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Project "Reassembly"

157423 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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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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Discussion Starter · #144 ·
Fatman i bieleve the 4 wire plug is for the factory fog lights
Thank you sir, I was thinking that was the case.

Fatman,
I want to use the type of mirrors you have on yours. Is there a certain bracket that you used to install those or did they bolt right up?
Heath
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.

We need to get a little NC wheeling trip done when the 3 or 4 of us get done with our restorations.
Amen to that, looking forward to getting this done. First trip Hilton Head, SC

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.
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:
 

· Box Man
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Amen to that, looking forward to getting this done. First trip Hilton Head, SC
I hope you can plan your route so you can have dinner with me and the wife when you pass by Florence on I-95 on the way to Hilton Head. Dinner or lunch or breakfast is on me! :cheers2:
 

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Thanks Fat!! That is how I was planning, but thought maybe there was a bracket that bolted right up!!

Mine is off at paint now!! Hope to be putting back together in a week or two! Yours is looking great, love the color scheme.
 

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The 4 wire plus is for the tail light harness. The red wire going to the fuel gauge is a ignition hot wire. I am not sure where it is fed from. I will check my parts Jeep when I get home since I have the dash loose and all of the wiring is still intact to see where the orange wire goes as well as the plug with the yellow and purple wires.
 

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Discussion Starter · #150 ·
The 4 wire plus is for the tail light harness.
Ed,
Actually the rear light / fuel sending unit harness is a 5 wire plug.

Female plug off main interior harness:


Rear light / fuel sending unit harness w/ male plug:


the yellow and purple lead was for the factory tach
Cool, I was thinking A/C or sump'n like that.
 

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Very impressive Fatman. I think you have do a required video of the start up and first drive.
Offnote - I have alot of your ideas for my next build up or restore of the current quick build. I appreciate all the great pics and advice of all of us CJ'ers:cheers2:
 

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Well after looking at my parts Jeep, my CJ (which is a wiring nightmare with the motor swap and fiberglass tub), and a bunch of wiring harnesses from other CJ's that I have parted out I think I have this figured out.
Yes your correct the 5 wire plug is for the rear lights and sending unit. The 4 wire plug is for the factory driving light switch which was standard in Laredo edition CJ's. The orange wire off of the headlight harness is where the factory driving lights would plug in.
Driving light switch and relay.


The orange and black wires should have plugs on them and they are for the under dash lights that came on Laredo's and Renegades.

 

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Discussion Starter · #154 ·
Very impressive Fatman. I think you have do a required video of the start up and first drive.
Offnote - I have alot of your ideas for my next build up or restore of the current quick build. I appreciate all the great pics and advice of all of us CJ'ers
Thanks man, glad to be of service.

The 4 wire plug is for the factory driving light switch which was standard in Laredo edition CJ's. The orange wire off of the headlight harness is where the factory driving lights would plug in.

The orange and black wires should have plugs on them and they are for the under dash lights that came on Laredo's and Renegades.
Nice Job, those pics helped a LOT!

X2. Looks way better then I ever thought it would. Be proud of yourselves...
Very proud, this thing has been a blast. not in any hurry to do another one though.

As ya'll can tell, I'm fix'n to get this dash installed soon.
So, (3) holes


(3) heater pulls, help me get this right the first time:
A


B


C


Got my switches set, RTV'd all my lights / indicators ... I'll set the dash and overhead and wire em up this weekend:








.
 

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Like the anti-rattle silicone treatment on the back of the gauges and dynamat on the firewall. Wish I did that when I rebuilt mine. I'll suggest some good thick floor mats, even though you don't need them with that sprayed bed liner. The sound damping will be even better.

I'll give her a look, but I'm not sure where there could be any interference?
pertaining to the brakes. If both front springs cycle at the same time, ala speedbump, the swaybar end where it connects to the link, may be able to kiss that brake line now that it's no longer a soft line. My braided brake lines have a longer connector lug than stock, this is where the interference occurred.
 

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How long did you have to attack that lever mechanism on the upper heater box with the wire wheel to get it looking that smooth?? I just took some rust reformer and brushed it on that plate thinking to myself, "This isn't really necessary but I don't want to look at rust when I'm under here." Everything I do you have to do twice as good :brickwall
 

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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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Discussion Starter · #158 ·
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.
Plans yes, when... who knows.
Where are ya going off to? Hope yer com'n to State. Daes gots good educamacation here!

Ok, on more what the ... does this go to?
Comes off the brake switch, .... Maybe for an electric brake switch?
 

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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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