Poor Man's CJ5 (Bringing it back from the grave)

[rkbell]

So I've asked lot's of questions and even answered a couple and I thought I should start a "Poor Man's" rebuild thread about my 77 CJ5 that I picked up the end of JAN 09. Hope ya'll like the pics - there will be more to come as I'm not even close to being finished yet but I plan to have her in decent shape by hunting season (September).

Warning - Scary pics follow....... But if I can do it, anyone can!



When I brought it home:


Front End:

Before:


After:


Transmission Rebuild:



Dash Rebuild:




Carb rebuild (Holley 4160):


Ignition:

Before:


After:


Motor cleanup (AMC 304):

Before:


During:


Body (Tub stayed on frame):

Ughhh...


Almost ready to part her out....


Getting her done....





I've done alot of other things that I forgot to take pictures of (Too much Miller Lite I reckon) and I'm sure I'll forget to list all here (In no particular order):

Rear Brakes
Clean / Service Diffs
Replaced fuel gauge
Fixed all wiring / lamps, grounds, etc
New wheel bearings
Repaired floor pans
Mech temp gauge
Replaced thermostat & radiator cap
Changed all fluids / Filters
Compression tested motor (Great compression)
Team Rush upgrade
Set timing
New Seats (not installed)
New windshield frame / glass (not installed)
New battery tray / battery cables
Inspected / lubed / painted drive shafts & installed new U-joints
New front (OEM) shackles & bushings
New shocks (Skyjacker Hydro 7000's)
Plastic glove box
New seat belts (not installed)
New heater control cables / knobs
New headlight switch
New blower switch
New tail lights
New fan belts
New air cleaner
New fuel filter
Clutch set
Lug nuts
Trans shifter boot / ring
T-case shifter ring
New Speedo cable
New exhaust manifold to downpipe flange gaskets

Anyway, my point is - I'm no more than a shadetree doing this in my free time and for those who are thinking about it but hesitant - Go for it! I'm having a blast, busted knuckles, stripped torx bolts, rusted fenders and all!

[silbotta]

Nice, looking good

[Coiz]

Looking good. Did you do metal repair on the rocker panel or just use all bondo?

[rkbell]

Actually I used fiberglass mat and resin. Very little bondo. Since I don't weld and I wanted to do this myself, I'm pretty much sticking to what I know (kind of).

[-jeep-jeep-]

looking good, another good build to give me more motivation for mine

[caleb7mm]

looking good so far! I want another 5 one day....

[Lifesgoodhere]

slick man, you do good work.

[syphonation]

Was it much trouble to pull the motor out and paint it? That's on my list for my restore, too and I'm dreading it. What parts did you take off and which did you leave on during painting?

Can't wait to see the finished product

[rkbell]

Originally Posted by syphonation

Was it much trouble to pull the motor out and paint it? That's on my list for my restore, too and I'm dreading it. What parts did you take off and which did you leave on during painting?

Can't wait to see the finished product

Didn't pull the motor, just cleaned it up as much as possible when I pulled the carb, valve covers, dizzy etc. I also pulled the alternator, fan, pulley's etc to spruce up a bit. Wire wheeled the intake (while on motor) and block as best I could. After doing a compression test on the motor plus no leaks & clean plugs, I figured I didn't need to fix what wasn't broke (yet).

[John Strenk]

This manual looks familiar.

[rkbell]

Yeah John, wondered if you'd notice. Your assistance has been invaluable up to this point! 1st CJ I've owned that all the electricals work (now)! I would probably have never started or at least done as much as I have without folks like you and Jeephammer (and many others) imparting their knowledge and wisdom on me!

[brian613]

looking good. i started a 77 cj-5 build also.




got body rust but its coming along nicely

[rkbell]

OK, I haven't gotten a whole lot further between work and all. Ya'll know the deal, once body work is started, its never good enough. Man have I been sanding, filling, sanding, primering, sanding, etc, etc, etc.

I went ahead and bolted up the roll bar so the bolt heads through the body get coated when I paint (paint should be in this coming week). I'll be leaving Thursday for our annual Rolling Thunder ride to "The Wall" in D.C. and was hoping to get the ol' girl painted prior to leaving so she can cure a week or so before putting her all back together. I've also been doing alot of interior work getting ready for the Herc. Lot's of work left though but I'm moving my "completion" date up to July as opposed to September. We'll see....

Roll bar back in, fenders (background) almost ready for paint



Rear end almost ready for paint



Hood and windshield frame almost ready for paint



More to follow...

[rkbell]

Well, the paint arrived today - Thanks for the info garbageman! (Gillespie Coatings Lusterless Desert Sand - Mil Spec 1970 - present) and I tried it out on the grill...



Propped it up for a poser shot...



I think it's going to look decent (at least way better than it did) with black armor and top.

[Dad03]

Originally Posted by rkbell

Actually I used fiberglass mat and resin. Very little bondo. Since I don't weld and I wanted to do this myself, I'm pretty much sticking to what I know (kind of).

I am facing the same body issues and was contemplating using fiberglass mat to repair some of the rusted out metal tub (floorboards). I have more experience working with fiberglass from my past boat repair projects.

You help further convince me to go this route.

Thanks