Jeep Enthusiast Forums banner

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:


81 - 100 of 377 Posts

· Registered
Joined
·
2,524 Posts
Discussion Starter · #83 ·

· Registered
Joined
·
2,524 Posts
Discussion Starter · #85 ·
Got a lil bit of garage time this morning.
Made up some brackets to relocate the Vanco PB's closer to the firewall

Used 11ga carbon plate with a 2" gap space. (stock was 3 5/8"
Almost gave me enough room for the air cleaner, but most importantly it sealed up the firewall hole.

Still need to re-thread the plunger about 1/2", and paint the brackets.

Stock bracket & new bracket:



I wish I had a CAD set up for this stuff:



Installed pics:






Also got the Russell SS braided lines and connectors run for the TBI.
 

· Registered
Joined
·
1,383 Posts
Looking good man, I wish I had all the skills and tools you had. ealousy. We need to go on a wheeling expedition sometime.
 

· Registered
Joined
·
2,524 Posts
Discussion Starter · #88 ·
now that the tub is done for good, we're going to start nock'n this thing out. Alpha Pup turns 16 next month so I need to get busy.

Going to set the cage tomorrow, still figr'n this brake out. It'll come to me tomorrow.


If you're going to run the Blazer blower, don't forget to cap the 3/4" mud hole.


Finished the Dynamat




Sealing the inlet on the air box


Cut outs worked well


And there was heat

 

· Registered
Joined
·
2,524 Posts
Discussion Starter · #89 ·
After looking at the $90 clutch rod kits I decided to see if I could make my own with some donor parts.
Cut & measure, then I drilled out the end of the stock rod about 1/4"


We'll see how well it holds up



Re-bent and aligned


Eric came out and wired up the engine compartment:



Relocated the starter solenoid:


Howell computer


Still have a bunch of parts to paint before they can be installed
 

· Registered
Joined
·
1,383 Posts
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.
 

· Registered
Joined
·
57 Posts
Fatman,

I am new here and have been checking out your threads and they are great. They help me see the end of the tunnel that is as of now a pile of parts in the garage. I was wondering if you had created a similar discussion on you Engine build. Thanks and the Jeep looks awesome.
 

· Registered
Joined
·
2,524 Posts
Discussion Starter · #94 ·
IAFF,
Welcome to the forum, I used to live in Chantilly as well as Vienna and Clifton.
Glad the posts help, I really didn't do a write up on the motor build but posted a bunch of info here:

http://jeepforum.com/forum/showthread.php?t=354885

James has some good info on his site, I coppied a lot of what he did.

http://www.bustedjeep.com/projects/rebuild.asp

If you need anything specific, feel free to ask.

Dazed,
The dynamat helps with sound deadening as well as a reduction of heat transfer through the firewall.
See it? Only if I have my eyes open.
 

· Registered
Joined
·
95 Posts
Fatman, do you think the starter solenoid may be a little hard to get to for future maintenance? Once you get the fenders on and such it'll be tucked up there nice and tight. Looks really nice, but I wouldn't want to be the one having to pull/replace it down the road. I'm digging the gas tank though, didn't that company go out of business recently? Keep up the great work, we all can't wait to see this thing out on the streets.
 

· Bicentennial Nickel
Joined
·
2,475 Posts
The gas tank company isn't out of business, they just can't get insurance to make tanks from what I was told.

They said they would sell me the pieces for about the same price, but I woudl have to weld it.

I am looking for other options now.

cb
 

· Registered
Joined
·
2,524 Posts
Discussion Starter · #97 ·
Fatman, do you think the starter solenoid may be a little hard to get to for future maintenance? Once you get the fenders on and such it'll be tucked up there nice and tight. Looks really nice, but I wouldn't want to be the one having to pull/replace it down the road. I'm digging the gas tank though, didn't that company go out of business recently? Keep up the great work, we all can't wait to see this thing out on the streets.
I wanted it off the fender. Trying to keep this as clean of a set up as I can.
Should be simple enough to slide under the jeep and replace if necessary.

I'm looking to see it running too! :)

The gas tank company isn't out of business, they just can't get insurance to make tanks from what I was told.
cb
I got lucky on that one, one of the last tanks to come out of there.
 

· Registered
Joined
·
1,383 Posts
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.
 

· Go Wolfpack
Joined
·
2,614 Posts
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.
But it's an easy swap, and even a kid would have trouble breaking a T-18.

I think an NV 3500 would be a great choice if FM decides on another 5-speed.
 
81 - 100 of 377 Posts
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top