Build Thread Aussie CJ7 - 78

[JAG811]

Tools down and I have to go into work tomorrow so that might be the end of it for this weekend.
So the diff is out now and it's round two in the "clean a diff" stakes.
Can't say I'm as enthusiastic, second time round ...
Once the diff was out I had to cut through the bushes (of the last spring) with the grinder and a cutting disk - To cut into the spring eye bolt that was firmly rusted to the steel sleeve
You'll noticed I drilled a small hole in the frame plate for the diff bump stop.
I'm hoping this will serve as a great way to get the sway bar out of the way when disconnected on the trail ... time will see if it works or not.
Lastly just out of sheer amazement I attached a photo of the cir-clips holding the sway bar bolts in ... I was NOT expecting to see them ... I've only really seen them used to hold disks onto wheels and they annoy the hell out of you if you need the disk off !!

 

[JAG811]

Tonight I had a go at undoing the body mount bolts .... fail.
The nuts were just spinning in the body, so it looks like I'll be spinning out some inch or so holes in the floor to access them ...
I'll post some photos soon but from what I can see on the web it looks like a common problem.

 

[JAG811]

Got a bit of work done this afternoon with an early knock off.
These three photos only show the straightening of the rear of the frame .... I love that shifter .... It's been used so many times to bend stuff !!

 

[JAG811]

Brackets for the rear bar ... I take photos of everything so I know which way it all goes back together and for things like that I just write on the picture....
The gas fitting is still on and you'll see I've cut it back at the where the chassis finishes but they also welded it on through that hole marked in red so I'll have to drill that out, and just clean up the end result.
Other then that it's all moving along.
Got one last bracket to pull off the steering box and they can all go to the powder coater.
I'll have to look at the body mounts and spinning bolts in the chassis at the same time. Weld them in, clean up the chassis while replacing body mounts and then it's all back together again ...
PS - That's my little Jeepin buddy

 

[mtnwhlr]

Thats the first right hand drive CJ7 I have seen and you have a very cute Jeeping buddy.

 

[JAG811]

Thats the first right hand drive CJ7 I have seen and you have a very cute Jeeping buddy.

Thanks Mtnwlr. Apparently it's hers .... not mine She tells me all the time.
Ironically I've never physically seen a left hand drive CJ

 

[JAG811]

On to the rear body mounts first.
They're hidden in a rear channel. There are drain holes to the outside of the mounts but from the looks of things, the thin square folded metal that should encase the bolts (flat bar) a prone to rusting away leaving the body mount bolts to spin.

First picture is with the 40mm hole cut in and you can see what's left of this retaining bracket.

Second picture is a little closer you can see how rusted the bolts get making it hard to get them out.

Third is all cleaned up ready to go.

Forth you'll see I was able to get a nice weld along the front edge, to lock the bolt in place. Some WD40 and the bolt came clean out.
Well done to me
I got lucky I think ...

 

[JAG811]

I got the rear gas filler bracket off but it took bit of time and messing around.
By the third picture you'll see I had cleaned it up and it was on to the drivers side body mounts ...
although some of you may argue I then went to the passenger side body mounts ...

 

[JAG811]

Picture 1 - When you look at the difference it makes you think well worth while replacing them.

Picture 2 - Gets you a good look at what the bolts actually look like. Again the folded sheet sleeve it should sit in is wasted clean away. This is looking through a hole I put in the foot well. This is the passenger front mount, up near the fire wall. I've got big dramas and you'll see by the third picture why.

Picture 3 - It just came clean out once I put a weld on it. The metal surrounding it was cracked and broken so one I put a bead on it and tried again to un-tighten the nut it just cracked clean all of the metal around it. I'll now need to weld in a new plate ...

Picture 4 - Very happy with all of the chassis points. All looking good with no rust ... The body on the other hand is a different story ..

 

[JAG811]

Picture 1 - This morning I was off to a good start cutting out the new body mounts.
I used this galv box and cut out two brackets to weld in.
It's around 2.5 mm thick so it will give the mounts 3 x more strength...

Picture 2 - I marked out what I thought should be enough room to get the job done.

Picture 3 - No turning back from here. We now have a big hole in the floor.

Picture 4 - I checked where the mount was to drill in two more holes into the bracket.

Picture 5 - Bracket welded in. Not my best work but it's in. Very hard welding in such tight spots, upside down, ect. It's really strong now though ...

 

[JAG811]

Not much to do with the CJ guys but this is how I just spent my weekend.
Mt Bartle Frere - Highest Mt in Queensland
Longest single day summit in Australia

 

[TroyaCantrell]

Wow, nice pictures. Envious.

 

[JAG811]

Wow, nice pictures. Envious.

Get the pack on the back and get out there TroyaCantrell - If you can drag yourself away from that 6 of yours. It's coming along nicely !!!

 

[JAG811]

I've decided to put some 1" 1/4 holes in the front and rear of the chassis.
It gives me a direct line to weld in those hanger nuts in the chassis.
The front holes (picture 1) showed the front end of the chassis were pretty clean with just a little bit of gunk.
The rear however (picture 2) was full of mud and gunk. I was blown away on just how much was in there.
As you can see in picture 3 one of the hanger bolts came straight out and that was the rear one I need to weld back down.
Picture 4 - It was so full of gunk I had to re-tap the thing.
They're all cleaned up now read to hit all of the nuts with the welder to keep them all in place for the next 10 years.

 

[JAG811]

Almost ready to rip into this chassis and get it as clean as possible so I can put Humpty Dumpty back together again !!!
I cut a hole in the frame because the middle Transmission skid plate bolt simply came loose when I was cleaning the Transmission ... couple jobs ago.
You'll see in picture two what it looks like.
You'll see I got two good welds onto it and it shouldn't be spinning free anytime soon.
Welded it back together and then clean up the welds. I gave it a few more hits with the welder just to fill those holes.
I just need to get to the grill body mount bolt that is spinning away in there, raise the grill up and it's full steam into a chassis clean !!

 

[JAG811]

Well I'm over cleaning this chassis already !!
I would have much preferred to have it blasted, tub off, the lot - Well the plan was to have it galv dipped but it's simply not happening.
Once I had the grill off I found that there was a fare bit of corrosion around that mount. So I filled it with the welder and brought it back again. The end result a lot better then when I started ... but I still maintain I'll get to it properly in a couple of years when I look at a motor/gearbox change.
I also started on the back of the chassis just no pictures.

 

[JAG811]

Tried to get the hangers on today but I'm reluctant to tighten anything up until it's all back on and good to go.
You'll see I had to take some off the drivers side to get the steering bracket on. This is pretty common I'm sure.
Pretty happy as it all looks pretty sharp.
Lastly it's one corner at a time on the chassis ... slow and painful !!

 

[JAG811]

Procrastination ....
Some are far better at it then others .....
I'm doing everything else but ! Getting back under the old girl and grinding the frame back ....
Anyway ...
After spending a few hours knocking the dints out of the top of the grill I welded on some mounting brackets I made up.
The idea is I'll first mount a black grill mesh.
Then mount the auto cooler.
And lastly there are mounts for the air conditioning condenser.
Only thing left to do now is make up a new cage for the mounting bolt and it's off to the sandblaster ..

 

[JAG811]

Right now it's time to get ready for Australia's Super Bowl ...
Depending on which code you barrack for ...
NRL GRAND FINAL TIME !!!
I don't think there's anywhere near the money in it as your NFL but I hope you like the game !!!
My team made the finals but was knocked out two weeks ago, so it's Melbourne Storm all the way today !!
They've got a few Queensland representatives !!
Get on it if you can boys !!!!!

Thought you might like this
Top 13 NRL Big Hits of All Time - YouTube

 

[JAG811]

I've been onto the front diff and I guess it's a bit exciting to see it all going back together !!!
I've just been cleaning it up and have started with the first coats of black but these photos show removing the calipers.
You need to remove the securing bolt - Which should be an alan-key tapered bolt - Instead mine was a hex head something someone had found lying around
Then it's a matter of tapping out the retaining clip.
That allowed me to get in to get all of the scale off inside the joints but I'm not concentrating to hard as I know as soon as it's roadworthy I'll look at a more detailed overhaul of the diffs ...