Keith, did you need to enlarge or relocate the holes for the windshield hinges in the tub? On my repli-tub i can't get the top of the hinges flush with the cowl. They are about 1/4 too high which results in a gap between the seal and the cowl.
Yes I did. Had to slightly elongate the holes in the Repli-tub to get the hinges lower to match that of the OEM tub I still had on hand. Just another peeve on the Repli-tubs that needed to be done.
Once they were filed and the upper hinges mounted, I used a 3/8" threaded rod as a jig to setup the bottom hinges. Factory settings are 12-3/4" spacing between the hinges center-to-center measurement. The threaded rod will align the bottom hinge pin hole with the upper hinge pin hole and use nuts to lock it into place while mounting the bottom hinge to the body. I saw them use a similar jig at the Jeep Toledo Ohio plant back in 1980 when I did a factory tour of the assembly line. I remember things like that but of course their jig was much more elaborate.
You can see them slightly elongated in the pictures below
I wanted to follow up on your mention of posting a picture of the fixed hood cowl radius. Are you still planning on doing that?
Also, there was mention of the primer coating, have you switched to something different?
Finally, I got a note from the folks at Willies Overland who has said they are now seeing the new bodies but have not done the work to see what improvements/modifications they now no longer need to make. I will continue to press them for that. Although it would be bad for their niche business I'd like to see them get to a place where they don't have to make any modifications to the bodies before they sell them.
Thanks for making the diagram, I look forward to seeing it. I know many other have thanked you for your hard work in improving your products and taking the time with us to listen to and address our concerns. That type of customer service and involvement is rare.
I've been chatting with Jay at Overland he has confirmed that he is now seeing the improved bodies coming in but says there are still some things his shop is doing to make them fully ready to install. I have asked him to detail what is still being done and will definitely pass on whatever it is he shares with me. I'm still a number of months away from being ready to acquire a body but my hope is that by then he will basically be out of the business of 'fixing' bodies because all the issues will be addressed at the factory.
To others in the forum, my Jeep came without a tailgate and it's never been an issue. A CJ5 isn't big enough to carry much cargo. As I go through the process of deciding on fiberglass or steel (I prefer steel and am now leaning well in that direction thanks to this particular forum) but I find myself wondering if maybe having a tailgate versus not might be a good thing. I'm interested to know if any of you find it useful to have.
I have a 78 cj5 that did not originally have a tailgate. Opted to go with one of the tubs with a tailgate. It is nice on occasion. I can take out my backseat and and fit more stuff in the back with the tailgate down. One thing I didn't realize when I specified I wanted a tailgate was that the tub also had the divot on the body that was a throw back to old soft top or spare tire carrier or whatever. See photo. Not a big deal but every time I tell someone who knows jeeps that it is a 78 they point out that I either have the wrong body or don't know the year.
I have been considering the tailgate, I spoke with a good friend who has had both and he pretty much said the same as you - it adds convenience. I'm leaning in that direction but I have a rear bumper/tire rack and matching front bumper that my dad and I built many years ago. It would require replacement or modification that for sentimental reasons I don't know that I want to do.
Have you removed the indentation mentioned above on the late 70's CJ5 bodies yet? Whether I go with or without a tailgate I would like to body to be model/year correct.
Thanks for posting the diagram. I take it then that you can do a tub with no tailgate if needed but generally don't make them or stock them regularly? You mention offering the tailgate chain later, I'm not sure what you mean. They don't come with the tub?