J20 Extended Cab - Paint - Page 4 - JeepForum.com
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post #46 of 64 Old 07-08-2019, 01:32 AM Thread Starter
BagusJeep
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I tracked down the shop the trimmers buy their materials from.

I got the compressed card that you find in door panels etc. A 1m x 2m piece was $4. You can cut it with scissors. all the rest of seat foam, vinyl, padding, underlay, carpet glue etc came to $150.

The card flops about too much for my headliner, toying with the idea of some ply reinforcement on the top. I got the pieces roughly cut but it kept on flopping on me, after an hour of struggle I gave up for this week, pain getting worse.

I changed out spark plugs and belts and she was running about 90%.

Interior is going to be mushroom cream headliner, brown / tan dash pad and panels, and black seats, offset by bare red paint in places. I will reupholster the seats in due course to tan. Hope this combo makes sense.


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1981 CJ7 258ci - Bagusjeep
1984 CJ7 258ci - Puthijeep
1981 J20 258ci - Gladys
1951 Willys CJ3A/MB/M38 - Little Willy
1995 Cherokee 4.0 - CHEROKEE
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post #47 of 64 Old 07-21-2019, 09:42 PM Thread Starter
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so the carb arrived and as I anticipated, it was a poor copy. No markings anywhere on the "OEM quality" part to identify which sweatshop knocked it off.

Two things, no way to attach the choke coil to it (that part of the casting is missing, nothing to screw it to) and no throttle post to connect the cable to. second one can be overcome with a part but the first just means there is no choke action. The pull off diaphragm is there and the choke flaps so it stays open but there is no way to close it. Complained to ebayer who sold it, wait to see.

In the meantime I fitted it just to see how it ran. Previously I was able to balance the idle with the two air bleed screws, no longer. No matter how many turns, it made no difference. It was sealed on the gasket and no manifold or hose leaks. However there was a high pitched whine from the venturis with the curb idle screw backed out, so I guess the throttle butterflys are not a good fit.

However, it ran well and it started first time.

As I was guaranteed 100% fitment, I am rather pissed. I could spend considerable time and effort in making brackets etc but i found my rebuild kit at the weekend and could spend just as much time making one good BBD out of my collection of used ones.
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BagusJeep lives in Bali.

1981 CJ7 258ci - Bagusjeep
1984 CJ7 258ci - Puthijeep
1981 J20 258ci - Gladys
1951 Willys CJ3A/MB/M38 - Little Willy
1995 Cherokee 4.0 - CHEROKEE
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post #48 of 64 Old 07-21-2019, 09:56 PM Thread Starter
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I paid someone about $120 some time ago to fix the electrics whilst it was in the shop. I am not a violent man, but I could punch him.

Nothing works as intended, no instruments, indicators are very rapid and high and low beams are controlled by the light switch etc. No wiper switch (though that appears to be only one problem with the wipers).

So I started at the back of the truck. Reversing lights came on with reverse or the indicators. No indicators. Side marker came on with indicator. Took it all apart, there were four wires back there, instead of three, none were original. Wired indicator to indicator, tail lamp to tail lamp and side marker. Hey presto, everything working except brake lights, and they connect at the dash to the circuits. Fixed. I do love these FSJ, the metal and original components are substantial, a pleasure to work on. The light cluster is heavy duty aluminium, so much more engineered than the tail lights on a CJ.

Next up was fuel tank sender. I remember getting that fuel gauge working with new sender and gauge, but no there is no wire. Opened up the loom about 3m to find a cut pink wire, spliced in new one. No idea how this happened.

SO that left me back at the dash. I took out all the switches and dropped the loom and started looking. The cluster is in reasonable condition, only one lifting circuit on the back f the panel. i cleaned it all up carefully and with contact cleaner. Tested the connector, I have 12v power on red but the earth on black is showing about 500 ohms difference to another ground, no wonder instruments are not working. Traced this back and it connected to a white wire but was spliced with the 4WD lamp, bizarre. Studied the wiring for 30 minutes and it was getting dark, so packed up. What a mess.

So I got it running sweet and have indicators and lights, so it is moving forwards. There is a Willys jamboree in central jawa in October, so my time may be diverted to the 1951 CJ3a to get that reliable for a long run.

BagusJeep lives in Bali.

1981 CJ7 258ci - Bagusjeep
1984 CJ7 258ci - Puthijeep
1981 J20 258ci - Gladys
1951 Willys CJ3A/MB/M38 - Little Willy
1995 Cherokee 4.0 - CHEROKEE
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post #49 of 64 Old 08-15-2019, 11:48 PM Thread Starter
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As a temporary measure I am going to install a 3 pack of Autometer gauges been in back of cupboard for 6 years. oil press, water temp, volts. Got another cheap Chinese 3 pack cluster but going to put in a fuel gauge, tach and vac gauge (these are not important to getting it back on road).

BagusJeep lives in Bali.

1981 CJ7 258ci - Bagusjeep
1984 CJ7 258ci - Puthijeep
1981 J20 258ci - Gladys
1951 Willys CJ3A/MB/M38 - Little Willy
1995 Cherokee 4.0 - CHEROKEE
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post #50 of 64 Old 09-08-2019, 08:04 PM Thread Starter
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Got a "copy" of a Type 2 bumper fabbed up. Without dimensions, we just estimated it. Square tube with a sheet metal cover, it is not particularly heavy and is more show than strong but at least I can step into the bed. Off to paint (black). Ordering up lights etc to kit it out, umber plate lights and a floodlight reversing light to go underneath. Toying with parking sensors.
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1981 CJ7 258ci - Bagusjeep
1984 CJ7 258ci - Puthijeep
1981 J20 258ci - Gladys
1951 Willys CJ3A/MB/M38 - Little Willy
1995 Cherokee 4.0 - CHEROKEE
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post #51 of 64 Old 11-13-2019, 10:52 PM Thread Starter
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Rear bumper painted and out in the sunshine with the fleet.
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1981 CJ7 258ci - Bagusjeep
1984 CJ7 258ci - Puthijeep
1981 J20 258ci - Gladys
1951 Willys CJ3A/MB/M38 - Little Willy
1995 Cherokee 4.0 - CHEROKEE
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post #52 of 64 Old 06-11-2020, 04:14 AM Thread Starter
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So, just before New Year I paid a mechanic to do a lot of maintenance to my Jeeps, the holidays were coming and I only had a few days off so I wanted to enjoy them. He got the 3 pack of gauges on, water,oil and volts. Did not put on the fuel gauge.....

I asked him to sort through the 2 original BBD carbs and the clone and get one running well, preferably an original. When I got back the carb was playing up, it really did not want to start. Hah, do it myself. But I could not get it to run even after a rebuild and clean.

Since March I have been on corona lockdown so sorting out some issues in the fleet. Took the carb off, gave it another good clean. No fuel. Replaced fuel pump.

No start, tried all carbs. Eventually drew some liquid out, it was a mixture of fuel and something else. Drained and cleaned tank, frog spawn looking mixture came out. Hah, must be fuel.

Now had clean fuel but no start. Tried all carbs and literally spent days on it. No start. 3 weeks ago stopped to work on a CJ.

One evening whilst whiling away the hours, I got out my 1976 Carter BBD manual. Oops, mentioned there were several gasket designs, some will block apertures in the base of the carb. I needed the gasket with the cutouts on the long edge.

Went out, carb off again for 30th time. Ahhhhhh, mechanic had removed the spacer and replaced it upside down AND with the wrong gasket. There are 2 cut outs on each long edge to match the carb, he had blocked them. when I opened the carb for one last look, it was filled with a wet sand like substance but it was organic, about 1/2 oz to 3/4 oz was blocking the jets and the float fulcrum. Don't know what this is but cleaned carb again (getting good at this) and reset the float levels (it was jammed open).

On went the spacer right side up with new correct gaskets, cleaned the spark plugs. Wrumph, up she fired and idled like a champ. I cannot say how happy I am!!!!

Next stop to get the alternator belt realigned, squeals bad. Then we can go back to the interior and electrics.
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BagusJeep lives in Bali.

1981 CJ7 258ci - Bagusjeep
1984 CJ7 258ci - Puthijeep
1981 J20 258ci - Gladys
1951 Willys CJ3A/MB/M38 - Little Willy
1995 Cherokee 4.0 - CHEROKEE
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post #53 of 64 Old 06-11-2020, 10:21 AM
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So frustrating to learn that you need to proof the work of a paid professional! That is a great feeling to finally get a win AND to know what the problem was. Nicely done.
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post #54 of 64 Old 06-11-2020, 10:42 AM
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That great congrats!

Hoss

Good judgement comes from experience; experience comes from bad judgement
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post #55 of 64 Old 07-02-2020, 09:27 PM Thread Starter
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The front brake pads sheared, only a year old. Literally sheared the friction material off one which stayed on the disc. Had to buy from US and wait some weeks for new pads, this thing has big Bendix calipers. Gave me the opportunity to clean up the brakes and get the pivot bolts greased, should be OK but slight pulsing from brakes as some of the old pad must be stuck on the disc surface. This should settle down as it is driven.

So I got the alternator realigned. A po swapped the side it was on so it did not have a factory bracket. After shimming and bending it finally ran without squealing.

During this the starter motor stopped working. It was replaced in January with a more modern unit, the old one was just not capable of further rebuilding so when it failed I got this one from an XJ Cherokee. It was brand new from the local parts pusher but was not a Mopar product. Five months later it stops working. Took it apart, outside was new but inside three of the four brushes were seized in their holders and dirt everywhere. Freed the brushes with WD40 and gentle pressure and then cleaned and greased it. Ran well after that.

Took it for a test run and the clutch hose burst, rat had eaten it. Made up a new hose and line from bits left over and it worked again.

Then the bottom radiator hose, six months old, decided to pin hole. Fortunately i have spare CJ7 258 bottom hoses which fit.

She is fighting me at every turn. Like a wild Mustang that needs breaking in.......

Now starting first time and running up and down, time for interior.
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BagusJeep lives in Bali.

1981 CJ7 258ci - Bagusjeep
1984 CJ7 258ci - Puthijeep
1981 J20 258ci - Gladys
1951 Willys CJ3A/MB/M38 - Little Willy
1995 Cherokee 4.0 - CHEROKEE
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post #56 of 64 Old 07-02-2020, 09:31 PM Thread Starter
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So i got materials last year and then got distracted by work Corona has given me time at home.

These are the colous of synthetic leather, good quality but not expensive.

Black for rear seat until I replace all seats, then natural leather colour

Natural leather for door cards

A lighter colour for headlining.
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BagusJeep lives in Bali.

1981 CJ7 258ci - Bagusjeep
1984 CJ7 258ci - Puthijeep
1981 J20 258ci - Gladys
1951 Willys CJ3A/MB/M38 - Little Willy
1995 Cherokee 4.0 - CHEROKEE
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post #57 of 64 Old 07-02-2020, 09:37 PM Thread Starter
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So I started on door cards, never done it before.

i had the right cardboard, literally $5a sheet. It had become a bit bent over the months but when the glue hits it will soften. I had got hold of amixd bag of trim fasteners, only one type fitted the stock holes in the door. Tubs of contact adhesive.

i had some JBL speakers, 7" front, 9x7 rears. An amp will fit in the Tuffy console. Looking at it there were no holes for door wires and it seems the rig only ever had a radio and sole speaker in the dash

BagusJeep lives in Bali.

1981 CJ7 258ci - Bagusjeep
1984 CJ7 258ci - Puthijeep
1981 J20 258ci - Gladys
1951 Willys CJ3A/MB/M38 - Little Willy
1995 Cherokee 4.0 - CHEROKEE
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post #58 of 64 Old 07-02-2020, 09:43 PM Thread Starter
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The 7" speakers screwed on two sides to the door metalwork. I therefore wamted to keep the door card away from them. I unfortunately did not have grilles so I will buy those later. I decided on raised circles around the speakers.

Made a template for the door card, cut the cardboard, cut out a speaker hole, put an accurate ring of card on the outside, glued leather on outside, ct and dragged the leather into the hole and around the outside. I had already measured and put in the fasteners on both sides.
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ast 4.jpg   ast 5.jpg   ast 3.jpg   ast 2.jpg   ast.jpg  


BagusJeep lives in Bali.

1981 CJ7 258ci - Bagusjeep
1984 CJ7 258ci - Puthijeep
1981 J20 258ci - Gladys
1951 Willys CJ3A/MB/M38 - Little Willy
1995 Cherokee 4.0 - CHEROKEE
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post #59 of 64 Old 07-02-2020, 09:45 PM Thread Starter
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So I was not 100% happy with the fasteners, you can see them through the leather. This stuff shows everything behind it!!

I decided along the bottom to go with zinc plated screws and cup washers. It looks alright
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BagusJeep lives in Bali.

1981 CJ7 258ci - Bagusjeep
1984 CJ7 258ci - Puthijeep
1981 J20 258ci - Gladys
1951 Willys CJ3A/MB/M38 - Little Willy
1995 Cherokee 4.0 - CHEROKEE
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post #60 of 64 Old 07-02-2020, 09:49 PM Thread Starter
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then i tackled the rear panels. The speakers had to fadten to the card so i doubled up in those areas on cardboard, cut it very accurately so the speakers would be a snug fit and the screws would bite in the carboard. Fastened to metalwork with same screws
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BagusJeep lives in Bali.

1981 CJ7 258ci - Bagusjeep
1984 CJ7 258ci - Puthijeep
1981 J20 258ci - Gladys
1951 Willys CJ3A/MB/M38 - Little Willy
1995 Cherokee 4.0 - CHEROKEE
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