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Smittybilt Products at Oconee Off-Road!Building a Bumper?Ruffstuff Axle Simple Swap Kit!

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Unread 05-01-2012, 09:37 PM   #1
nacheswheelin
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1960 CJ5 
 
Join Date: Sep 2011
Location: Selah, Wa
Posts: 543
Justins "Civillian Jeep" Build

I have been wanting to do a build thread for a while and started compiling pictures when I had started my build. My build includes a axle swap, re-gearing, lockers, carb. swap, custom tube fenders, rear tool box, tire carrier, s-10 heater fan, fender notch to move my seat back, paint, and a few odds and ins. I started this build last september with a fairly stock CJ. It is an ongoing project with lots of blood sweat and years.

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Unread 05-01-2012, 09:43 PM   #2
nacheswheelin
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Tire carrier build
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Unread 05-01-2012, 09:54 PM   #3
nacheswheelin
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The best way to use a motorcycle jack
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Unread 05-01-2012, 11:10 PM   #4
nacheswheelin
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For my fenders I used 14 guage plate and .049 wall 7/8 th tubing. The harbor frieght tube bender did the job until I tried to tweak the pipe a little while in the bender. Before I could finish my last fender the bender die which was cast broke. So I used some pieces I had messed up on tweaked the bends and welded them together. The fronts turned out good, the rears are a little different but my main goal was to stop a lot of the mud that those 35's throw around. The flairs are 6 inche wide which is almost exactly in line with the tires.
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Unread 05-02-2012, 06:35 AM   #5
Shiftace
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What are your 44s out of?
Are they narrowed?
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Unread 05-02-2012, 10:20 AM   #6
nacheswheelin
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Quote:
Originally Posted by Shiftace View Post
What are your 44s out of?
Are they narrowed?
I got my 44s out of a 79 wagoneer, becuase I have passenger side offset pumkins. I narrowed the front 3 1/2 inches on the drivers side. The axles have discs in the front and will in the rear soon.
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Unread 05-02-2012, 11:01 AM   #7
nacheswheelin
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This was the original size of the axle
What I did was measured three different places on the yoke back towards the pumpkin 3 1/2 inches. Then i cut the weld around the yoke with a grinder. I went straight down into the axle tube so I would not cut my yoke. After the weld was cut I scribed my measurement lines with a grinder into tube and yoke so i could re-align them the same way they came off. I cut the tube with a chop saw. To get the axle tube out of the inside of my yoke I took a sawzall and cut in a couple different places then beat it out with a chisel and a hammer. I then stuck my yoke in the oven on 475 about four hours, ran outside playing hot potato in my welding gloves and stuck it on the tube. After a couple home-run swings with a double jack it was aligned and ready to weld. If any one reads this remember to tack it a couple times before you run your bead otherwise it will move after it is heated and it is a pita to get off and on.
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Unread 05-02-2012, 11:14 AM   #8
nacheswheelin
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You can see my lines that I used as a reference to get my yoke properly aligned. I ran three welds on this yoke, no gas with .035 Flux cored wire.
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Unread 05-04-2012, 09:34 AM   #9
nacheswheelin
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Yesterday I put in a fourteen hour day on my jeep trying to do a power brake conversion on my cj the po hooked up the clutch and brake manual m.c. backwards he had the brakes and brake pedal ran to the clutch side. Does anyone know what or why it was like that? All I could figure is that it must have been a European m.c. to be backwards or my jeep used to be a mail truck that didn't seem possible though. I had started with a booster off of a scout I got for a 20 dollar bill at a local yard. I wanted to go with the bigger booster and m.c. for my Dana 44s tuning those 35s. It was too big so I ripped into an old ranger that I have and took the dual diaphragm m.c. and the individual clutch cylinder. Is that called a slave cylinder? I cut out a hole in my firewall and re-sheeted it with some 14 gauge steel I was going to use 11 gauge but I thought that might be too heavy. The pedals were the biggest issue that I had. I spent about five hours fabbing up a break pedal the at nine I went to bed.
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Unread 05-04-2012, 10:08 AM   #10
2girlsAndaGuy
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did you weld those rear tubes to the tub?
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Unread 05-04-2012, 02:30 PM   #11
nacheswheelin
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Quote:
Originally Posted by littledochawk
did you weld those rear tubes to the tub?
I drilled the tubes in set them with a tach weld. Then I tied it all together with the sheet metal.
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Unread 05-04-2012, 11:21 PM   #12
nacheswheelin
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I got my clutch master cylinder in, the pedals are hooked up and I got a roll of brake line. So tomorrow I will run new brake lines and hook up my prop. valve. I will also be re- building my carb and setting the dwell. If anyone has advice on the dwell I could use it first time I've ever messed with it.
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Unread 05-05-2012, 09:44 AM   #13
nacheswheelin
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Thanks to a couple of j.f. members I have found out that the electrical plug on my prop valve is not going to effect my setup , going out to finsh the brakes and clutch,
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Unread 05-05-2012, 08:49 PM   #14
nacheswheelin
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Well I had everthing hooked up bled the clutch and brakes, started my jeep and was ready for a test drive. I threw it into first gear and the jeep started to move with the clutch pushed all the way in. Huge disapointment, my best guess is the m.c. I used for the clutch. I got it off of a 3/4 to chevy but it does not have enough force to actuate my clutch. Does anyone know why? Or have any suggestions on a m.c. I could use that will work?
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Unread 05-06-2012, 11:37 PM   #15
nacheswheelin
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Today I swapped out the chevy clutch master cylinder for one out of a cherokee it goes into gear but still wants to take off without the breaks on. I got busy and couldn't make it to the yard to pull a m.c. so I bought one at o'riellys for 30 bucks. I am kinda wishing that I had not started this swap, watching all the jeeps drive by my house to go up in the mountains was a big heartbreaker and it became a reality when I failed on my swap. Exspecially if I wasted 30 bucks for something that will not work. I am sure that the problem has to be air in the line, or a worn slave cylinder I will finish this tommorow one way or another.
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