[gregj]

I certainly wish I had a small portion of your talent, I’m in for $20, eight more to go to get Jeff a lifetime membership!
gregj

[jscherb]

Originally Posted by gregj

I certainly wish I had a small portion of your talent, I’m in for $20, eight more to go to get Jeff a lifetime membership!
gregj

Thank you!!

I've certainly got a lifetime of project ideas... with a lifetime membership I guess I'd be posting them all here

[jscherb]

Today's work on the Gaucho is all about smoothing the tub. It's an 87 (or 89, I forget) Wrangler tub, so it needs a bit of smoothing from its years of usage, plus I need to smooth the sheet metal work I did to close in the back.

Here are two of my favorite bodywork tools. The top photo shows my long board sander. This one is about 30" long. I made it from some plastic composite deck boards, although you could make one from wood that would work just as well. It takes 2 3/4" wide PSA (pressure sensitive adhesive), that comes in long rolls. I'm using 80 grit at the moment, I'm still in the roughing in phase.

Why is the board so long? Because Jeeps have so much flat area. It is extremely difficult to get a perfectly flat side on a Jeep tub with a short sanding block or a power sander of the type you might use when woodworking. Only a long board will really give you a flat surface. The longer, the better. And being so long, it sands more square inches in each pass than a smaller board might, so the work goes more quickly. If you're doing bodywork on your Jeep tub, make one of these sanders for yourself, you'll really like the results.

The second photo is a file cleaning card that I use to clean the sandpaper. Body filler loads up sandpaper very quickly, much sooner than the sandpaper wears out, so by cleaning out the sandpaper periodically with this tool, you'll save a lot on sandpaper. Should be available at a good hardware store.

[marylandjeeper]

i never thought to use a file card on sandpaper, good tip.

[jscherb]

Originally Posted by marylandjeeper

i never thought to use a file card on sandpaper, good tip.

Here's another tip...

"It isn't right until there's no light." You can quote me on that.

I use a straightedge constantly when doing Jeep bodywork. With so many flat and straight surfaces, the straightedge is the perfect tool to check your work. It may feel smooth when you run your hand over it, but even a few thousandths of an inch variation will show up in a glossy paint job. If you can put a straightedge on it and not see light between the edge and the body, then you're good. I've got a few minor high spots to work on in this photo, there's one just under the tip of my index finger, you can't see light there... a little more time with the long board sander and this will be perfect.
,

[ReconRabbit]

I always put the blowgun on my air hose to clean the crap outa my sandpaper. Just my 2c.

[Johnnylaw]

Simply amazing, outstanding work!

[CjinPA]

Originally Posted by jscherb

Today's work on the Gaucho is all about smoothing the tub. It's an 87 (or 89, I forget) Wrangler tub, so it needs a bit of smoothing from its years of usage, plus I need to smooth the sheet metal work I did to close in the back.

The tub is from an 87 Wrangler and its looking better every day.




-

[jscherb]

Originally Posted by CjinPA

The tub is from an 87 Wrangler and its looking better every day.
-

Thanks for reminding me

The bodywork is going very well. I plan to have the bodywork and primer done by Wednesday. Probably photos of the Gaucho reassembled and all in the same color by the end of next week.

[offroadaction]

Awesome build! I came across it on the Hemmings blog at Hemmings Auto Blogs Blog Archive Four-Links – Gaucho stepside CJ, Thought Police bikes, GM Fremont assembly plant tour, oddball Euro trucks then did my own at Off Road Action | Off Road Action

Again, great jobs!

[T-birdJunkie]

Wow.

71 pages.

Girlfriend is mad at ThunderbirdJunkie. Jeff, you make ThunderbirdJunkie feel lazy...and you've given him some nifty ideas for his own junkpiles! You, sir, are an inspiration.

Time to go buy a welder!

[dieseltank]

Jeff,

I stumbled on your articles while looking on the internet for hints to install the door weatherstrips. I really gives me great pleasure to see the enthusiasm, skills, accuracy and style you show with this project. I wish I could spend time like you on my car. For, my dilemma is I have to use my CJ7 (with original Isuzu diesel engine) every day to go to work. This means repairs and improvements have to be carefully planned in weekends and holidays.
I bought a set of used doors without window, locks and weatherstrips to replace my rusty doors. Just finished welding to repair the famous cracks and spraying and cut new plastic film to cover the holes behind the door panel. Some upcoming weekend I ‘ll dismantle the old doors and install the “new” ones.
Thank you for giving the information I needed on this subject, and lots of success with your project.

Regards,

Bert

Maasdam, The Netherlands

[jscherb]

Originally Posted by dieseltank

Thank you for giving the information I needed on this subject, and lots of success with your project.

Thanks, I'm glad my posts helped you!

Thanks also to those who contributed to me, I'm now a premier member. Now I no longer have to deal with the hassle of a 5-message PM inbox! Yippee! We made it about half way to lifetime member, but I'm really happy to have gotten to the premier level. It will make my online life here a lot easier.

My most sincere thanks to those who contributed. You all get to drive the Retro Wrangler now

Jeff

[jscherb]

Another little "how to" today - installing windshield glass.

First step is to put the weatherstrip on the glass. I'm working on a Mover's Blanket, they're really nice for working on painted or primed parts - they are designed not to scratch furniture and have thick padding. They're often available on sale at Harbor Freight for $6 or so. Or maybe your mover will forget one, like he did with me

Also remove anything that will get in the way, such as the visors, VIN plate and defroster deflectors.

BTW I'm working on a blanket on the floor, but this is just as easily done with the windshield frame still installed on the Jeep.



Next, put some small rope in the weatherstrip channel where the weatherstrip will go around the sheet metal of the window opening. Wrap it all the way around and overlap it as shown. The twine I'm using is really slightly small for this job, it might break when I'm pulling hard on the last few inches later, but it's all I had on hand this morning. Sometimes it helps to lubricate the groove in the weatherstrip, you can use glass cleaner for that, some people use dish soap. I didn't use anything.



Set the bottom of the weatherstrip over the sheet metal of the window opening from the outside, making sure the rope is inside. Using your finger, make sure the weatherstrip is seated fully across the bottom of the window opening.



Now begin pulling the ropes out, as shown. This will pull out the weatherstrip from in front of the sheet metal to the back and seat it. Usually it's easiest to pull alternately on each side, so eventually the rope ends meet in the middle of the top of the windshield.



Once you've pulled the rope all the way through, run your hand all the way around the weatherstrip to make sure it's seated properly. Then reinstall the visors and other parts and you're done.



It took me way longer to write this up than it did to install the windshield.

Jeff

[jcal73]

YOU ARE SOOO AWESOME!!!

Jeff