Build Thread $600 CJ5!

[Serdich77CJ5]

Looks good Tim

 

[Tim_Coble]

I hope they aren't wrong! I did a YJ spring conversion and those are the new shackle hangers from Rocky Road with Old Man Emu springs.

Looking at photos on the RRO website and everything looks okay. I imagine when I get 1000lbs of engine and drivetrain in there it will look a little closer to normal.

 

[Tim_Coble]

Looks good Tim

Thanks. I'm so happy to have the frame off of the sawhorses and ready for the next steps.

 

[KRUPP]

I hope they aren't wrong! I did a YJ spring conversion and those are the new shackle hangers from Rocky Road with Old Man Emu springs.

The shackles might swing forward under more weight of the motor and body. Maybe they’ll make it far enough.
I’ve had issues with front YJ springs being too short, once the new shackle hanger is installed a bit forward from stock CJ position.
Sometimes manufacturers just make em too short (Rubicon Express did).
You can check by measuring your old springs, from the center bolt to the eye, along the edge of the main leaf. Then, compare this to your new ones. New ones should be about 1-1/2 - 2” longer.

 

[Tim_Coble]

Holy cow, it's been a minute since I last updated. Not much in the way of visible changes. I found an engine stand on marketplace and modified it for back yard use. My AMC 304 is now suspended and I have been slowly working on that tear down. I had a broken engine mount bolt in the block that took me a couple of days to conquer and now I'm trying to get the exhaust manifolds off without snapping anything else. If anyone has some tips, throw 'em out there. Removing the alternator and water pump have had their own special challenges and I have discovered a crack in the timing chain cover (Just Empty Every Pocket indeed).

If anyone is interested, I have found a recent project on youtube "Bryan's Projects" - he is taking the best parts from a 77 and 76 to build one good CJ. It's fun to see someone else having the same struggles.

 

[Serdich77CJ5]

Good to hear from you, Tim. Glad to see you’re making progress. Sorry to hear you’re having so many trouble troubles. Keep us updated.

 

[Phoenix827]

All I know for rusted bolts is heat/cool and pb blaster. But I am running into a few of them too.

 

[Tim_Coble]

Two things I learned this weekend:
- 6 point sockets over standard 12 for anything frozen, even bolts that had started to round over got a good grip on. Thankfully, I had a few random chrome 6 pts that worked as there are quite a few places where the impact socket would not fit.

- if you are planning on replacing a part anyway, don't be afraid to cut it/drill it. I drilled a hole through the exhaust manifolds right above each bolt and sprayed in my penetrant - each one came out with no problem after. I had already planned on replacing them because they were so rusty, so it didn't make any sense to not try (I saw some dude on youtube take a torch to his).

By Sunday afternoon, I had the exhaust, intake, and heads off. I found an ant nest in my water jacket - that was creepy when they came pouring out with a spray of brake cleaner. Do not leave your engine under a tree without blocking every open orifice. Thankfully, the timing chain cover cracks were only into the water pump channels - so no water intrusion into the block from that.

Head gasket looked good but you could tell this thing had been burning oil for a while. I'm going to inspect all the lifters and replace the umbrella seals on all the valves when I inspect them. The cylinder walls look pretty good.