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Clay's Build Thread

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#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:
 

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#1,399 ·
No MAN hours... just BOY hours! :D I don't know MoC. Quite a few for sure. if it wasn't for AJ and his initial help we would still be working on it! Clay found some primer that started flaking up, so we're not out of the woods yet.

Beautiful! Scott, you now have a market niche. I will send you mine this Fall.
Oh Great!! But seriously, I would try!! :thumbsup:

Sorry I missed ya'lls posts!
 
#1,404 ·
The primer is lacquer primer from Oreilys. It's good stuff. I'm sure we missed a spot when we were degreaing or something. No biggie, but aggravating! And I'm out of space in the shop so it is hard to store primed parts without getting them filthy or scratched.
 
#1,401 ·
BEWARE! Lots of pics ahead...

In spite of the foul weather today, Clay and I got some real good work done. We would STILL be working but Mom kinda killed the desire! She put a pork loin on the smoker.... it is the last of Clay's hog from the early pics on this thread.

Clay and I figured out how we were going to create a reinforced mount area for the body bushings, eliminate the potential for rotting wood, make the tub set on all the bushings, and add general strength to the tub.

I set up my fan to help blow away the glass dust, and we gave ourselves a good, heavy coating of baby powder. With dust masks and safety glasses we got busy...

The first problem was making a flat area for the bolt and washer on this tub mount. We have to remove this lip.


Showing how the stock bushings will not touch the tub. Same problem on both sides. I guess that's a GOOD thing!



Going to use this 18" long piece of 2X6 PT. The bushings are not inline with each other, and I want to eliminate multiple pieces here, so a 2X6 gets it done... wide enough to hit both bushings.


Clay cutting out the floor with a die-grinder.


A useful tool!


New hole in floor with both bushings visible.


Test fit...


Showing how both bushings make good contact.


You can use any tool you want... we used three different ones, but you have to have 3"-4" of good, clean glass to overlap your glass repair. This is for strength.


Another test fit. I beveled the edge of the wood. It is DIFFICULT to bend heavy glass around a 90* angle, so smooth the transition from plane to plane. Glass will "pucker" on a 90. I just used my floor sander to round the edge. It could have been done better with a router.


Clay doing some custom fitting.


An example of fitting... showing a beveled edge.


This area is deep, and even with the 2X6 there is quite a bit of space left open. These 1X4 PT pieces are for a filler. Factory used Luaun plywood (1/4"). It is NOT durable, and is NOT a good filler. We won't have that problem!


More filler pieces and notched wood for access to bolt and washer. Clay's side looks different... probably better!


Using this glass to fill gaps.


Cut the "stray" pieces of glass into a more usable size. This stuff came off the edges of some heavy mat.


Showing the glass fibers shoved into "pockets" to act as a filler. This is for added strength. There is still plenty more to do!


Just showing the original plug put back into place. We're not ready for it yet, but this is how it will go.


Like I said, we would have gone farther, but I am too bloated from marinated pork loin! :D And the shower felt soooo good! We'll pick up some cheapo paint brushes to use with the resin. Once we have the glass work done on the top, we'll complete it when we flip the tub. More to come...
 
#1,403 ·
Thanks, Jim. It's kind of a "design-as-you-go" process. I can't tell you how many nights I have laid in bed thinking about what to do! I finally worked it out and got started. Clay is doing the DS after watching me. His side is a little tighter than mine since he is not making the same mistakes. I will probably notch the wood a bit more at the bolt head to allow for the floor plug to be replaced. We want to be able to put a socket on the bolt. All that area will be glassed and strong when we're done. And BTW- the washer is used for setting it up. We won't put those rusty parts back on! :D
 
#1,405 ·
Scott, you might want to check the compatibility of the primer and the paint that's going to be used. It might not make a difference, I'm not sure.

Bill
 
#1,406 ·
That's a Big 10-4 Rubber Duck! Clay can't decide what color he wants! First it was red, then it was/is green, but now he's talking OD or camo!! Whatever we do we'll make sure it works with this primer.
 
#1,407 ·
Are you guys painting it? Rattle can or from a auto paint store. The reason I ask. When I went to the paint store, ( using a base coat/clear coat) the counter person ask what primer I was using. I was using Dupli-color, well he changed my mind. Still used a rattle can primer, one that he said was good with the paint. Sanded all the Dupli- color off and reprimed.

Bill
 
#1,408 ·
Scott I've been looking at your support and wondering something. The wood and the surrounding glass, are they on the same level? Since the wieght of the tub will always be pushing down on the 2x6 should you tie it in everywhere? Like maybe even run some 1/4" x 2" flat steel across the wood and onto the glass and bond that in there too?

Maybe you already have that covered, if so never mind me. :D
 

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#1,409 ·
Scott I've been looking at your support and wondering something. The wood and the surrounding glass, are they on the same level? Since the wieght of the tub will always be pushing down on the 2x6 should you tie it in everywhere? Like maybe even run some 1/4" x 2" flat steel across the wood and onto the glass and bond that in there too?

Maybe you already have that covered, if so never mind me. :D
You're dead-on Jim! :thumbsup: They are not the same level. The factory had used a 1/4" piece of plywood between the two glass layers. It rotted out and created a void. In addition, the floor slopes downward as it goes toward the back of the tub, creating an even larger gap. The 3/4" 1X4s help fill that bigger gap in the back. We have some heavy mat to apply that will take up a lot of space. Then I have some heavy chop to apply on top of that. I will probably use a 1/4" piece of plywood as a filler too (wasn't planning on it, however) because it fits well. Once all the glass is done on the inside, and the filler (wood) material is in place, we will reattach the original plug that we removed from the floor. It will be stronger than factory on the inside, and once we turn it over and finish it from the bottom, it will be bullet-proof! :D

Here are some pictures from today's adventure! With all the English Sparrows swirling around the sky it was hard to get Clay in the shop!! :D Our goal this evening was to tack down the wood in a semi-finished state. Since we went through so much hassle to get the tub aligned, we couldn't pull the tub and do this on a stand... we had to do it on the frame to make sure our mounting holes stayed in alignment. Now that we have the mounting structure where it won't move, and the holes are where they need to be, I can feel better about working on this thing. I was afraid to lean on it too hard for fear of moving it on the frame, knocking the tub out of square! We're nearly out of resin. We used the last paint brush. And we need more glass! So this week we will just go out to the shop and look at it... sort of admire our work! :laugh:

These are just pics of Clay doing his side. He really got into as he went. He made a mistake and I corrected him... and he reached down and grabbed the wet glass to move it before it kicked off!! He looked like a cat with a piece of tape on its paw! :rofl:

Clay is screwing down the wood to keep it from moving around when he lays the glass down.


This is actually my side, but this is what it would look like.


Here Clay is dabbing resin into the cut fibers he shoved into the voids.


Clay painted the wood with a layer of resin to seal it, then he applied strips of heavy mat to the joints. He was hurrying and I corrected him, and he grabbed the strip and moved it with his fingers to get it right. I don't know what he THOUGHT was going to happen, but from that moment on, anything he grabbed he couldn't turn loose!! :rofl:


Clay is finishing up his second strip.


A layer of 3 oz chop over the top of the mat strips and the wood body. This will seal the large "pores" in the mat, and better join the mat to the wood.


This is done for the night. We will add another layer of mat, and another layer of chop, then the 1/4" plywood. The plywood will be coated in resin to seal it and make it water proof. Then the floor plug will go back in place.


To be continued... :thumbsup:
 
#1,411 ·
Sheesh! :D ^^^


Just went out to check it and see how the glass did before I went to bed. The resin has not kicked off yet!! No reason for it not to, except maybe humidity. Poor Clay was tired after this long weekend. I think I need to just do a chunk of it so he doesn't get discouraged. He is ready to start driving it!

Keep your fingers crossed.
 
#1,412 ·
Wow, nice progress!!! The floor is looking great!!! The window frame looks even better!!!!
 
#1,417 ·
Yes, yes... it set up. I was starting to wonder if there was something wrong with the catalyst. That's never happened to me before. I guess the cool front and humidity did strange things to the resin. Here's some pics of the hardened glass. We will sand it down lightly to get all the sharp little nubs off of it. Nothing hurts like a piece of fiberglass under your nailbed! Makes me draw up thinking about it!

The plywood is/was for filler. You can see the differences in height. That was from the original rotted out plywood. Still may not use it... might just build the rest of the way with glass. It's only $$$!

And Katz iz Dum...

Garden pic for Jim... let your cukes run on a piece of fence. You have to "train" them to do it. Cukes are easy to see and pick this way.
 

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#1,416 ·
MoC, wasn't riding one of the other J's, riding the Roadking... ;)
 
#1,419 ·
Scott, nice glass work:thumbsup:. The heavy wood will last a lot longer than the original luan. Now I know who to call when I need some help with glass:D...something I hate doing:mad:.

Funny how you can train a cuke, but not a katz:rofl::rofl:
 
#1,420 ·
MoC… the Harley isn't mine… PM sent… :D
 
#1,423 ·
Had to go out and talk to the Okra... they were picking on the eggplant!

What happened with the hood problem?
Also, I never heard back from the individual I e-mailed on that extra windshield frame for you. Sorry.
Shaun... no worries about the windshield frame. Honestly, I had forgotten about it! The hood doesn't fit well at all, and has pretty big gaps around the fenders. If I can't move the fenders up a little (they are level right now) to take up some of the gap we'll just run with it. I figure only Jeep experts will ever notice it, and they have all been there too!
 
#1,427 ·
*Update*

Hey Fellers! :D

We've decided to bag this Jeep and get an F150 for Clay. NOT!! :rofl:

I have a buddy at work who builds airboats on the side. I was picking his brain about fiberglass work and generally complaining about the expense of resin ($35/G). He said, "Shoot, Scott... I throw out better'n a gallon everday!" So I offered to buy his excess resin and scrap glass (at a substantial discount of course... I mean, I was going to provide the jug!), which he readily agreed. COOL, says I! ;) BUT, he says, "Whyn't you jus bring the tub to th house, and we'll bead blast it, and shoot underneath it, and inside th tub with th chopper gun, then we'll gelcoat and nonskid it and web it out!?" So I asked him to twist my arm and make me! :rolleyes: It'll probably be a couple weeks before we get it there. He said I could do the work and he'd just supervise. I CAN'T WAIT!! We're just stripping the tub and doing anything to aid in the prep.
 
#1,431 ·
Do us all a favor, Scott, and bring your camera. This process sounds intriguing. What media will you use for the bead blasting...regular fine, glass bead, or something more gentle, like soda blasting?

After you shoot the tub with the chopper gun and re-gelcoat, will you have to drill all new holes for tub-to-frame mounting, steering column, etc?

I don't blame you for being excited. That's a great opportunity!

Rich
 
#1,428 ·
Man, that doesn't happen all that often on this coast!!! Hehehehe. Very nice!!'
 
#1,430 ·
Although he hasn't actually said "No Charge" he is making it sound like I can't pass it up. We'll soon see. It will make the glass work go sooo much faster.

Hope he didn't hurt your arm. :D

That sounds like a great deal. Explain gelcoating to me Scott and the nonskid surface. I got one of them non skid surfaces on my hood where the sand got into the por15!! :laugh:
There is a bright side Jim... when you hop up to sit on your hood, you won't slide off! :D
 
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