Build Thread 1959 CJ5 "One Piece at a Time..."
- Posts
- 2,330
- Media
- 45
- Thanks
- 6
- Location
- Eagle, WI
- Vehicle(s)
- 1979 CJ7 V8 304 T18 w/gran low D20 w/TeraLowD30 D44,
1959 CJ5 Rebuild 74 Buick 231V6 oddfire T14 D20 D30 D44 frame boxed roller engine ready,
1967 CJ5 V6 225 T86aa D18 D27 D44 runs needs work,
1954 CJ3B F4-134 T90A D18 D25 D44 Half Cab needs tub,
One Piece at a Time - Based on the Johnny Cash song written by Wayne Kemp. No we didn't steal it but the rest of the song fits!!
This build is based on a 1959 CJ5 that we bought a few years ago. At least that’s what the Wisconsin title, nameplate and numbers stamped on the frame all match to. But the rest of this CJ is a mix of different parts from different year Jeeps and some that are not even Jeep at all. So we called it the rat jeep.
The engine is a 75-76 Dauntless Buick 225 V6 231 odd fire based on the casting numbers I found. The Transmission a T86aa and Transfer Case a Dana 20 . Here’s where things get strange. The axles are Dana 27 front and Dana 30 rear. Have you ever seen a Dana 30 rear? They are really small even compared to the Dana 44 in our ’54 CJ3b . After a little research, I believe the donor vehicle was a ’67 C101 Commando. That axle setup was only used for one year as the Dana 30 rear was a very weak rear axle. The person that built this mess put the wrong length rear springs in so the rear wheels did not line up in the wheel wells
and actually rubbed on the tub. These springs don’t measure to anything “CJ” or “jeep” that I have found and really caused a problem. The V6 conversion was done totally wrong – mounts in the wrong places – chicken tracked welding and well you get the idea. The engine actually sat at an angle, and because of the wrong rear springs the rear driveshaft was compressed and tight jammed up between the Transfer Case and the rear differential. No free play in the drive shaft at all. The engine actually ran pretty well, and things weren’t too bad as long as you were not moving. This CJ wouldn’t steer or brake correctly and kind of hopped around the yard. It also came with a full Kelly steel top that is in good shape. It has an aftermarket tub with some really strange looking front fenders all pretty much rust free. So for $600 I thought it was a great deal! It was originally bought as a parts jeep for our ’67 CJ5 – but hey this one has potential on its own. 
Now the original plan for this CJ was to make it more 1959ish. A while back we found a ’60 roller frame in better shape that our ’59, complete with D25 front, Dana 44 rear (offset) 5.38 ratios 19 spline, and 9 inch brakes. When I bought the ‘54 CJ3b the owner threw in another (running) F-134 complete with T-90 and Dana 18. So we would be all set for a ‘59ish CJ, but I wanted at least 10 inch brakes, and we decided to use this CJ for the 2014 Colorado trip so our plans have changed.
This is basically our plan:
1. Use the better frame, repair, box where needed, blast, prep and paint.
2. Use the Buick 231 V6 T86aa Dana 20 combo from the rat jeep.
3. Obtain Dana axles that would work for our set up and allow for a rear locker. So I think I need a 30 spline and at least 10 inch brakes and also want the option of putting disc up front. The thinking is something like a Dana 27 front and Dana 44 rear out of a mid 70’s CJ should work, but this is still under investigation.
4. Install a 2 or 2.5 in lift with new springs, shocks and everything.
5. We have 4 wheels from the 3B set up for 31’s so we will clean these, find a spare and buy 5 new tires.
6. I’m not sure right now on the steering, as that depends on the axles somewhat, but we want the option to install power steering (at some point). :drool: The engine already has the drive pulley. Onboard air would be great too.:drool::drool:
7. The tub, hood and front fenders from the rat jeep are strange – but steel and good shape, so we will use these. We might cut away some of the front fenders or adding some fender flares might make it look better. It’s functional now – it just looks weird.
8. This CJ will be totally rewired and a fuse box installed. I have read a lot about CJ wiring using the frame for return current and the problems this can cause, especially in starting circuits, so each circuit will have a ground (DC return) wire run (and of course the frame will be grounded).
9. We need to find comfortable high backed seats we can install drivers and passenger side. We have none at this time. Suggestions on what would work out of other vehicles would be appreciated. We can make seat brackets as needed (well my husband can).
10. I want to install a roll cage – I don’t want to need it, but I want to have it. I think I have seen kits or plans that a soft top will fit over. (my husband says he needs a tubing notch tool for this… there are more tool purchases in our future…)
11. I will probably just buy a soft top. I could rob the soft top and door hardware from the ’67 CJ5 and just recover it or fabricate one from scratch, but I don’t think there will be time.
12. I’d like a winch, but don’t know if that will happen right now.
This is obviously my first build (thread). I promise there will be mistakes – wrong terminology and the like. I’ll add some pics next. And everyone can laugh at where we are and how far we have to go….
But I believe…. and I hope you will too!...
This build is based on a 1959 CJ5 that we bought a few years ago. At least that’s what the Wisconsin title, nameplate and numbers stamped on the frame all match to. But the rest of this CJ is a mix of different parts from different year Jeeps and some that are not even Jeep at all. So we called it the rat jeep.
The engine is a 75-76 Dauntless Buick 225 V6 231 odd fire based on the casting numbers I found. The Transmission a T86aa and Transfer Case a Dana 20 . Here’s where things get strange. The axles are Dana 27 front and Dana 30 rear. Have you ever seen a Dana 30 rear? They are really small even compared to the Dana 44 in our ’54 CJ3b . After a little research, I believe the donor vehicle was a ’67 C101 Commando. That axle setup was only used for one year as the Dana 30 rear was a very weak rear axle. The person that built this mess put the wrong length rear springs in so the rear wheels did not line up in the wheel wells
and actually rubbed on the tub. These springs don’t measure to anything “CJ” or “jeep” that I have found and really caused a problem. The V6 conversion was done totally wrong – mounts in the wrong places – chicken tracked welding and well you get the idea. The engine actually sat at an angle, and because of the wrong rear springs the rear driveshaft was compressed and tight jammed up between the Transfer Case and the rear differential. No free play in the drive shaft at all. The engine actually ran pretty well, and things weren’t too bad as long as you were not moving. This CJ wouldn’t steer or brake correctly and kind of hopped around the yard. It also came with a full Kelly steel top that is in good shape. It has an aftermarket tub with some really strange looking front fenders all pretty much rust free. So for $600 I thought it was a great deal! It was originally bought as a parts jeep for our ’67 CJ5 – but hey this one has potential on its own. Now the original plan for this CJ was to make it more 1959ish. A while back we found a ’60 roller frame in better shape that our ’59, complete with D25 front, Dana 44 rear (offset) 5.38 ratios 19 spline, and 9 inch brakes. When I bought the ‘54 CJ3b the owner threw in another (running) F-134 complete with T-90 and Dana 18. So we would be all set for a ‘59ish CJ, but I wanted at least 10 inch brakes, and we decided to use this CJ for the 2014 Colorado trip so our plans have changed.
This is basically our plan:
1. Use the better frame, repair, box where needed, blast, prep and paint.
2. Use the Buick 231 V6 T86aa Dana 20 combo from the rat jeep.
3. Obtain Dana axles that would work for our set up and allow for a rear locker. So I think I need a 30 spline and at least 10 inch brakes and also want the option of putting disc up front. The thinking is something like a Dana 27 front and Dana 44 rear out of a mid 70’s CJ should work, but this is still under investigation.
4. Install a 2 or 2.5 in lift with new springs, shocks and everything.
5. We have 4 wheels from the 3B set up for 31’s so we will clean these, find a spare and buy 5 new tires.
6. I’m not sure right now on the steering, as that depends on the axles somewhat, but we want the option to install power steering (at some point). :drool: The engine already has the drive pulley. Onboard air would be great too.:drool::drool:
7. The tub, hood and front fenders from the rat jeep are strange – but steel and good shape, so we will use these. We might cut away some of the front fenders or adding some fender flares might make it look better. It’s functional now – it just looks weird.
8. This CJ will be totally rewired and a fuse box installed. I have read a lot about CJ wiring using the frame for return current and the problems this can cause, especially in starting circuits, so each circuit will have a ground (DC return) wire run (and of course the frame will be grounded).
9. We need to find comfortable high backed seats we can install drivers and passenger side. We have none at this time. Suggestions on what would work out of other vehicles would be appreciated. We can make seat brackets as needed (well my husband can).
10. I want to install a roll cage – I don’t want to need it, but I want to have it. I think I have seen kits or plans that a soft top will fit over. (my husband says he needs a tubing notch tool for this… there are more tool purchases in our future…
)11. I will probably just buy a soft top. I could rob the soft top and door hardware from the ’67 CJ5 and just recover it or fabricate one from scratch, but I don’t think there will be time.
12. I’d like a winch, but don’t know if that will happen right now.
This is obviously my first build (thread). I promise there will be mistakes – wrong terminology and the like. I’ll add some pics next. And everyone can laugh at where we are
and how far we have to go…. But I believe…. and I hope you will too!...
