading JeepHammer’s insights on Head Bolt Stretch
, I’ve purchased a new ARP head bolts and will be receiving and installing those later this week. Thanks again, JeepHammer!
Finally installed the motor between the frame rails. The motor mounts are all firmly in-place but look like their being squished non-uniformly. Does this look correct?
Driver Side Motor Mount
Passenger side motor mount
Put a new Carolina Clutch in. It would be fairly quick and straight forward if I only had to do this once—but being inexperienced and apparently having an off day, I did it 3 times. 3rd time’s the charm, right?
After the clutch ordeal I put the transmission and transfer case in place and forced the transmission skid in place. It seems that when the skids and fuel tank were removed they miraculously re-shaped themselves resulting in reassembly struggles. The Jeep laughs at me quietly as I struggle and strain.
The sandblaster (soda-blaster) just called yesterday letting me know the tub is ready. I asked how it looked and he laughed, stating, “lots of bondo and rust! You’ve got your work cut out for ya!
”. Crap. That’s not what I wanted to hear.
Anyone want to come by my place and teach me to weld? I’ll pay for materials, labor, fuel, pizza, beer, etc.