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Project "Reassembly"

157419 Views 376 Replies 106 Participants Last post by  SKT
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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Hey fatman.......where did you get that horn button for the new steering wheel? I have the same wheel in mine and have been looking for a horn button for it.

I would love to know what the part number is.............:D
 

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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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Discussion Starter · #204 ·
Hey fatman.......where did you get that horn button for the new steering wheel? I have the same wheel in mine and have been looking for a horn button for it.
I would love to know what the part number is.............:D
Have a spare that says: GT Grant.

Can get the Jeep one here:
http://www.4wheelparts.com/prodDetail.aspx?partNo=GRA5675&jeep-parts=true

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.
Kinda what I'm thinking.

What color are those seats? I agree- they don't look right in there with all that black and yellow.
Spice, Made by American Auto. PO had them installed right before I bought the Jeep. Wish he'd bought black
 

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Hey Dave, Did you drive it yet? If so any pics of the ear to ear grins from you and the young workhorse? By the way I know I have said it more than once awsome build and thanks for sharing. JC
 

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Discussion Starter · #206 ·
Hey JC, where have you been!

Eric & I have to bleed the brakes Tuesday and install the fan controller.
After that it's ready to roll. I'm going through everything making sure I didn't forget something, checking torque, voltage, etc.

Still have a bunch of grounds I want to run, need to install a bunch of relays for the aux lights, fuel pump, etc.
Gotta call and get a windshield, find a new rear view mirror.

It's real close! The kid is gett'n excited. Maybe I'll let him drive it. :)
 

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if you just want black as opposed to spice, those seats are very reasonable... I got mine shipped (same ones)for under $125 (CB Jeeps had them on sale)...

'course, if you're going to upgrade...

Hoss
 

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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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I know how teenagers like to rip gears in their toys.
X2. I had to rebuild the transmission in my truck back in high school (almost $2k :brickwall) and Ive already had to replace the clutch in my DD. Go ahead and get a spare tranny and clutch for when it happens. :thumbsup:

Awesome work. I would be happy if mine turns out half that good one day.
 

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Discussion Starter · #210 ·
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.
I'm look'n for a T18 and a bell housing.
if people would stop giving em away. :laugh: Eddie, ... EDDIE, you listen'n?
http://jeepforum.com/forum/showpost.php?p=5092965&postcount=100

The kid understands that if he breaks it, it sits.
I cleaned the outside of the T4 case, that's about the same as a rebuild! :)
 

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Discussion Starter · #211 ·
if you just want black as opposed to spice, those seats are very reasonable... I got mine shipped (same ones)for under $125 (CB Jeeps had them on sale)...
Hoss
Hook a brutha up with a link.

'course, if you're going to upgrade...
what'cha ask'n Willis? :cheers2:
 

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Those steering wheel anti-theft devices start out nice, and turn bad after a year or so. Being they are made of aluminum, they eventually get wiggly, at least mine did. I got one about ten years ago and took it off after 3 or 4 years because it felt so loose. It was never a safety issue, it was just sloppy feeling. Also, I got tired of that wheel being an extra 2 inches closer to me.

I removed mine and have never looked back since. But I know how you feel when it comes to security and your freshly revived jeep. Someone tried to steal mine once already and your battery disconnect is the best solution available in my opinion. They can only tow it away with a dead battery, not drive it. Most car thieves don't bring tow trucks.
 

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Dave, I relocated the business to another hanger around Feb. and jeep time has been scarce. I have checked in from time to time but nothing like before. I have been watching your project weekly and look forward to the finished product. I am still dreaming of the day I will be in your shoes but I am shooting for late Aug. Keep pushing we all are watching. jc
 

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Discussion Starter · #216 ·
I thought while I'm at it I'd upload a few pics.
Still have to reverse the fan wires, it's pushing.
Speedo's not working.
Windshield goes in tomorrow.
Have to make up a few ground wires.

Small things!

Drove it yesterday, very solid, strong motor, steering is tight. Lot of wind without a windshield. :D
Serious WOOD ! Few hundred miles of break in, change the fluids, and it's another day.

Few adjustments to the steering wheel




Fan controller set


99% pics

 
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