Build Thread 1980 CJ5 resto/mod

[thiswontbetooexpensive]

Finally made the decission last night........

Body off restore/slight modification! The Lady was running, but the oil leaks and non-functioning gauges have gotten the best of me. Borderline OCD is a terrible affliction!

I have a lot of pictures to post and here goes a shot at getting it done...


Attached Files

SDC10608 Small.pdf (124.0 KB, 0 views)

SDC10609 small.pdf (117.8 KB, 0 views)

SDC10610 small.pdf (109.3 KB, 0 views)

SDC10611 small.pdf (106.7 KB, 0 views)

Like I said, the Lady was driven into the garage today. Not too much damage to the body, frame inspection to come after tub has been removed......
Attached Files

SDC10612 small.pdf (107.1 KB, 0 views)

SDC10613 small.pdf (122.0 KB, 0 views)

SDC10614 small.pdf (110.3 KB, 0 views)

SDC10617 small.pdf (104.0 KB, 0 views)

SDC10618 small.pdf (110.7 KB, 0 views)

I haven't found anything new to replace while removing the front clip off the Old Girl.

Not anything I didn't already know about anyway......
Attached Files

SDC10639 small.pdf (114.5 KB, 0 views)

Here goes nothing !!!

 

[thiswontbetooexpensive]

I have found the error of my ways when I had attempted to start this build forum.

Lets start with the pictures of before:



The lady was driving when it came to belong to me. Long story short, it has belonged to a friend of mine for about 20 years. I had a four wheeler that was no longer used too much, and he had two jeeps. This 1980 CJ5 and a 2008 Wrangler Unlimited and said he only wanted one Jeep. I was given the option on the one above that is just what it shows, no frills!

I will get some more pictures up loaded real quick and get the next stages documented here.

 

[alpha6]

Shouldn't be to bad...overall looks in pretty fair shape. The only major thing was the rust on the windshield frame. New one is fairly cheap. Windshield Frame 5758971

 

[thiswontbetooexpensive]

Over the Thanksgiving Holiday, I decided to replace the horribly leaking valve cover gasket. Got me in the garage and some alone time anyway! I had changed the oil and washed off all of the years of oil, dirt, and grease from under the hood and went for a short drive down the road. The thing had leaked a half quart of oil in about a 30 min drive in first and second gear!

After replacing the gasket, decided to take it to my Mom's house about 10 miles one way from my place. Drove great, considering loose things and iffy brakes.

After the visit and drive home, the oil was everywhere. I hate leaky things, really hate them. Why just repair the engine and wait on something else to break? So....now there is jeep all over the garage and barn. The repair list is getting long but, barring the engine rebuild, not TOO expensive yet. As someone had said the other day, these CJ5 's are wonderfully simplistic in their design.

Now the reward for reading this far..... More Pictures:



I do not have another vehicle that is mine, I have a company vehicle with the privilidge of driving it home and the little lady has a 2013 Explorer Limited with the Ecoboost engine. This should be an exciting project that my children (boy 7 and girl 5) have enjoyed helping me with once the grease and dirt was cleaned off anyway!

 

[thiswontbetooexpensive]

Shouldn't be to bad...overall looks in pretty fair shape. The only major thing was the rust on the windshield frame. New one is fairly cheap. Windshield Frame 5758971

Thanks alpha6!

Right now the replace list is as follows:
windshield frame, new seats (greatest mother-in-law in the world already hooked me up with these for Christmas!), new brake master cylinder and complete line set, complete bushing set, undercoating the tub and frame, replacing the rear axles with one-piece jobs.

Oh, and new brake pads and rotors all the way around. I think I might go with disk conversion on the back axle. I am not opposed to drum brakes, but the passenger side rear rotor is shot. I know these should be replaced in pairs, but more on that in the other forum. Trying to stick with rules and regulations, I really like this forum and would not like to get censored or removed.

Not much rust to speak of on the frame, got a convertor and new paint over all that already. Working on rear axle now, brakes included. Have to see where the weekend takes me on it....

 

[thiswontbetooexpensive]

Almost forgot, the Jeep has a name!

My dad had a 1978 GMC half ton stripped down he bought brand new off the showroom floor with one exception, he had ordered an 8 track player for it!

He had that truck for 18 years and 450,000 miles and had replaced an alternator is all. (Not all that needed replacing, but all he replaced anyway!)

That truck was Old Blue to our family and numerous friends. The CJ5 is hereby commissioned Old Blue. Now all I have to do is sit in it when it is completed and drink a 24oz red-and-white dynamite. Bud Heavy, the breakfast of Champions!


This won't be too expensive Dear! That's what I keep saying. Over and over again.

 

[alpha6]

No, no, don't name it...now it will never leave!

 

[mtnwhlr]

Sounds like it should be Old Blue the 2nd

 

[Bowbender]

I guess we know what color you're going to paint it!

 

[thiswontbetooexpensive]

Thanks for the input! The jeep still has the original color to it according to the VIN plate. If anything is done to the paint, I would just clear coat over what Mother Nature has done over the last 32 years. Then I would be worried about driving through the yaupon where I live! I think the color stays the same.


This won't be too expensive Dear! That's what I keep saying. Over and over again.

 

[thiswontbetooexpensive]

Going to spend the afternoon replacing the rear brakes. Got new rotors and all new hardware to go with new wheel cylinders and new shoes sitting in the garage. I will take the advice of a friend and make sure the safety glasses are on my eyes and all glass is out of the way in the garage!

 

[thiswontbetooexpensive]

If I never mess with drum brakes again and all of those associated pieces again, it will be too soon! If those rear differential seals are leaking when Old Blue starts running the roads again, the rear disk conversion will occur, thats a fact!

Now that that was done and the sun was still out, I changed gears (pun intended) to get the tranny and engine out.

Good thing it has only been 20 years since I handed my Dad and Uncle wrenches while they performed this manuver, I might have forgotten a thing or two!

Couple things to consider that have not changed in a while:
1. Metal is heavy.
2. Bolts that havent turned in 32 years are a lot easier to turn when they are covered in leaked motor oil.
3. Gravity can be both your friend and enemy within mere seconds of each other.
4. Motor and Transmission mounts have a tendancy to loose structural integrity after 32 years as well.
5. Metal is always heavy. And yes, that bears repeating!

I will get some pictures posted after the open wounds on my nuckles heal up!

 

[mtnwhlr]

If I never mess with drum brakes again and all of those associated pieces again, it will be too soon! If those rear differential seals are leaking when Old Blue starts running the roads again, the rear disk conversion will occur, thats a fact!

Now that that was done and the sun was still out, I changed gears (pun intended) to get the tranny and engine out.

Good thing it has only been 20 years since I handed my Dad and Uncle wrenches while they performed this manuver, I might have forgotten a thing or two!

Couple things to consider that have not changed in a while:
1. Metal is heavy.
2. Bolts that havent turned in 32 years are a lot easier to turn when they are covered in leaked motor oil.
3. Gravity can be both your friend and enemy within mere seconds of each other.
4. Motor and Transmission mounts have a tendancy to loose structural integrity after 32 years as well.
5. Metal is always heavy. And yes, that bears repeating!

I will get some pictures posted after the open wounds on my nuckles heal up!

Sure sounds like you are having a good time

 

[thiswontbetooexpensive]

Strangely enough, this is thoroughly enjoyable! Be it an old end table, or a great Jeep, making something new again has always been rewarding for me. The availability of others experiences has proved invaluable for my own whirl at performing this restoration. After looking over some others build forums on this site, I am pretty fortunate with the shape my Jeep was in when I acquired it. Some of the folks here have done amazing work and I am pleased to now be a part of this community. Y'all run a nice place here, please keep it going!


This won't be too expensive Dear! That's what I keep saying. Over and over again.

 

[thiswontbetooexpensive]

And now the pictures I promised:
View attachment 12432
Starting to get real light now!
View attachment 12433
Head is just a little bit dirty
View attachment 12434
I'm hoping all this oil is from the rear main...tranny was full anyway!
View attachment 12435
Bottom of head with valves still in it. Like I said earlier, this Jeep started first time every time, amazon how much stuff can get in an engine and it still run well.....
View attachment 12436
Motor mounts get tired after 32 years.




This won't be too expensive Dear! That's what I keep saying. Over and over again.

 

[thiswontbetooexpensive]

I will try and get these posted tomorrow from a real computer. This app is great for reading, but not so good for adding pictures!


This won't be too expensive Dear! That's what I keep saying. Over and over again.

 

[thiswontbetooexpensive]

Finally acquired a lift and engine stand, this is a worthy investment for those who might be contemplating the expense. I was just tired of asking around to try and borrow one and the used ones I looked at all needed either a new jack, wheels, or both.

Glad I have them both now.

The engine was tired and I am getting nervous about the final verdict to be handed down from the machine shop. Here are some more pics of that mess:


I don't think the PO was very keen on engine oil changing.....or he just was thinking he replaced enough because of the leaks to call it good.

With all of the stuff removed from the frame, the very minor (thankfully)rust was repaired (read buffed off) and painted back over with some good old black paint. The rear tub mounting holes/frame section has a solution that requires a welder and some new metal to mount on. I know this might not be the best long term solution, but for my needs I think it will provide the structural integrity it is currently lacking.

So now the big question to myself, where to next? I have posted a question in the Drivetrain forum with some engine rebuild questions, a link to that is provided here:

http://www.jeep-cj.com/forums/f2/what-do-you-think-16973/

After engine repairs, going with all new bushings and SS brake lines then start re-assembly. The clutch looked good. I will probably go with new clutch plates themselves and a new throwout bearing while it is out anyway just on GP. Will change out fluid in tranny/Transfer Case and also front differential.

Rear cover was removed and new seal installed last week.

Now I can say I have something shiny on Ol Blue!

I was told that the reason the belt was off of the PS Pump was due to a leaking hose. When trying to remove said hoses, they didn't want to move. At all. I just kept turning back and forth and broke them off.

Fluid was present in the broken ends, I've got my fingers crossed that the new hoses and belt gets that back operational. The PS gear assembly was about the only part on the Jeep that was not covered in fluid of some sort, but it is full of fluid internally.

The simplicity of design in the CJ Jeeps is still an amazement to me. That being said, I have WAY more pictures on my computer than what is in my gallery on this site, I hope it is enough to get it all back together! I might be requesting video chat from Mr. CJ to be added to this site before this gal is running the roads again!

I hope the wiring wont be too bad.........I do plan on some sort of LED Tail Lights, just havent decided which direction to go there. The original lights were trashed in the teardown, bare metal in confined spaces downstream of those 31X10.50's was not a good combination! Thanks goes out to vise grips, a cold chisel, and a 2lb hammer for the assistance with that.

Gauges...... So. Many. Choices.........

I was also wondering where my garage went, there was a small CJ5 in the third car side of my garage but it has exploded into pieces as you can see in the first pic of this post!

 

[alpha6]

You have been a busy boy. Is that just a touch of carbon I saw on those heads?

 

[thiswontbetooexpensive]

You could say just a touch. I honestly can't comprehend how it was running so well. Just bump the starter from a cold engine and it fired right up. I might try to get Jeep to sponsor the rebuild as a testament to what they USED to make!

The AMC 258 i6 / 4.2l must be one tough engine, I guess that's what it was made for so long!


This won't be too expensive Dear! That's what I keep saying. Over and over again.

 

[JAG811]

Looks like it's all progressing