Build Thread $600 CJ5!

[Tim_Coble]

Mouse can nest anywhere! Need big wheels for soft dirt ground...

Yeah, those little buggers can get into everything.

I thought I was sized good enough but some rain last week softened everything up and hanging the engine was too much!

 

[CJ]

Rain is a good thang! So is corn, cotton and Jeeps! I'm from the South!

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[Tim_Coble]

I'm in north Alabama, we were certainly happy to get the rain.

 

[Tim_Coble]

Finally completed the tear down! The spring bolts were basically welded in - it took a lot of pounding, cursing, and some fire to break them loose. Now, I can get to the rust removal and start rebuilding.

 

[CJ]

Nice work. What are you going to do with that wonderful front bumper?

 

[Belizean]

Nice work. What are you going to do with that wonderful front bumper?

That thing is ready to take down some doors if needed.

 

[Tim_Coble]

Nice work. What are you going to do with that wonderful front bumper?

My wife asked the same question with the statement that "that's hideous, it's got to go"!

 

[Tim_Coble]

Another weekend and a little more progress. I started tearing down the axles and it looks like I will be going the 1 piece upgrade route. The driver side didn't look too bad, but the passenger side spun at some point. I thought about just replacing the one side axle and hub but it's less than double to just upgrade both sides and be done with it.

 

[Tim_Coble]

So far I have only looked at the outer shafts on the front, not horrible but I will probably just go ahead and replace both with chrome moly and be done with it. Driver's side looks worse than the pass.

Both Warn manual hubs were locked up and full of dirt, those will get a replacement unless I can find a rebuild kit.

Need to get the spindles pulled and figure out what socket to use for the yoke on both front and rear.

 

[Belizean]

Here’s my 41 1/2 year old front axel u joints and spindle bearings from last week. 2 caps were done. Spindle bearings were good but replaced

 

[Tim_Coble]

Those look like the ones that came out of my drive shafts. I'm pretty sure before mine was moved to the hill I picked it up on, it was sitting at the bottom of a drainage.

Here’s my 41 1/2 year old front View attachment 105165axel u joints and spindle bearings from last week. 2 caps were done. Spindle bearings were good but replaced

My driveshaft u-joints looked similar - lots of red. I'm pretty sure that before my jeep was parked on the hill I picked it up from it was at the bottom of a drainage. Everything has been full of dirt.

 

[Tim_Coble]

A little more progress before the rain - received my Amazon tool order with the spindle puller and the ball joint split ring socket on Friday. Saturday morning, I got to work and the Dana 30 spindles came off surprising easy with the slide hammer. Axles shafts came out with a ton of sand and mud from the tubes. I was not surprised about that. Shafts are rusted but in decent shape. I'll make a final decision when I try to swap the u-joints, but I'll probably just clean them up and reinstall with a note to replace with chrome moly shafts at a later date.

Popped open the pumpkin and got about a half cup of gear oil. Most of it had seeped through the pinion seal I imagine based on the caked on gack around the yoke. Thankfully no water and everything looks good, so I'm calling that a win. New seals and bearings are on the way.

I spent the rest of the day (with a short break for yard work to keep the wife happy) trying to pull the knuckles. The ball joints appear to be rust welded in place. Both upper and lower nuts came off with the impact but I can't get them to budge otherwise.

Impact and a 3# sledge has had no effect. I'm wondering if my impact just doesn't have the 'oomph' I need. I picked up a MAPP torch while running rainy day errands, maybe that will give me the heat I need. If not, I may have to find a shop that can help.

Didn't get as far as I had hoped but everyday I make some progress is a good thing.

 

[Tim_Coble]

Got the Dana 30 completely torn down. I finally got smart and realized that the upper ball joints were loose once I backed off the split ring inserts so a pickle fork, heat and 3# sledge released the lowers. More heat and my press got the ball joints out of the knuckles.

Wore out a wire wheel getting the rust off, she looks pretty without all the crust.
Finished with a coat of Rustoleum primer, my first step in putting things back together!

 

[dimitri]

How is the progress going so far?

 

[KRUPP]

It is really satisfying to wire brush clean a housing, isn't it?
While you have that front Dana 30 loose, consider installing a drain plug in the bottom of the center casting. Fairly easy/inexpensive to do and a nice mod too.

 

[Tim_Coble]

It is really satisfying to wire brush clean a housing, isn't it?
While you have that front D30 loose, consider installing a drain plug in the bottom of the center casting. Fairly easy/inexpensive to do and a nice mod too.
View attachment 105683
View attachment 105684

I like this idea. I did pick up a tap and some tube fittings for the vent (the old one was rusting away).

 

[Tim_Coble]

How is the progress going so far?

Slowly. My wife works for the fed, and while she was working during the shutdown, she wasn't getting paid. I decided to be responsible and held off on ordering anything until she got her paycheck. I got the last of the front axle parts on Wednesday so I'm ready to finish that off.

Last weekend, I started cleaning up the frame. Waiting on delivery of my Rust Buster parts to get that going too.

 

[Tim_Coble]

My frame work has made some progress over the last couple of weeks. This is the dry fit of the repair parts from Rust Buster and AutoRust. You can see how much of the frame had to be cut out on the other rail.
I managed to get both sides tacked in last Saturday before I came down with the flu.
I wanted to have the finish weld done by today but a 104 fever kept me in the house for the week. Maybe next weekend.

For anyone curious, I'm using a HF Titanium 125 flux core welder. It's working great, nice penetration and when I do my part, some really decent welds. I used a weld thru primer on everything before I started and hit it all with Rust Reformer to protect the bare spots until I get back out.

I carefully measured the location of the e-brake brackets and body mounts. Still need to get the new rear x-member tacked in place. Obviously, I need to get the surface rust cleaned up and get everything painted.

I need to make a decision on new springs so I can get them on order, either OEM or Skyjacker Softride 2.5". I haven't ordered tires yet so if I go OEM, I'm think 235/75 but if I go the lift, maybe a 31". This will be a trail rig, I'll tow it if I want to ride farther than an hour or so from my house. Let me know what you experts think!

 

[Belizean]

I’m no expert but 31s won’t be trouble.

 

[Jeep Soup]

You have plenty of work ahead of you.

"Unexpected Technical Deficiencies have caused Delays and Cost Over Runs!! But these are to Be Expected in a Project of This Magnitude!"

Feel free to share that with your wife when the Credit Card Bill arrives......