Jeep Enthusiast Forums banner

Clay's Build Thread

556K views 5K replies 145 participants last post by  Skerr 
#1 · (Edited)
I have been contemplating posting a build thread for awhile. After viewing some of the current ones I got really pumped! I also figured that as long as I was going to be asking for help fixing stuff I might as well have it in the thread... so here we go. My 16 YO son, Clay, and I are building his CJ5. It's a 79 that I acquired in a boat/Jeep trade nearly 2 years ago. I got it for myself but I don't fit well, so I got a 7 and gave him the 5. He is really stoked about building the Jeep and I can't think of a better father/son project. Clay will be doing the work while I supervise ;). The 5 has a 258, T18A, D20 with axles from an 85 CJ7, D30 and AMC20. Gears are 2.72. We will probably go to a 3.73 in the future. It will get the RC 2.5" lift, Procomp 9000 shocks, and a urethane bushing kit (already purchased). It also has a FG tub which will require a bit of glass work. We had already completed the frame resto when we discovered that we didn't do it right. So we took it back down to bare metal again, finding some rot and a few cracks. We should have those repairs made in the next couple of weeks. After that the frame gets POR-15 and black implement paint. In the meantime, we'll be working on getting the engine painted and installing the MC2100. In these pics Clay is prepping the T18A for paint. He wanted to paint it silver with a red stripe, but I put the Kibash on that! So he settled for a silver tranny and red shift levers... when we get there. He plans to paint the rig International red (tractor paint) with a silver tub floor. Hmmmm... maybe! It MIGHT look good. We just finished watching the entire Season 2 of the Rat Patrol... so guess what HE wants to mount up!?!? :laugh:
 

Attachments

See less See more
5
#704 ·
Right now I'm golden!!! My kids are at the age that they keep asking me AND mommy when they are gonna get to ride in daddy's jeep!!! Aparently mommys unlimited ruby JK isn't cool anymore!!!

And I went and spent $300 of my Jeep fund on her Jeep since it was having electronic throttle control issues... Stupid technology!!! And I got to put tires on it soon... So this spring when I drop $1500 on 38's, she can't say a darn thing!!!

There is a method to my madness!!!!
 
#707 ·
I distinctly remember the ground shaking when he wheeled his rig into my driveway. I thought the entire logging crew that's working down the road was pulling in all at once. It's true his tailgate is only 8" tall, but it's also 4' above the ground, and I think the "boom" was actually a 10,000# crane! :rofl: The first thing Jeff said when he fell out of his truck (Jeff ain't real tall!) was something about it being a borrowed truck... that it fits into the bed of his regular truck!!! And did I tell you his truck is spotless!? :wave:

'appreciate ya, Jeff! :2thumbsup:
 
#710 ·
Finally got off my sorry good-for-nothing-buttocks and got some work done on Clay's rig. Hood and dash are in HB primer. Have to get more. Thinking about webbing-out the underside of the hood, inside fenders, and firewall. I understand that you can buy the paint. I think it would be a neat effect.

Clay signed up for a 16 week welding course at the local community college. He is dual enrolled there, and as long as he is dual-enrolled, the class is free!

After looking at dashs on Double D Fab website, Clay is determined to make his own. We have AutoCad 2008 on our computer and Clay has a basic level certification. So he's excited!

Pics later...
 
#711 ·
Sweet! Will he have access to a cnc plasma or water jet? Think he would think about making two dashes if I provide the design?
 
#712 ·
To be more clear, we are a long way from making a dash. Clay's immediate goal is making the "kicker" that welds to the dash, not a whole dash. Clay won't have access to CNC or anything else. The class he is taking will be in the spring semester, and it's just a beginner weldor class. I am contemplating buying a tabletop brake.

The biggest part of this, and in my opinion the best, is the sudden direction Clay is finding for his life. At 16, he has an idea what he wants to do. He WANTS to be a Fireman! With a little fab work on the side that might actually pay!
 
#714 ·
I had welding (gas, stick and intro to Mig, Tig) and metal fab (manufacturing) in college as part of the industrial side of my degree. I keep telling myself that I can do this. But it has been 25 years?? God where has the time gone... Anyway, I don't remember anything. I want to take the class with him, but for me it's a $1000!! So maybe one day Clay will let me play in HIS shop!
 
#717 ·
Scott have you got a welder? If you do then get that thing fired up and start welding. What you learned will come back to you. For a long time I used a stick welder for everything I made and it worked great. Although I got tired of chipping slag. It doesn't cost allot to get started in welding either.

Congratulations to Clay!!
 
#716 ·
Fireman is the way to go!!! If I had it to do over (and I have thought of ways to try and change now, it's just a little too late in my life), I would be a fireman!!! I know a lot of Fire guys that have side gigs... they work a job, get medical benefits and great retirement and do what they enjoy on the side. That's not to say they don't enjoy the fire science, it's just to say that is their "paid" job. Good to hear that Clay is looking for direction in his life!!! I work with High Schoolers at church, and I see a lot that just think they will get by when the opportunity is handed to them, instead of actively seeking opportunities. It may be a regional thing, but it's more likely that he seams to have a good relationship with his dad!!! :) You da man Scott!!!

OK, since there has been work on the Jeep, why aren't we seeing pictures?!?!?!?!?
 
#720 ·
AJ came back over today and did a great deal of work. Clay and I spent the day pretty much watching him! He made 5 trips home to bring back materials, tools, etc, and he went to work on the hood. Then he started on a fender. He showed us how to remove the rough areas without gouging the workpiece. He showed us how to remove the Bondo without removing too much. He aslo showed us the right way to mix the Bondo and apply an effective skim coat. I keep thinking that Clay's Jeep is going to be nicer than we had planned, being as how Clay wants it done so he can drive it! AJ has taken a personal interest in it. They are talking Candy Apple Red instead of International Red. I didn't take a lot of pics since we'd be beating a dead horse at this point, but here are some pics of today's work. This is AJ's work.

AJ grinding down the FG slop that Clay and I made when rebuilding the fenders!


I never thought about the visible part of the fender when we repaired the PO's damage, so AJ is removing all of that extra resin.


First Bondo... AJ ain't shy about it!


I had gouged the gelcoat with 24 grit paper when I removed the PO's original rattle-can paint. AJ is fixing it. He first sanded with 80 grit to remove much of the scratches, then the Bondo. I SHOULD HAVE USED 180 TO REMOVE THE ORIGINAL PAINT! Would have saved a LOT of work!


Making the transition at the lip.


AJ ground down the hood, sanded it, skim coated it, sanded it some more, wiped it down with prepaint cleaner, and primered it again. I think that makes 6 times we've had primer on the hood... used over a quart of primer on just the hood. That will tell you that good prep from the start will save time and money. Here is Clay glazing the hood. No more homemade brews!



Here is the hood with black rattle-can for a blocking coat.


And just a reference shot...


Overall it was a great day. I can see I need to get some more tools to be effective, and I need to work smarter. Hope I can produce some comparatively nice work on the pieces to come...
 
#724 ·
Man, it was a beautiful day, but I sure wish it'd rain for a 2 or 3 days! The hood does look good, but keep in mind that it's not MY work... credit goes to AJ. Hopefully, Clay and I paid attention!

Looks great Scott!

I learned a lot from an old mechanic growing up. He turned wrenches for Chevy, Olds, Saturn and Honda and it was amazing what he knew. The number one lesson I learned is don't run around his shop barefoot, he smoked like a freight train and could care less about burning cigarettes on the ground because he wore boots.

I think I stepped on four burning cigarettes while we were rebuilding the Powerglide one summer. I would scream, gripe at him and he would just smile and flick another cigarette on the ground :D
That's one of those tough lessons! I've had one or two in my life. Probably didn't take long to pay attention to where you were stepping!! AJ told me and Clay to just watch... that he could show me better than explain. It was a tiring day. He kept telling me to rub my hand acroos the fender. I couldn't feel anything at first, but then I detected a slight, and I mean slight, imperfection. I would have left it and been happy. But it is good to understand the difference between quality work and "good enough". We'll aim for the quality.

The hood and fender are looking good Scott. Hey what's AJ got that he's mixing the bondo on, glass or plexiglass? Also what kind of sander is that?

Candie Apple Red :thumbsup:
AJ is mixing on a piece of plexiglass. He explained that you don't want to use anything porous as it absorbs the solvents in the plastic. That can cause curing problems. After he skimmed the fender and cleaned up, he "donated" the plexiglass to the Kerr fund! Along with a 900' stack of various and sundry sandpapers. Because, he said, I'd use it! :D The sander is a 4" (?) random orbital air powered HF sander... 39.99. Gonna have to get one! He also used some kind of high end air grinder that took a 6" disc. He used 36 grit on it with a very light touch. We found some leftover home brew putty that had caused Saturday's primer coat to peel. He made short work of it! Learned a lot.
 
#722 ·
Looks great Scott!

I learned a lot from an old mechanic growing up. He turned wrenches for Chevy, Olds, Saturn and Honda and it was amazing what he knew. The number one lesson I learned is don't run around his shop barefoot, he smoked like a freight train and could care less about burning cigarettes on the ground because he wore boots.

I think I stepped on four burning cigarettes while we were rebuilding the Powerglide one summer. I would scream, gripe at him and he would just smile and flick another cigarette on the ground :D
 
#725 ·
It's always been easier for me to learn by watching. Like I've told you before, if and when I get to Florida to visit you we need to plan on a good bit of time at AJ's house. I want to find out more about him!!

Glad to hear things are coming along and thanks for the info on the sander. :thumbsup:
 
#727 ·
I can't believe how much you miss when you're offline for a day. You guys are Rock-N an Roll-N'!

I wanted to wish EVERYBODY a safe and Happy Thanksgiving! Don't drink and drive. Remember, the highways are super crowded during this time of the year.

I have 4 days off.... hunting and Jeep and hunting and Jeep...

God Bless-

Scott
 
#733 ·
The squirrel pic??

Over the weekend, I took AJ south, to his old shop, to pick up a trailer load of machine tools. It was a wild and fast trip! Didn't get his mil or lathe, as they were made from some part of a Battleship! Got back home in time for Clay and I to throw a skim coat of Bondo on both fenders. Right now, I'm late for work... ya'll have a good day! :thumbsup:
 
#737 ·
I hope you guys are having the same fun that I'm having!? This is what's going on at our house tonight. Tomorrow afternoon, after my dentist visit... JEEP!

Pics of Mom and the Brood!
 

Attachments

#739 ·
yeah, part of the reason I got so little done today is because the wife made me start hanging the lights on the house, set up the tree so we could decorate it when the boys got home from school.

Good family times!!!!!
 
#750 ·
:rofl: I guarantee that was me about 40 years ago!!

You are so right about our soldiers that are serving away from home. Especially the ones in other countries. Those people are making great sacrifices!

So the fenders are near done and so is the hood. You have a glass grille to do yet? Then the tub. You are making very good progress. This body work just seems to go slow no matter how it's done. Great work from both of you. :thumbsup:
Clay's grill is steel. The only steel on his Jeep. It's in pretty good shape except for a broken bolt when removing the fenders. I can't wait to get to the tub, where you can actually sand with a full stroke of the sanding block. We have to do some significant reinforcement under the bed, as the floor is very soft. AJ said something about soaking a piece of roap in FG resin, and glassing that in the ribs underneath. He said it is very rigid but has some flex to it. Never heard of it, and I'm skeptical, but I need to learn to trust!

Now that you appear to be comfortable working with Bondo I'm going to tell you something you've already heard from a bunch of us but I feel like I have to tell you one more time. I'm a car guy so lets use a car analogy.

Bondo is like driving a Toyoda Corolla around a race track. It's a little slower and rough around the edges but it will eventually get you to the finish line.

Evercoat Rage for instance is more like a Ferrari. A little more expensive but a lot more fun to drive. It will get you to the finish line faster and always with better results.

After driving both and they are sitting side by side in your garage, which one are you going drive, the Corolla or the Ferrari?

If you've got much more body work to do, do yourself a favor and please, please, please, get some better filler. That is the last I'll mention it.:ignore:

Carry on with your regularly scheduled bondo dust program. :wave:
I hate Corollas! I'll try the Evercoat on the tub. Just wondering... can you use Bondo as a wood filler???
 
Top