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Discussion Starter · #1 · (Edited)
I've been a Jeep fan, CJ's specifically, since I was a kid in awe of the Fire Department brush fire vehicle. Bought a '78 CJ-5 in high school (death trap) and had tons o'fun. Always said I'd get another "$um Day".

Sometime around 2001-2002 E-Bay was taking off and I spent hours searching the site for my next CJ. Found a decent looking, mostly stock specimen in Tulsa OK with almost 200,000 miles on the odometer. Placed a bid on a whim, and surprise! I won it for $3k. A quick road trip from Chicagoland to Tulsa, loaded her on a trailer, and dragged it home.

Engine was definitely tired, so I yanked it out and had a local race engine builder do a full long block treatment; bored .030" over, decked, ported, Crower RV cam, new Clifford intake and exhaust, and a Holley 390cfm 4 bbl.



Put on a Powermaster starter and AGR steering gear, Rancho 1" leafs, and ran it that way for several years.



I've always said no matter how much money I spend on my CJ, it'll always be a Piece of Junk, thusly named P. Sajunk with an Illinois vanity plate to match.

Now, 20 years later.... The transmission won't stay in gear, it has some typical rust and holes in the drivers floor, and starting it after months of sitting is a challenge.

The plan is to install a new Novak-Adapters T-19 4 speed, Holley Sniper fuel injection, and perform sheet metal surgery.

Off we go!
 

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Discussion Starter · #2 · (Edited)
Moving Day

I'm fortunate to have a good friend with some shop space and more tools than I could ever amass. Once he cracked the door to offer some space, I jumped to get going.

Cleaning out P. Sajunk to prepare for the move, I noticed a pile of "fluff" under the engine. It seems the mice had moved into the bellhousing.



Time to arrange for a trailer. I'm pulling the trans and clutch anyway, so I'll take it to the shop space and do it there.

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Discussion Starter · #5 ·
Patch it, or pitch it?

Starting to feel a bit over my head here, but I think I'll be better off buying some panels instead of patching.

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No turning back now!!

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I sourced full body sides from Quadratec that include an actual "Jeep" stamping, plus applied A and B pillars

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Discussion Starter · #6 ·
Key Parts - Mopar Panels

The driver's floor repair was part of the original plan. Having the full side off definitely makes fitting the piece easier.

No need to go all the way to the firewall, so I just cut out the bad spots and trimmed the panel to fit. The Key Parts floor panel is excellent quality

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I debated with my friend about butt welding or lap welding the panel in. I'm not a welder, or a mechanic for that matter, just an old worn out carpenter. My friend won out and we went with the lap weld.

I'm planning to do some type of bed liner finish for the interior, so the visible welds shouldn't be a big deal.

--

Even though the replacement side panel goes all the way up to the cowl and firewall, there is so much going on around all the different body parts I would have ended up dismantling the whole front end. I made the decision to just chop the A pillar as high as needed to get to good steel, and leave the rest in place.

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Discussion Starter · #8 ·
New Transmission

I needed a break from Bondo and sanding, so I bolted the Dana-300 up to the new Novak T-19.

The new T19 case is quite a bit wider than the old T4. The transfer case shifter assembly almost touches, and I had to shorten the shift rod shaft in order to get the correct installation clearance.

There's enough room to slip the cotter pin in after redrilling the hole for it, but it's tight...

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Discussion Starter · #9 ·
Novak T19 Mod #2

Preparing to install the trans and transfer case, the bracket provided by Novak needed a slight modification to match the original T4 setup.

Had to add a center hole, and cut and weld the bracket with the holes 2" further to the front.

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Discussion Starter · #11 · (Edited)
Holley Sniper EFI

Working on the fuel injection from Holley. The Sniper BBD is designed as a direct replacement for the factory BBD carb.

Since I replaced the factory intake and exhaust with Clifford units, and had been running a Holley 390 cfm 4 bbl, some customization is necessary.

I have a 4bbl to 2bbl adapter plate, and have the fuel injector rotated 180 from the factory set-up. Since the factory BBD and Holley sniper both rely on the throttle cable in a "pull down" configuration, it won't work while the throttle linkage is closer to the valve cover side.

I'm going to weld on a relocated ball mount, and cut off the factory position...giving the unit a "pull horizontal" operation

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Finally, I butchered up what was left of the factory cable bracket, and mounted it to a head stud.
 

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Discussion Starter · #14 ·
Dana 30 Slime

I've had some setbacks, parts availability, additional work needing to be completed...

Anywho, we decided to open up the front diff while it was on the rack. really glad we did!!

 
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