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Project "Reassembly"

157366 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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Discussion Starter · #61 ·
Dave, looking good there. Almost warm enough for the Herc job now.
It's 48* at 9am. I'm going to go out about 10-ish and wash it out with "Dawn". (gotta be careful with our current water restrictions)

If it gets close to 64* and I can get the tub dry enough, I'll get the primer put down.

Eric may be coming down around noon, you're more than welcome. Just not sure what we'll be able to get done with the temps. Give me a call.

As for the filter thing, these days it's pot luck with anything you buy.
 

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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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Discussion Starter · #63 ·
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.
We got that same stretch of warmth, Friday was in the 80's. Today's not going to hit 45*

Got some other stuff done, can't do anything on the interior, so...

New plastic thinga majiggers for the clutch thina mabob


Drilled and added a spring to keep the actuater rod in place


Put in the rear cage tie-ins


New O-rings and connected the PS lines


Put the Vanco Brakes in place, this was a waste of $, bout an inch too wide. :brickwall


SS battery tray


Gotta go up to the shop Monday and size some Russell Hardware for the Fuel pump, TBI, and return lines
 

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Discussion Starter · #65 ·
the vanco brake assembly was too wide? or the air filter?
it'll fit, just not with the K&N




I'm wondering if I'm going to need to put a solid motor mount on the pass side to keep it from flexing. I've got about 1/4 - 1/2" of room between the linkage
 

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either a solid mount or a turn buckle from an engine bolt to the frame somewhere..I have used a length of chain on drag cars without solid mounts...Like the 77 trans am I'm slowly building for Pinks..
 

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Discussion Starter · #67 · (Edited)
Vanco Brakes

Ok, I'm kinda concerned that I've got the wrong Bracket with my brake booster.

I know someone is going to pick up on it, yes I know the threaded extension is up side down. :thumbsup:

The flexible rubber piece does not reach the firewall and I didn't get any type of gromet to fill this area?


When I but the two components together and align the brake turn out to match the clutch stop I have over an inch of thread.
This is about equal to the distance of the rubber away from the firewall.


Close ups:




This showes it well:


Am I missing a piece or do I have the wrong brackets?
 

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Ok, I'm kinda concerned that I've got the wrong Bracket with my brake booster.

The flexible rubber piece does not reach the firewall and I didn't get any type of gromet to fill this area?

Am I missing a piece or do I have the wrong brackets?
Hmm, weird. Why didnt you just do the YJ swap instead of the Vanco system? Nothing wrong with Vanco, just curious.
 

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What are the brackets you have now for, it looks to me as if there about an 1 1/2 to long themselves.
 

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Discussion Starter · #73 ·
Hmm, weird. Why didnt you just do the YJ swap instead of the Vanco system? Nothing wrong with Vanco, just curious.
No offense to any one with a CJ running YJ brakes, but I was not about to put junkyard brakes on something my family will be driving.
Van has a hell of a good reputation, nuff said.


I have been waiting months to see those steps. Functional and something a DIY can do.
BTW sweet project.
Glad you like, nice for DD, easy to pop off when it's LOW - GO time.

Man, I am trying to catch up with you, but you are moving on with the reassembly! Good job. Your pictures are going to be very helpful.
Let's get that 300 back together, let me know if I can help

What are the brackets you have now for, it looks to me as if there about an 1 1/2 to long themselves.
They are 3 5/8" from booster to firewall.
2" would be perfect.
 

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Can you not call vanco and confirm the bracket size then go to your buddies shop and have him brake u out some new ones out of stainless
 

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Discussion Starter · #76 ·
Can you not call vanco and confirm the bracket size then go to your buddies shop and have him brake u out some new ones out of stainless
Sent Van a PM 4 hours ago. I'm sure I'll hear from him tomorrow.
I'll let ya'll know how their customer service goes but I have no doubt it'll be top notch.
 

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I actually thought I was responding to his PM.

His brackets are correct. We do have a boot for the firewall (It's a stock new one which most vehicles should have). There's other things I want to discuss with him though.
 

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Discussion Starter · #80 ·
Spoke to Van earlier today, and though his current design is for 3 5/8" brackets, he did indicate it would function very well with a 2" bracket. Just not something he is manufacturing at this time. That is my next procedure for the Power Booster.
Moving the booster rearward will solve two functions, providing greater clearance at the TBI, and the rod seal will butt up against the firewall hole.
I’ll also be obtaining and installing a firewall seal that I didn’t have with my manual brakes.

Van, was great to talk to. Glad to have him on this site as a vendor and someone that stands behind his product. I'd buy from him again tomorrow if I needed to.


Pictures of bracket modifications to follow soon.
 
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