Build Thread 1986 CJ7 Rebuild - Chasing my youth

[Impory]

Impory, how was cutting those ducts? You have the same pinched seam towards the inside of the tub that was an absolute bear? I’m almost wondering if my duct holes were too far back and that’s why I ran into that seam. But I mocked my windshield and template up a bunch and the holes seem right on


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I took measurements from the old tub before I scrapped it...used a hole saw to cut both ends and zipped the sides out...honestly didn’t give me any real trouble...I started manufacturing various captured nuts too...I don’t think there was any other way..tailgate hinges were the worst...then 2 body mount nuts that were buggered...there is something quite therapeutic about working steel...well...when you have all the time in the world....lol

 

[mdeluca]

Windshield wash squirters. Don’t forget tailgate too. I’m kind of stuck on the spare tire carrier. I’d really like to run the stock one, I do have the carrier and latch, but don’t have the mounts. And there doesn’t seem to be any after market ones. I know I’d have to weld plates into the tub too. Bumpers with tire carriers are pricey.

With your welding skills it wouldn't be hard to fabricate a couple of identical tire carrier mounts. It is a simple "C" channel with a hole drilled in it for the hinge bolt and and a couple of mounting bolt holes. If you need measurements, let me know and I'll take them for you.

 

[Masscj7]

Yes, if you don’t mind. The big thing is whether I feel comfortable that I can get enough plate welded to the tub to support the weight of the tire without distorting or cracking the paint over time. Upper mount has easy access, lower mount would be a real bear to get at.

Side note, I think you did Raptor interior, hows it holding up and do you still like it?


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[Masscj7]

Finished up a few small things this week.

Drilled and tapped mounting holes for dash piece.

Need three in the new piece. Plus needed to do the two for mounting the defrost duct. Gave them a little counter sink to not impact the seal.






Also, sandblasted pulled the two large metal drain plugs in the foot wells and could not find either new or used replacements, so just welded up new ones.





Lastly my original dash was mangled and full of bondo, scored a really clean one that still had the under dash lights, glovebox door, and shaft style radio cut out. Stripped it down and ready for sandblast






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[Masscj7]

Small progress in last couple weeks. Had to fly out and get this guy (little nerve racking given the current corona state), but been on a waitlist for months prior to this. And he takes up a lot of time as him and his older sister or non stop! So between traveling and watching him, been slow.





Spent time stripping my gate. I had hit with heat to get the bedliner off but think was starting to warp. So paint stripper and patience. Bedliner, 3 different coats of paint and a primer.



And no finished product picture, but the gate was in real good shape

Also started on plugging YJ gate mount holes.


Before I fill all these, anyone know what they’re for? Not threaded, just through holds.




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[Masscj7]

Couple good days of filling remaining unused holes and cleaning up stuff that I didn’t want.







Then moved into the fun dust fest of body filler and block sanding.





And pretty pumped how they filled YJ gas fill came out.






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[Ultrunner]

Your tub is looking really nice. Lots of work put into it. I’m having trouble finding a tub and wrestling with the idea of getting new floor panels for mine and getting it brought back to life. Not sure what that’ll cost.

Did you have your tub blasted before you started working on it?


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[Masscj7]

Thanks. Yeah, most folks probably would have just have scuffed up the tub I got and throw paint on it, but I have a problem. I wanted to fill a lot of the unused holes. Yes, I had it blasted. I burnt the factory undercoat off and then had it blasted. Gave it to my painter who tweaked some small things, dug out all the seam sealer and then sand blasted it again. Then he hit it with several coats of heavy primer.

It’s going back to him Sunday for final body work. I don’t want to fill my garage with dust and take several weeks when he can do it way quicker and then shoot it. Once he’s done, I’ll actually be headed down your way to have the inside of tub shot with Bullet Liner.

Let me do some digging for you, I’ve got a salvage yard out here in Western MA that has two YJs and two CJs. Think the CJ tubs are toast, but one of the YJs didn’t look bad. I also have a couple contacts up here too.


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[Masscj7]

Ultra, sending you a PM.


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[Ultrunner]

Ultra, sending you a PM.


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Got your PM. I’m on the list.


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[Masscj7]

Got your PM. I’m on the list.


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Sweet! I hope you score something Arizona clean!

Decent week and weekend. Started with clearing a big paperwork hurdle. Since I got the CJ out of a storage locker foreclosure, I didn’t have a title. The communist state of MA won’t retitle without a massive amount of paperwork, unless the vehicle comes from out of state and currently registered.

Step one done


They just want to cash a big check and boom, registered! Now in couple weeks I can go to MA and they will retitle to me.

Then I decided to start block sanding and body working the tub. Attached some factory weld points with hammer and dolly and began the dust fest. What a lot of work, but guarantee it’s straight as can be as kept slowly working with guide coats and thin filler coats.




Then on Saturday night my paint and body guy said he was ready for me. Well then, see ya! I’ll let him do that miserable work.

Also got more parts back from sandblast.

Also got my newly cerakoted headers installed. Plus a shot of the exhaust as I prepped the tub to go.

Before


After,





I also tried this interior header coating from Eastwood. It seems pretty good. A little goes a long ways and coats very uniformly and dries fairly well.



And tonight, off it went to the paint shop!


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[Ultrunner]

Looks awesome. Your build is really coming together. I’ve got a lot of irons in the fire and should have a confluence of work within the next couple of weeks when my engine gets back from the machine shop and I finish my front axle rebuild.

I’m right behind you, haha. Not really.


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[Masscj7]

Sweet, my thread is back. Haven’t been doing a whole lot as been waiting on the body, but been picking at a few little things.

Repaired and added a new stud to the dash panel



This stuff is amazing! Mdeluca mentioned and I decided to try it. It is unbelievable. I wish I had exact before and after, but both fresh air baffles looked like this before.




And couple days of soak!




Some more exciting things though, sent out a rim to a chrome shop in California, took several weeks and not cheap, but, results were awesome and think I’m committed to sending the rest out now.

Before

After


And lastly, got my spray out for colors.



Went and checked them out in the light today. Think I’ve got a winner.


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[Ultrunner]

Colors look awesome and very close to what I’m thinking for mine. Original color was silver so trying to remain true.

You’ll have to let me know what color you’re going with.


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[Ultrunner]

By the way. I completely redid my fresh air box and heater. Let me know if you have any questions.


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[mtnwhlr]

Sweet, my thread is back. Haven’t been doing a whole lot as been waiting on the body, but been picking at a few little things.

Repaired and added a new stud to the dash panel



This stuff is amazing! Mdeluca mentioned and I decided to try it. It is unbelievable. I wish I had exact before and after, but both fresh air baffles looked like this before.




And couple days of soak!




Some more exciting things though, sent out a rim to a chrome shop in California, took several weeks and not cheap, but, results were awesome and think I’m committed to sending the rest out now.

Before

After


And lastly, got my spray out for colors.



Went and checked them out in the light today. Think I’ve got a winner.


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What color did pick?

 

[Masscj7]

Pretty sure going with the GM goldish, tanish, light bronzish color on the outside.

Honda bronze in the middle and a Mazda greenish/earthy have no idea how to describe on the other outer. That one looks black sometimes in lower light. The carbon bronze in middle is what Mdeluca has.


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[Ultrunner]

Awesome color. I agree the other one is too dark. I have been leaning towards the Honda silver as Mdeluca did.


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[mtnwhlr]

It's going to look nice. I like all three.

 

[Masscj7]

I would like to start out by saying F you EPA!!

I spent 6 hrs on Saturday removing paint from my hood because I ran out of the good aircraft paint stripper. I didnt realize that the can that I had was from 2018. EPA banned and pulled all paint strippers that contained methylene chloride from the market, late 2018.

Now granted the stuff would almost knock you off your feet when you cracked the can, but it just literally melted the paint right off, regardless of how many layers.

The sandblast shop was struggling to blast my original hood. They were afraid of warping it. My body guy got into it a bit and found the nose had some rot.



So I found a donor hood for $50 and commenced stripping the nose portion to be used to graft in. Hood had several layers of paint, but the good stuff sizzled the paint right off and fully stripped in two applications.




So I go to buy a new can and see it looks different. Start researching and see the reviews are bad for the new greener, safer formula. Well it does suck. On epoxy stuff, it barely curled the paint. I did find that if I scuffed the clear coat good first, it would peel ever so slightly better. But there was a super thick coat of polyester primer I think under the top green color and that was a mutha! Found the only real way to win was to go to town with my 5” HF DA with 60 grit and hope it held up. Two packs of discs, 6hrs later, and can’t feel either of my hands, it’s ready for a finish blast.








Also had same issue with windshield frame, blaster had trouble. Thankfully that didn’t have the poly primer, so the paint stripper worked better.



Today, had a good score, unfortunately no photos, but found a guy fairly local who has all kinds of CJ items and several donor vehicles. Just a back yard enthusiast. But he had some original tailgate strap brackets for the tub side of the strap. I was trying to fab up replicas with insert nuts, but I wasn’t overly pleased. Now I can get these OEM pieces welded in to get one step closer to full CJ look alike.


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