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Project "Reassembly"

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EDIT:
Thanks to the greed of photobucket, the photos are no longer embedded into the threads. It has been a pleasure to share this information with forum members and guests. The following link will lead to the bulk of relevant photos related to this thread:
http://s130.photobucket.com/user/Fatman_CJ7/library/Reassembly?sort=2&page=1

Well today is the first day of final assembly for the CJ. We have done all the mock up, we've painted, welded, sanded, tweaked, all the major parts that are going to be messed with for the most part. (Sorry the tub is not done yet) but we've got to get the roller ready so we can go pick it up soon.

I'll be brief in a lot of this thread as most of the sub assemblies have been done and discussed in other threads, ie. you will see the suspension go in as a whole but I not be going into detail about regearing, caster, hubs, brakes, etc, as I have threaded this information in the past and a majority of this was done in mock up. I'll try to hit on some of the details that you won't see on most other jeeps, why I'm using or making a certain product as well as providing information on the products and distributors that I use.

In 3 days 11/27/07, I will have had this Jeep for one year, I'm sure I could have done this project quicker and spent more time working on it, (ask my wife, she'll tell ya this is where I spend ALL my time) but truthfully I have to balance this with family and work. I am estimating that I have four more months of work before I am 100% complete and ready to road test.

This is thanksgiving weekend so, I do want to thank some people who have been a tremendous help in the past year. My Son who has done ALL the stuff I didn't want to do, he has been great and I think has learned a lot in the process. I can't wait to give him the keys. I'd also like to thank my buddy Eric who comes over and helps every time I ask, he's helped me with parts on my jeep, tools, vendors, just a great friend. Eddie has also been just an incredible asset with the products he makes to custom one offs he's done for me and being able to bounce ideas I had for this Jeep off him when I was first planning the build, THANKS BESRK! And there are another 10 dozen of you guys out there that have sent tools, needed tools, bought, sold or traded parts as we all needed them. Thanks to all you guys for making this an enjoyable platform to receive and provide information. !!!!!

OK, so I finished the 2nd coat of Chassis Black on the frame and misc parts on Wed (nice 75* day), rolled everything into the garage and cranked the heat up until I got back in town last night.




This morning Aryn & I moved the frame out to the driveway and put the suspension back in place. Completely rebuilt, regeared D30 & D44 with new everything! Rebuild and gearing was done by Ted Wendel of Richmond VA.






Brakes, were all reinstalled, sway bar, shocks, pitman connection, bump stops, ...




Brake lines, prop valve,


One thing I'm doing is running the rear lighting harness inside the frame as well as the tow electrical setup:


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Pacfanweb said:
Looks great. I've really got to come by and check it out if I can ever get done being perpetually sick.
I agree with this man.:tea: I need to check it out as well next time I'm down that way.
 

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Fatman said:
The Herc will overlap the paint by about an inch all the way around.

Overspray? I'm going to be a little bit more careful than that. It will be taped off and sealed before the first can of Herc even gets opened. :thumbsup:
Ill warn you, the Herc gets EVERYWHERE. I'm talking it traveled at least 5 feet and got on my frame when I was doing the inside of my body. I'm still finding new specks of it in my shop.
 

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TetanusCJ7 said:
The flip flops are a standard issue item when working on Jeeps down here in Florida! At least he doesn't have a cigarette hanging out of his mouth like one of my neighbors....does Tyvex burn?????

But seriously, good work Fatman...your project looks fantastic. And you have thoroughly convinced me that my Jeep is a hoopty.
He could of made a new one rolling off the line in 1985 look like a hoopty.
 

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BESRK said:
<---------- Sitting outside Fatman's window waiting patiently for the painted tub to show up. Seriously.. look out the window Dave... :D
Eddie, do you have my cage with you?:tea:
 

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uh-oh, let me know when you come get your Jeep from the painter man, we can do lunch, my treat.
 

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It hasn't been as warm down there as it has up here has it Dave? It was 70+ 3 days this week up here. I sprayed some of my last stuff actually, and it set up great.
 

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Looking good man, I wish I had all the skills and tools you had. ealousy. We need to go on a wheeling expedition sometime.
 

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No hydro clutch fat man? I'm sort of surprised. I figured you would be the one to do the AX15 since the son will no doubt be driving it quite a bit.
 

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Gotta break the T-4 first. Then I'll find a T-18.
Your going with a non-OD tranny on a semi-dd? Or is this just going to be his toy? I understand the strength diff, but unless your going big tire I dont think you'll need the grunt of the 18.
 

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I do like those mirrors fat. Howd you do those? If I have one thing against my CJ it's the goofy looking mirrors. We need to get a little NC wheeling trip done when the 3 or 4 of us get done with our restorations. I thought my CJ was nice, you make me feel ashamed. Also, didn't you say your painter was in Hickory? PM me with some details, I wouldn't mind a pro job depending on how proud he is of his work.
 

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Thank you sir, I was thinking that was the case.

The brackets come with the mirrors.
The ones I got were from 4WD:
http://www.4wd.com/productdetails.aspx?partID=3644
$90.00 for the pair.
Eric drilled and taped the existing hinges and then we took a cut off and flushed the threads on the inside of the hinge. I used SS Allen machine bolts with nylock nuts to mount the hinges.

Amen to that, looking forward to getting this done. First trip Hilton Head, SC

You need to knok that crap off. your rig is sweet, Eddie did you a nice cage!
My painter, ... Let's just say I'd find someone else. Not the most pleased as I thought I was. :thumbdown:
Thanks man, your jeep makes me feel good. Any plans to hit Tellico or Uwharrie in the summer? Buddy and I are thinking about taking a little trip before I start college.
 

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Plans yes, when... who knows.
Where are ya going off to? Hope yer com'n to State. Daes gots good educamacation here!
Going to NASCAR tech actually, but I've got several friends going down to state. Our trip is in the extreme early planning phases. If you want to join let me know man, we can plan around you, as the two of us can take any time off we want with like 3 weeks notice.
 

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I sent you a PM man, requesting help, I feel like a patsy asking for donations or something. Curse all your good designs.
 

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Dave, if you like the comfort of the seats but not the color you could always get them re-covered. Most any auto restoration place or even some furniture manufacturers could set you up. It would look good with yellow insets and black side bolsters.
 

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Any wagers on how long the T4 is going to last with the young'n driving around? (relative term, I'm only two years older). I know how teenagers like to rip gears in their toys.
 
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