Build Thread 1959 CJ5 "One Piece at a Time..."

[oldjeeplady]

Back to the CJ build. Here are some pics of things we ordered for our build:

New shocks and springs - a 2.5 in lift kit:



Stuff from Eastwood:



Steering gearbox and pitman arm:



Misc suspension parts (vender sent one wrong part....we finally got it):



more interesting things to come....

 

[oldjeeplady]

We were getting tired of moving the frame around to work on it as it was getting heavier from boxing. Anyway, my husband had plans and the steel cut and some drilled for a "Rotisserie" so we decided to build that before we progressed further. I posted some pics of this project in the "Welding Projects" thread if you want to look.

Here are some pictures of the CJ frame mounted on the Rotisserie which makes it much easier to work on (unless you really like drilling and welding upside down....)

 

[oldjeeplady]

Next we assembled the suspension and made a rolling chassis so we could figure the correct place to weld the engine mount brackets and the correct holes for the Transmission cross member. We needed to align the engine/Transmission / tranfer case assembly at the same angle as the rear differential - they are on parallel planes. We ended up with a pinion angle of 8 degrees.

 

[IOPort51]

oldjeeplady (lady jeeper extremely fond of old CJ's)

Read more: http://www.jeep-cj.com/forums/f98/1959-cj5-one-piece-time-21347/index5.html#ixzz31JqrqQVI


you need a comma in here someplace. old,jeeplady vs. oldjeep,lady.
​

 

[Petescj]

Very nice. I bet you'll like that rotissere even more when you move on to the tub. Send it my way when your done.

 

[IOPort51]

that would be almost as cool a thing to own as it would be to have room to put it!!

 

[mtnwhlr]

I'm glad to see you guys are making good progress on the CJ and tell your Hubby good job on the rotissere they sure make things a hole lot easier. And poor Peanut it seems to keep sticking its nose where it shouldn't

 

[HackFabrication]

Really nice!

 

[oldjeeplady]

I wanted to post some pics to update, but when reading from my camera memory card I got the dreaded "error telling me the disc needed to be formatted" and Windows file format shows it as RAW. My oldest son has a BSSE, and said he might be able to read the card from a different operating system or write a program to read it...My husband has some pics in his phone, but for now I will just do a verbal update.

When we brought the engine/tranny/Transfer Case out of the barn to test fit the engine placement, we also decided to clean it up. When cleaning the T-86 /Dana 20 , I discovered a crack in the adapter plate and also the upper front of the T-86 case. These had been welded - but it does not appear to be nirod. Well, we found a replacement adapter for the T-86 (to our Buick 231 V6), but finding a replacement case or replacement T-86 (there were some bad gears in ours too) has not happened.

Just recently we found what was advertised as a T-15 /Dana 20 combo from a '75 CJ5 , and picked that up. After scraping the massive grease and gunk away this turned out to be a T-14 /Dana 20 combo. This will still work. Of course now we need a different adapter (kit) to our 231 V6, and one has been ordered.

The brakes are done on all four hubs with all new pads, cylinders and the drums turned and ready to go. (These are 11 inch)

The wheels have been blasted, painted and new tires mounted. (Except the spare....we just found a rim for that)

It turns out the body was in worse shape than I thought, so it now has all new floor in the drivers/passengers area, a custom doghouse, and the firewall is being reinforced and replaced in areas. The windshield frame is worthless - it was all rotted - but the glass is good and both wiper motors work. So a new windshield frame will be coming. Even the blower motor worked.

I walked out to the shop while my husband was working on fitting the steering column and he had one of the seats on boards to raise it to the correct height to clear the gas tank. He was sitting in the seat and his elbows were below his knees and that's with a "tilt" wheel. He is 6-2 and not a small guy and he looked folded like a pretzel. I cannot imagine how he is going to be comfortable in this little CJ. He doesn't fit. I don't think I'll make a CJ guy out of him unless I can find a CJ7 or 8.

With the new tires and lift I now need a step ladder to get in and out of this thing. I can climb onto a horse easier...

I hope to have some pics next time...

 

[oldjeeplady]

long time no update but we work on this most every day...
I didn't get the pics from my memory card so I took some more to show why we needed a different Transmission .

T86AA with cracked and welded case



The other side



The adapter plate was cracked and welded too.



We had found a replacement adapter plate for the T-86 , but finding a better case proved a lot harder. We found a T-14 /Dana 20 combo that is supposed to be from a '75 CJ5 . We ordered a new adapter kit from Advanced Adapters and it fits, but it came with the wrong pilot bushing. We told them exactly what engine we have, but their kit doesn't support the '75 Buick 231 V6 oddfire. Of course we didn't find that out until after it came.

We did find a correct pilot bushing from another source. It seems it's always hurry up and then wait for more parts.

While we were waiting we did a test fit of the body as we knew there were going to be some floor replacements and firewall changes. The PO had cut away part of the firewall and put "something" in place to allow room for the 231 V6. So here are a few pics of what it will look like with a body.

Bringing the body parts from the barn with our '41 Farmall A.



We use this tractor a lot to lift heavy things around here. The tub qualifies.

Here are a few more pics with the body test fitted:







While we had the body on we discovered that with the longer shaft water pump that came on this engine, we were right up against the radiator or actually a little past it. Comparing that water pump to the one installed on our 1967 CJ5 w 225 V6 we knew we needed the short shaft water pump. We also needed a different water pump pulley and the other stuff for our power steering installation. So there was more research and eventually a trip to a junk yard to get the parts we needed. Pics on those later.

We also sandblasted the wheels, painted them and installed some new tires.

Old tires on rims we are using:



Getting rims ready to paint



New tires on painted rims. These are BFG Mud Terrain T/A KM2 32x11.50R15LT



Here are a couple pictures showing the T-14 mounted with the adapter plate.





Since this Transmission mounts differently than the T-86 we needed to weld a steel plate on the Transmission crossmember and then drill new holes. The T-14 we got came with the mounting assembly and even a mount, but the holes don't line up the same as the T-86 mounts, plus the bolts are a larger size. That is why it's sitting on wood blocks in these pictures.

Our older son spent the week of July 4th with us and did a lot of work to the engine, rebuilt the carb and a lot more. We even made a youtube video of the first time we started it after his work. I'll try to get those posted soon.

 

[Helomedic1171]

I like the posts and the photos. It gives me an idea of what I'm getting into when i start my '58 this winter. I've got the F-head motor and the T-90 /D18 combo. How do you like them? Looking at ditching the motor for a buick or chevy V6 (easier to find than a Dauntless Buick 225 V6 )

 

[mtnwhlr]

Glad to see it's coming along

 

[Petescj]

long time no update but we work on this most every day...
I didn't get the pics from my memory card so I took some more to show why we needed a different Transmission .

T86AA with cracked and welded case

The other side


The adapter plate was cracked and welded too.

We had found a replacement adapter plate for the T-86 , but finding a better case proved a lot harder. We found a T-14 /Dana 20 combo that is supposed to be from a '75 CJ5 . We ordered a new adapter kit from Advanced Adapters and it fits, but it came with the wrong pilot bushing. We told them exactly what engine we have, but their kit doesn't support the '75 Buick 231 V6 oddfire. Of course we didn't find that out until after it came.

We did find a correct pilot bushing from another source. It seems it's always hurry up and then wait for more parts.

While we were waiting we did a test fit of the body as we knew there were going to be some floor replacements and firewall changes. The PO had cut away part of the firewall and put "something" in place to allow room for the 231 V6. So here are a few pics of what it will look like with a body.

Bringing the body parts from the barn with our '41 Farmall A.

We use this tractor a lot to lift heavy things around here. The tub qualifies.

Here are a few more pics with the body test fitted:



While we had the body on we discovered that with the longer shaft water pump that came on this engine, we were right up against the radiator or actually a little past it. Comparing that water pump to the one installed on our 1967 CJ5 w 225 V6 we knew we needed the short shaft water pump. We also needed a different water pump pulley and the other stuff for our power steering installation. So there was more research and eventually a trip to a junk yard to get the parts we needed. Pics on those later.

We also sandblasted the wheels, painted them and installed some new tires.

Old tires on rims we are using:

Getting rims ready to paint


New tires on painted rims. These are BFG Mud Terrain T/A KM2 32x11.50R15LT



Here are a couple pictures showing the T-14 mounted with the adapter plate.

Since this Transmission mounts differently than the T-86 we needed to weld a steel plate on the Transmission crossmember and then drill new holes. The T-14 we got came with the mounting assembly and even a mount, but the holes don't line up the same as the T-86 mounts, plus the bolts are a larger size. That is why it's sitting on wood blocks in these pictures.

Our older son spent the week of July 4th with us and did a lot of work to the engine, rebuilt the carb and a lot more. We even made a youtube video of the first time we started it after his work. I'll try to get those posted soon.

Lots of great progress. I know it mustve felt good mocking up the body and getting and idea of what she'll look like. Hang in there. Your making progress and its starting to come together a bit.

 

[oldjeeplady]

I like the posts and the photos. It gives me an idea of what I'm getting into when i start my '58 this winter. I've got the F-head motor and the T-90 /D18 combo. How do you like them? Looking at ditching the motor for a buick or chevy V6 (easier to find than a Dauntless Buick 225 V6 )

I wish I could give you an answer....We own two F-heads. One is from the '54 CJ3b . We didn't run that one long once we discovered the oil line to the timing cover was crimped off - so no oil getting in that way. The '54 tub has serious rust issues and will have to wait until Curt retires. He plans to make a new tub from scratch.... The other one was going back in this CJ, but then we decided to go with the Buick 231 V6 oddfire that came in the '59 when we got it. I wanted the option of PS which seemed a lot harder to manage with the Limited output of the F-134 engine. Looking back, we would probably have a functional CJ now if we had just used the F-134/T-90 /D18, and the front D25 and rear offset Dana 44 we had purchased with our doner frame. It would have been pretty much stock complete with "Armstrong" brand steering.

Because of the choices we made and problems along the way we have a lot more parts for our other two CJ builds. But I don't think the next build will be a CJ. Probably either my '47 IHC KB-2 truck or our numbers matching '67 Mustang Coupe.....

Based on our problems trying to find information and get correct parts I would stay away from the 231 and the 225 and go with a SBC.

 

[mriplaybass]

OK, I guess it’s about time that I poke out from behind the mess and make a few entries to our build thread. It’s been quite awhile since there was any activity on our build thread, but we figured that since Busadave said that he wanted to take a year off from doing the annual Ouray, CO. ride (we just ran into too many problems with our RJ5 build so we had to take our Ford Explorer) we basically had the better part of 2 years to complete our project for hopefully the next Ouray ride. Had a great time, would have loved to do it again in 2015, but I understand Busadave wanted a year off. Besides, lots of things on the honey do list, had knee surgery, sounds like a good plan. So RJ sat for 5 months…………………………..Then came Posi and 007……………… Dave! Let’s do Ouray again this year! So let the mad dash begin again! Instead of 2 years to complete the project, now we have 6 months! We will keep the trusty blue oval on deck just in case. It did great last year, and we don’t plan on missing another great week in Ouray with a great bunch of guys.
Here we go………..Back to the shop where RJ lives……………. Yes, RJ5, this is not a type o. For those of you who have followed our thread, you know what we started out with, and all the surprises we have encountered along the way. This jeep was a true rat rod, but he still looks like a jeep…………Rat Jeep? OK, the name stuck. We have had our……..let’s say differences of opinion? (RJ keeps putting us to the test, and so far we are slowly winning!) Oldjeeplady and I keep telling RJ that he is going to be completed, but he does everything possible to prove us wrong!
I won’t go through everything that is already on the build thread already but let me briefly recap.
Starting point:
59 CJ5 , Engine:[FONT=&quot]75-76 Dauntless Buick 225 V6 231 odd fire, Transmission : T86aa Transfer Case : Dana 20 , Axles: Dana 27 front and Dana 30 rear. [/FONT]
[FONT=&quot]Simple enough, right? OK, reality check! Some people should not be allowed to own old jeeps unless they do NOT own any tools, and most of all, a buzz box welder! What a mess!! We need to petition congress about passing a law! I have[/FONT][FONT=&quot] worked on a lot of old vehicles, and this is my first jeep due to the wife’s love of old jeeps, but geezzzzzzzzzzz! [/FONT]
[FONT=&quot]Just a few things, if I list them all, I may very well go insane. Transmission and adaptor plate: cracked and welded, not with Ni rod as cast should be, but with whatever was handy at the time. OK, need a different tranny and adaptor. Radiator: who knows where this came from. Solder joints all let loose. Toss the radiator. Suspension: rear wheels are not even in the wheel wells! Not even jeep springs! Toss them. Frame: bent, front horns crushed and 1/2” plate chicken track welded to hold up the front springs. Too much other extracurricular welding on the frame to list. Out with the frame. I could go on, but……………my head hurts! Oldjeeplady has posted a lot of information already, so I will move on…………….(sigh…)[/FONT]
[FONT=&quot]Here’s what we are left with. The tub needs a new floor, but that aside, it’s pretty solid. The front fenders are kind of weird and no one seems to know what they are, but they are solid. Hood, grill, inner fenders, all pretty good. Axles look good.[/FONT]
[FONT=&quot]The plan: use a 1960 frame that we have in the barn and replace the rusted front cross member with the good one off the 59 frame. Replace the Dauntless Buick 225 V6 with a more period correct F head that we have in the barn. Look for a different Transmission and adaptor plate. Upgrade the old 9” brakes to 10” and upgrade the master cylinder. This is beginning to sound like an enjoyable project for a first time jeeper who had only ridden in a CJ once……..40 years ago![/FONT]
[FONT=&quot]This is going to be fun! Really a quite simple project. Should only take a few months, plenty of time to get ready to join the others in Ouray. Until…………………..”Curt?”.............”Yes dear”……………”Can we put power steering on the 59? I don’t think I can turn the tires we want to put on it when I drive it off road”. “Sure, no problem”……………… I’m an idiot!!............ I don’t think that an F head will really be enough to handle power steering! (maybe I’m wrong, but too late to turn back now!) Back to the V6. Let the insanity begin! ([FONT=&quot]Pictures to follow soon!)[/FONT]
[/FONT]

 

[007]

Good to know your back at it! You know when it's all said and done you'll have a mostly 59 Jeep, about as "mostly" as "most" of us anyway.

I don't know much about the power differences but I'd hate at this point to put much money into an F if I had a period V6 needing the same work. Depends on a lot of variables as you well know.

The fact is that Jeep's going to be solid no matter which direction you go with it. Looking forward to the posts...


Sent from my iPad using Tapatalk

 

[mriplaybass]

[FONT=&quot]Though the tub is pretty solid, the floor is pretty rusty. Time for a new floor.[/FONT]







[FONT=&quot]Bad sections of the old floor have been removed[/FONT]








[FONT=&quot]We started with a sheet of 18ga sheet metal.[/FONT]





[FONT=&quot]Ran the sheet through a bead roller to give it a bit of strength before bending the flanges.[/FONT]




[FONT=&quot]Made the side bends with a brake.[/FONT]





[FONT=&quot]The sheet was too wide to bend in our sheet metal brake, so it had to be clamped to the table and hammer formed to make the long flanges.








[/FONT] [FONT=&quot]Rather than pay a small fortune for hat channels, I made the frame work out of 1x2x 1/8 tube. A lot easier to make, and a lot stronger.[/FONT]




[FONT=&quot]Once the flanges, beads and under floor frame work were all in place, the entire floor was welded into place.[/FONT]

 

[007]

So cool having the tools and the know-how on this. Looks great and very well done.

 

[Posi]

Well done on the floor
I've owned both the F-134 and V6. The F-Head is a good engine, but you'll be much happier with the V6 in the long run.

 

[mriplaybass]

Thanks for the kind words guys! Here is a little more of our progress:


[FONT=&quot]A previous owner had put in rear springs from who knows what kind of vehicle, but definitely not a jeep. Instead of the axle being centered on the springs, the alignment pins were forward from center. This is why the tires were not centered in the wheel wells. Why this bit of information leading into the replacement of the floor you might ask? Here is what I discovered. Instead of getting the right springs, and maybe the appropriate drive shafts instead of what apparently was just laying around the junk pile, so that everything would be in correct symmetry, he merely moved the engine back. In order to do this the fire wall had to be……….well…………..butchered to make way for the bell housing. So, time to repair the fire wall. I tried to salvage as much original metal as possible. That is why the cut seems to be on an angle. (no cooler full of beer out of the picture causing the angle!)[/FONT]



[FONT=&quot]After a lot of cutting, grinding, and pounding, the fire wall is as straight as it is going to get.[/FONT]




[FONT=&quot]After numerous passes through a planishing hammer, the patch panel is ready to be tacked in.[/FONT]








[FONT=&quot]Lots of grinding, hammer and dolly work, and sweat later, (you got me into this dear, so you get to do some of the dirty work too), we have a passable fire wall replacement. I will be adding extra reinforcement from the inside as we go. Still have to figure out where the pedals, master cylinder, etc. have to go.[/FONT]




[FONT=&quot]Any sheet metal parts that we made were first made out of card board then transferred to the metal for cutting[/FONT]








[FONT=&quot]New floor panels fabricated and tacked in, but our son took a week of vacation to come out and help, and his thing is engines. So, the body goes back into the barn while he helps with the engine and we do a bit of research in order to figure out which pedals will work, how to mount them, where to put the master cylinder, etc., etc., etc.[/FONT]