Body Firewall Replacement

[rustonrust]

i need to do some significant repair work or more likely replace my firewall. also need to replace both passenger and driver floors as well as other misc cut and replace around the tub exterior.
main concern is firewall replacement and wondering if anyone has done this and has feedback? lower portion of the firewall is shot. cant find any videos specifically talking about firewall replacement. would it be easier/ better just to replace whole tub and be done with it?
opinions, suggestions and recommendations from folks that have done this before appreciated.

 

[CJ]

I have never replaced a CJ firewall but have replaced others. Should be the same concept as any vehicle. (Link)-> firewall replacement - Google Search -<
It looks like there are many available. (Link)-> 1986 jeep cj7 firewall - Google Search -<
As for floor pans and side panels Classic Enterprises is the best. Great quality and made in the USA.

Made in USA | Jeep CJ7 Body Parts - Classic Enterprises

1976 - 1986 Jeep CJ7

www.classicent.com

If replacing all those parts is more work than you want to do, a replacement tub is a good choice. There are different ones (aluminum / steel) and depending on how much work you want to do, the prices vary a lot. The closest to a direct bolt on is from Willy's Overland and is called the Repli-Tub and is more expensive because they rework the tub for you instead of you having to do so. I have purchased a Repli-Tub.
The steel tubs are all created by one manufacturer (Juan bought the AMC dies) but sold by different companies.

 

[Manic Mechanic]

Id just replace the whole tub. Cheapest way is to modify a an 87-95 YJ tub. I've done several

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[Eggman]

Depends on your skill level. How bad is the lower firewall? Can you pattern all of the holes in new metal if you replace the rusted out section?

 

[rustonrust]

thanks for the responses. not a seasoned metal worker but have done this type of work in past - just very time consuming for me. one thing i was thinking was to purchase a new firewall and cut off at about midpoint and weld back onto existing - but again this would be very time consuming for me to do and thinking it probably worth the extra money to just purchase a new body and minimize the metal work i need to do. more cost but will probably save a pile of time.....

 

[Manic Mechanic]

You can get a good rust free YJ tub for 500-600 bucks. Make a few small metal changes and bolt it right on.

This is a 92 YJ tub on my 85

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[Petescj]

I'm with Manic on this one. If your on Facebook look through marketplace in your area. I see 3 in mine right now all around $500. '92 on a '78 myself.



I don't drive mine in Winter so I didn't have to modify the cowl for heater. I've also become a fan of the side opening YJ tailgate for my use. Not difficult to swap in a CJ tailgate though if you want.

 

[Manic Mechanic]

I drive mine year round. I've upgraded the heater to use the blazer blower and my factory fold down tailgate

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[rustonrust]

ok thanks for the info and i like the idea. just did a quick check and seems like there are several available here in South FL. can you provides highlights on the type of modifications that need to be made to make this tub fit an 86 cj. its a Laredo but don't suspect that matters.

 

[Manic Mechanic]

I'll take some pictures and try to do a write up for u. Stay tuned

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[Manic Mechanic]

This will be a fairly long post. Feel free to contact me if you need or want something explained in more detail or if you want me to walk you through a question or section.

First off the YJ tub has very few differences mostly cosmetic.

This picture shows the placement of the gas opening as it's opposite of the CJ (left side for YJ right side for CJ)

 

[Manic Mechanic]

Next is frame mounting. YJ frame is really close. You can see the original YJ frame horn location versus the stock CJ. There is a factory nut cert on most if not all tubs. In the back you simply have to drill a new hole in your rear cross member as the YJ tub mount is out board a little bit from the CJ (like 1- 1-1/2")

 

[Manic Mechanic]

Next begins a little modifications the tailgate on a CJ is fold down you have options here either A cut a hole in the back of the inner tub and use nut and bolt (what I did at the time) or B use nut certs (what I do now since I have the tool) then simply cut off and weld on the tailgate latches (I didn't do this and had to source a set from the junkyard years later)

 

[Manic Mechanic]

I took this opportunity to add YJ fold and tumble rear seat and belts so the kids could ride

 

[Manic Mechanic]

Moving on things get a little more tricky. The top of the cowl. CJ uses the windshield frame for defrost and YJ uses ducts. I failed to do this on my swap but do it on all since. The hold down is also a little different as the YJ is out board a little bit.

You can weld some or all of the cowl in as they are the same except for the two spots (dead center and the very edges) pictured is my CJ (didn't transfer over the cowl as I didn't know and made my own duct) the other is the last CJ I did.

You can also opt for a YJ windshield frame and run a better defrost and intermittent wipers if you want.

I plan to just modify my hold down tabs for now and I don't really drive in the rain so I don't care about the wipers

 

[Manic Mechanic]

Next step is going to depend on how anal you are. Once again when I did mine I was clueless (I swapped 20+ years ago and it was my first time)

CJ has JEEP stamped into the tub where as YJ has JOOP stamped into the tub and uses stickers to say Jeep. I do plan on correcting this on mine when I paint it down the road.

 

[Manic Mechanic]

That's about it everything else bolts right up and in place. Doors on 82 (I think) through 95 work either half whole or soft. Your hardtop remains unchanged as well as the soft top. However I do recommend switching to the YJ style soft top as the plastic slides or inserts work world's better than the snaps. I ditched my entire soft top in favor of a bikini top in the summer and hardtop in the winter.

I also switched to YJ seats that recline however I had junk quadra seats in mine.

If you can find a 94-95 tub they are the best as they tend to rust less for some reason
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[Manic Mechanic]

One last thing you need to drill a hole for the windshield squirter and fill in the square holes from the YJ tub

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[Belizean]

Next step is going to depend on how anal you are. Once again when I did mine I was clueless (I swapped 20+ years ago and it was my first time)

CJ has JEEP stamped into the tub where as YJ has JOOP stamped into the tub and uses stickers to say Jeep. I do plan on correcting this on mine when I paint it down the road.

View attachment 102567

View attachment 102568

I have an 84 CJ and it’s JOOP with stickers on both sides.

 

[Manic Mechanic]

I have an 84 CJ and it’s JOOP with stickers on both sides.

As seen in the pictures mine won't be a JOOP forever

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