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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:
 

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#1,730 ·
Hey Scott,

sorry I've been out again.

It looks like you have maid some great strides, I just got all caught up again and wow.

As to the tire clearance on the body lift it looks like you could true up the arch of the fender and get the spacing for the 35's and go for it. since the PO already chewed the fenders with the tires what have you got to loose.

glad to see that all is well with you and yours, and tell clay I can see a big improvement in his welding and well done.
 
#1,731 ·
Hey Scott,

sorry I've been out again.

It looks like you have maid some great strides, I just got all caught up again and wow.

As to the tire clearance on the body lift it looks like you could true up the arch of the fender and get the spacing for the 35's and go for it. since the PO already chewed the fenders with the tires what have you got to loose.

glad to see that all is well with you and yours, and tell clay I can see a big improvement in his welding and well done.
Where ya been Dog!? We appreciate your comments. Clay is definitely moving up on his welding skills. Tractor Supply is having their Grand Opening this weekend, and Clay stopped by. He came home with the story that the Hobart Handler 140 was on sale for $199!!!! :eek: So I called the store... WRONG! Oh well, I got excited for nothing!

Gotta pull the tub one more time. MAW add tranny fluids and other things while the tub is off this time. Then it will be bolted down and the body work begins, including sealing up the back where the PO installed his homemade tailgate. Also gotta go over all the nuts/bolts one more time and check torque. Some of them were stuck in and finger-tightened.

Last of all... I moved my climber to another spot on the creek. I was trimming branches with my machete for shooting lanes. Whack, whack... I was beating these branches with an UN-sharp machete when I heard an incredible crashing coming through the woods! It was coming closer, and it was coming fast. I had no weapons on me! I had reconciled myself to the idea that either the Predator or Sasquatch was fixing to break out and get me, when a beautiful, and I mean NICE, cow-horn spike popped out of the understory 10-12 yards away, and stood looking at me through a scrub tree! I watched him, he watched me. I guess I must have sounded like a buck fighting a buck!? He took off after 15 seconds. Cool stuff! :thumbsup:
 
#1,732 ·
I've been out sick for the last 6 months, needless to say my work and my bills have been piling up and the doctors still can't figure it out. It isn't contagious so I've just been trying to bull through and get some work done, but after a half day I'm so wiped out that sometimes I have a hard time just driving home and when I get there it's right back to bed.
 
#1,736 ·
Need some help!!

I am bolting everything down... tight. I need to get everything "square" or "plumb". I have the tub where it needs to go. The grill is plumb. The tub is level left to right.

In the pics that follow I have some issues.

First pic is showing the grill with 2 1/4" bushings. This makes the tops of the fenders level from front to back.

The second pic shows the bottom of the fender even with the bottom edge of the tub. This creates a pretty huge gap between the fender and the hood.

The third pic shows the distance from the shop floor to the bottom of the pass. fender. The fender has been pushed up as high as it will go to reduce the hood/fender gap. It is 27 1/4" as denoted by the red line. The driver's side is 26 1/2"... 3/4" difference. Shouldn't they be the same? It's possible the PO did not bore the fender-to-firewall holes in the right places. Is it that simple??

The fourth pic is showing how the pass side hood extends out beyond the curve of the cowl.

The fifth pic shows how I can push it down with my hand and make it flush with the cowl. This also improves the gap between the fender and hood. But I can't figure a way to make the hood to stay in that position. It's almost like the hood is slightly sprung.

I need ya'lls help setting this up so it is close. I assume the measurements should be the same on both sides of the Jeep? Should I drill new holes? Should I pull in the side of the hood somehow?

Thanks!
 

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#1,737 ·
Need some help!!

I am bolting everything down... tight. I need to get everything "square" or "plumb". I have the tub where it needs to go. The grill is plumb. The tub is level left to right.

In the pics that follow I have some issues.

First pic is showing the grill with 2 1/4" bushings. This makes the tops of the fenders level from front to back.

The second pic shows the bottom of the fender even with the bottom edge of the tub. This creates a pretty huge gap between the fender and the hood.

The third pic shows the distance from the shop floor to the bottom of the pass. fender. The fender has been pushed up as high as it will go to reduce the hood/fender gap. It is 27 1/4" as denoted by the red line. The driver's side is 26 1/2"... 3/4" difference. Shouldn't they be the same? It's possible the PO did not bore the fender-to-firewall holes in the right places. Is it that simple??

The fourth pic is showing how the pass side hood extends out beyond the curve of the cowl.

The fifth pic shows how I can push it down with my hand and make it flush with the cowl. This also improves the gap between the fender and hood. But I can't figure a way to make the hood to stay in that position. It's almost like the hood is slightly sprung.

I need ya'lls help setting this up so it is close. I assume the measurements should be the same on both sides of the Jeep? Should I drill new holes? Should I pull in the side of the hood somehow?

Thanks!
I lose track of all the details of everyone's build, so, I have to ask...are the hood, grill, and fenders steel? I'm assuming so.

If they are...

..as far as the fenders being different heights off of the floor, did you compare the dimensions of the mounting holes in the fenders ( both sides) to see if they're the same? As well as the mounting holes in the firewall?

Is the driver's side fender (26.5" off of the floor) even with the bottom of the tub, like the pass. side fender is? Did you check to see if the bottom edge of the tub is the same distance off of the shop floor, on both sides?

With a steel hood, you may be able to wrap a ratcheting binder strap around the hinge end of the hood, and tighten it to reshape (narrow) the hood to fit the shape of the cowl better.

Always go easy with this kind of "modification". Get an initial baseline width measurement. Measure the width across the cowl of the tub. This would be the number that you'd want the hood to end up being.

Then, measure the starting width of the hood. I'd try cranking the binder so that the hood is 1/2" narrower than the finish number that you are striving for, to allow for springback. Then take the strap off, and see what you've got. If there's NO change, try it again, and go 1" beyond.

If it moved just a little, you'll have to use your own intuition and try again.

Good luck!

Rich

P.S. If the hood's fiberglass...forget what I've suggested!!
 
#1,739 ·
I lose track of all the details of everyone's build, so, I have to ask...are the hood, grill, and fenders steel? I'm assuming so.

If they are...

..as far as the fenders being different heights off of the floor, did you compare the dimensions of the mounting holes in the fenders ( both sides) to see if they're the same? As well as the mounting holes in the firewall? No in both cases... good idea.

Is the driver's side fender (26.5" off of the floor) even with the bottom of the tub, like the pass. side fender is? Did you check to see if the bottom edge of the tub is the same distance off of the shop floor, on both sides? The driver's side is not the same as the pass side. I actually trimmed off an inch along the bottom of the pass side. I still have to do the driver's side.

With a steel hood, you may be able to wrap a ratcheting binder strap around the hinge end of the hood, and tighten it to reshape (narrow) the hood to fit the shape of the cowl better.

Always go easy with this kind of "modification". Get an initial baseline width measurement. Measure the width across the cowl of the tub. This would be the number that you'd want the hood to end up being.

Then, measure the starting width of the hood. I'd try cranking the binder so that the hood is 1/2" narrower than the finish number that you are striving for, to allow for springback. Then take the strap off, and see what you've got. If there's NO change, try it again, and go 1" beyond.

If it moved just a little, you'll have to use your own intuition and try again.

Good luck!

Rich

P.S. If the hood's fiberglass...forget what I've suggested!!
Rich, you always have good and thoughtful advice. I sure am glad you're checking in! Alas, it is all glass! The only metal is the windshield frame and grill.

as I recall you had this problem before and were going to run a piece of bent steel along the bottom of the hood, between the hinges and rear edge, to correct the warped fiberglass.

of coarse I could have your build mixed up with someone else's, it has been a while.
I may have said that at one time, but I suffer from CRS! :shhh: At any rate, I don't plan to do that now. MAY do something else... but not sure what yet!
 
#1,740 ·
I'm feeling some better about this. I've got it level from side to side. The back of the tub is a little higher than the front. I removed 1/4" of bushing from under the grill. That helped with fender to firewall fitment, although they are not level anymore. However, they're not off a great deal, and I can't see it with my eyes. So no biggie.. right? As I mentioned earlier I suffer from CRS, and one significant point of interest is the fact that there is a CJ7 sitting right next to the 5! :eek: What a goof! So I measured around my 7 and found that there are plenty of inconsistencies. So who's gonna know? I think I'm gonna nail it and call it done. The fitment, that is. Still have lots to do. I walk around this thing and I stare at it!!!!! To me, it looks so dad-gone cool! The hood comes to my chest and I'm 6'3". I CANNOT wait to drive this beast. Pseudo-beast! :D No disrespct intended to you guys who ACTUALLY HAVE a beast!

Here's a few more pics of where we iz! Remember I installed the blocks at the back of the tub for the rear crossmember bushings? DANG!? Did I do it right, or what? Also, here's a pic of how the tub meets the bushings along the pass side.

The hood hinge pics show what I did for hood adjustment. Of course, I ruined my hinges! :mad: I cut square slots in them so I could move the hood around. I can't stand the washers... anybody got some hinges you would part with? Under the cowl I used a piece of 3/16 steel, drilled holes, and tapped them. MUCH more strength for a glass Jeep.

I'm Stoked! :D
 

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#1,755 ·
The hood hinge pics show what I did for hood adjustment. Of course, I ruined my hinges! :mad: I cut square slots in them so I could move the hood around. I can't stand the washers... anybody got some hinges you would part with?
Looks like you are making some good progress. :thumbsup:

On the hinges, can't you just weld the holes shut, grind it flat and re-drill them?
 
#1,743 ·
Skerr said:
Does he look as OLD as he does in his pictures!?!?!?! :rofl:
My next stop may be White Springs. You had best start working out right now! Old, I'll show you old.

Had a great time meeting Jim and his wife,and it was a surprise, Vic and I just showed up.
We were so close, and I really wanted to meet Jim.
Long story short. Went to the address on his website, pulled into the entrance/driveway and stopped. I asked Vic if we should go ahead in. That Vicki, she is smart, she said "would you want someone to stop at are house" I never said a word, just drove in.

Scott, Jim has a beautiful place, hope you can make it there one day.

Bill
 
#1,753 ·
She's called "first dibs" on driving it when done! I'll get a pic then. No way was I going to wake her up last night. She sleeps with a gun! :eek:

that's looking good.
Thank you, Sir! :D

Scott the body looks to be lining up very good. The grill and fenders look a little too high to me but the tub itself looks to be right on the money so there's really now way to get the other stuff lower. Before you put the final screw down to it all I'd roll it outside and take pictures from the sides ar different angles. Post them on here too. I lost track of how many times I've seen things in my own pictures on the thread that I missed when I actually took the picture. I sure like the looks of it though!!!

I'm sure glad Bill and Vicki stopped. I'd have been disappointed if they'd have backed out and not came to the house. They almost caught me in my Sunday afternoon nap!! :D Wish they could have stayed longer though. One thing we can all be thankful for too is that we've got some real nice people on this forum and I for one am always glad to meet them.

Someday I may show up at your house. Have plenty of food on hand too. :D
I agree the fenders and hood seem high. But that's the only way to get the mating between the fenders and the hood. I hate that big gap at the grill mounting point. Hopefully it will be hidden when we add the winch.

I talked with Bill last night. He and his wife had a great time visiting with you and yours. Bill said your place is beautiful, your shop is awesome, your shooting bench was something to envy, and that you look sexy in bibbs!! With a pocket knife clipped in your chest pocket... growl!! You made his day! He also told me that he is pleased to learn that he isn't the shortest old fart anymore!? :rofl:

Looking great man. I took the cat out of the tire and it still thumps. I may have to pay for this one. Clay must be all smiles. Hope you guys had a great weekend. BTW- No schools in FL are in the top 25, but both SC scools are....tee hee. Talk to you later, again, nice looking rig.
Meh... we laid out this year to give the rest of the nation a chance! :D

Sorry the cat didn't solve it for you. Did you remember to get your MIL out of the trunk?? You're for sure gonna pay for that one!! :rofl:

PS- my fenders and grill will require some tweaking during the re-assembly. I have a 3/4 inch gap between the hood and the pass. fender, and it is tight on the other side. I think the grill and fenders are whacked but the hood is good. I am not sweating it now, but when the time comes you will get the distress call. Later dude.:2thumbsup:
If the curvature of the hood is even to the curvature of the cowl, then it is probably the fenders. I've seen some threads where the fenders sag and create an uneven gap. I think that's pretty common. Unless you are building like Keith, or a couple other guys, I wouldn't worry too much about it. Nobody is ever going to notice it. But I can take measurements for you from my 7 when the time comes, if you like.
 
#1,750 ·
Scott the body looks to be lining up very good. The grill and fenders look a little too high to me but the tub itself looks to be right on the money so there's really now way to get the other stuff lower. Before you put the final screw down to it all I'd roll it outside and take pictures from the sides ar different angles. Post them on here too. I lost track of how many times I've seen things in my own pictures on the thread that I missed when I actually took the picture. I sure like the looks of it though!!!

I'm sure glad Bill and Vicki stopped. I'd have been disappointed if they'd have backed out and not came to the house. They almost caught me in my Sunday afternoon nap!! :D Wish they could have stayed longer though. One thing we can all be thankful for too is that we've got some real nice people on this forum and I for one am always glad to meet them.

Someday I may show up at your house. Have plenty of food on hand too. :D
 
#1,751 ·
Looking great man. I took the cat out of the tire and it still thumps. I may have to pay for this one. Clay must be all smiles. Hope you guys had a great weekend. BTW- No schools in FL are in the top 25, but both SC scools are....tee hee. Talk to you later, again, nice looking rig.
 
#1,752 ·
PS- my fenders and grill will require some tweaking during the re-assembly. I have a 3/4 inch gap between the hood and the pass. fender, and it is tight on the other side. I think the grill and fenders are whacked but the hood is good. I am not sweating it now, but when the time comes you will get the distress call. Later dude.:2thumbsup:
 
#1,757 ·
I really appreciate the kind words, and thanks for checking out the thread. We're definitely getting closer.

Looks like you are making some good progress. :thumbsup:

On the hinges, can't you just weld the holes shut, grind it flat and re-drill them?
Mike, I can't think of any reason why that wouldn't work, and Clay would love it! Not too many chances to weld on glass Jeeps!! Thanks for keeping us straight.

Scott,

Your project is coming along really nice. You have no idea how much you, Paul, Mike, Keith and Dave have motivated me on my project.

Thanks! :thumbsup:
Thanks, Fred, and I think it's ironic! Because I'm looking to you for several things, including electrical. Glad to be of service, and thanks for your own inspiration. I look up to those other guys, too!! :thumbsup:
 
#1,758 ·
I don't care who you are, or how well you know your stuff... there is NOTHING joyful about sanding fiberglass! :nono: This is the singlemost issue that would cause a person to turn to ANY other material in a build. Think of it as having the most beautiful woman in the whole world. She's ALL yours! But her breath smells like a dead armadillo!! You just have to work through the bad to get to the good! :D

You have to dress apprpriately. This is to protect your skin from the dust. If you don't do this you will claw yourself apart from the itching. You're gonna be hot and sweaty, and your clothes are going to stick to you. I HATE that!

WEAR A DUST MASK. Don't breathe the dust. If it makes your skin itch think about what it is doing to your lungs.

I was fooling around for awhile and started to clean up the back of the tub. Using 80 grit on my DA. Also elongated some wholes for adjustment, and I have the fenders where I want them. The gap b/hood and fenders is even and consistent on both sides.
 

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#1,759 ·
Why, all the sudden, has the word embellishment come to mind. :)

The only two pictures of the entire trip.

Sorry Jim, Scott was like a kid in a candy store last night. He wanted to know all about my surprise visit.



Bill
 

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#1,763 ·
Why, all the sudden, has the word embellishment come to mind. :)

The only two pictures of the entire trip.

Sorry Jim, Scott was like a kid in a candy store last night. He wanted to know all about my surprise visit.

Bill
Nice, Bill. I imagine ya'll sat apart after eating all of those sauteed veggies!! :laugh:
 
#1,760 ·
Man, that is what I call measuring 15 times, cutting once!!! Looks nice!!!
 
#1,761 ·
hey Scott you may have already tried this but you can pick up paper suits at the depot for painting. there reusable and breath pretty well, I use them when I have to do the low crawl threw attics with fiberglass insulation. In the summers hear it's not unusual for the attic space to get into the 130-140 range, so I usually just were shorts under the suit and it keeps the fiberglass out. you can get them with or without the hood, but with your mask and the hood you'd be pretty well covered
 
#1,762 ·
Yeah, I've worn Tyvek suits many times over the years. It's a very good idea. It will be especially good when the weather cools a bit. It was so humid with the rain we've been getting it would be miserable right now!

Usually, I will wear a flannel shirt. It's good for catching dust. I use an old pair of socks with the toes cut out, and I slip those over the hands/sleeves. Of course some jeans. Take a towel and wrap around your neck. Baby Powder for any area you can't cover. It's a pain to get into all that garb (Tyvek suit is so much easier) so you need to plan on doing a lot. Then you'll want to strip before you come inside! Straight to the shower...
 
#1,765 ·
I haven't posted anything in awhile regarding Clay's welding. He came home this evening and said, "Dad... you wanna see my weld?" And, of course I do, so he brought it in and showed it to me. Their booths are tiny, and they constantly weld "T" plates, cut them off and weld them again. Over and over. Seems like it would get boring quick. But Clay remains enthusiastic about all of this. He's talking about welding engineering. Which sounds like it would mak LOTS of money!! Anyway, here is Clay's vertical flux core welds. This is his test piece which passed. The last pic shows his 90* angles that he welded up.

*note... I think it is awesome as Clay is most concerned about whether he got his angles correct, and my wife and I are most concerned about the $8000 we lost this past month in the market! Sure is great to be a kid! Funny how your priorities change...
 

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