Build Thread Project Jeep CJ8SS (Scrambler Sleeper)

[gaspipe]

Wow...those Scout knuckles looked like they came out of the Atlantic. :0

Awesome build. Can't wait for more!

 

[0822]

Great looking project. very nice work!!!!

 

[85LaredoCJ7]

Good job!

 

[Kane]

So I have been squeezing whatever available time I have into this project which isn't much compared to some people but I managed to stay on my timeline to have a roller by February. So far I am where I need to be to make this happen. Over the last couple weeks I did all the prep work to make my front Scout II Dana 44 ready for a CJ with proper caster and dif angles. Here is a link to the whole thread as I decided to make that one separate for people who have questions in the future.





http://www.jeep-cj.com/forums/f2/scout-dana-44-prep-cj-pics-17048/


With the odd diff that has the spring perch right on it I had an interesting issue which is the CJ spring plate will not work without welding the old holes and making new holes for the much larger u bolts. This left very little room for the bolt since the plate is actually slightly too small to do this. Since I might go to a wrangler type spring I decided to make my own perch that can accept both the 2” and 2.5” wide spring. The last few days I whipped up this little baby. Sometimes it is the small project that give me the most satisfaction.

 

[Bowbender]

"Sometimes it is the small project that give me the most satisfaction."


Nice job on the plates! I enjoy fabricating too, and look forward to wading into my project soon.

 

[Kane]

Thank man. It is not perfect but I cut everything by hand and I use a hand drill for the holes. Either way it is strong and will work just fine.

 

[Kane]

Not what I wanted to see when I pulled the pinion gear out of the Dana 44 rear end. I guess I have a choice to make at this point. I can just buy some new rear gears in the same ratio which is 3.73-1 or go lower in both axles.


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[Kilo19]

not what i wanted to see when i pulled the pinion gear out of the dana 44 rear end. I guess i have a choice to make at this point. I can just buy some new rear gears in the same ratio which is 3.73-1 or go lower in both axles.


​

is that what you call pitting? Or what it would look like.

 

[Kane]

Yes that is pitting. This is most likely from the rear axles sitting for so many years in one position. This can happen to bearings as well, even new ones on a shelf.

 

[Kilo19]

with those gears being under high stress, pressure, are they/would they be at risk of shearing, shattering, or just not use them period. reason i ask, from my novice, inexperianced eye for metal their, they look like they would be ok. please help correct my thinking....i know not to use them, but i always ask why.

 

[Kane]

The pitted metal is no longer polished and smooth. It will start to dig into the other gear teeth and accelerate wear. Eventually this will lead to failure. I am in the axle now so $200 for new gears is money well spent and no extra work. I pulled it apart to replace bearings and seals anyway. I could easily pay that amount to be towed home if I blow up the gears somewhere. To be honest if this was the front gears I might take the risk since it doesn't see daily use and will not strand me if it dies. He'll maybe I can swap the fronts to the back and vise versa.

 

[Kilo19]

Makes sense. Thx


Sent from my iPhone using Tapatalk

 

[Kane]

Some new updates. I rebuilt both axles in the last month and i am very excited. The last two things I need to do is make the rear brake caliper mounts and finish up the steering linkage otherwise they are down. Here is the link to the front Scout axle housing prep. http://www.jeep-cj.com/forums/f2/scout-dana-44-prep-cj-pics-17048/

I didn't really take alot of front end picture but I have a few here plus the link. I reused everything but I replaced all the bearings and seals. The front brakes and steering are from my Dana 30 Jeep axles.

 

[Kane]

For the rear end I had to rebuild everything. The gears, bearings, spiders and carrier all had significant wear and pitting. I ended up buying a new set of gears and then I bought a detriot Trutrac. The axle shafts were good enough to reuse with a new set of bearings and seals. I also took the opporutunity to do a disk brake conversion home built style. I am working on the caliper mount design this week and should have a mock up done over the next few days. I am going to have the mount water jetted from a CAd drawing. Judging by the caliper position the mount is very easy and straight forward. The rotors are from a 1998 Suzuki Sidekick and the calipers are 1988 Nissan 300 ZX with the built in e-brake. I haven't figured out the cable set up yet.

 

[Kane]

New Trutrac and G2 gears

Working on the gear pattern



All put back together and ready for the brakes


Ready for the bracket mock up

 

[Old Dog]

Look'n good

 

[rr41mag]

You said you got an extra engine. What was it? Interested in getting rid of it?

 

[Kane]

I have two AMC 258 i6 / 4.2l 's and since I am leaning towards an LSx motor I will have an extra. One of them will be going into my other CJ at some point. I would sell one but I couldn't even start to guess what shipping 600 pounds would cost.

 

[Kane]

Here are a couple pics of the disk caliper bracket I am designing. I laid it out on construction paper then cut one out of lexan with a dremel tool. I then drew up the white paper one on CAD and cut it out to make sure it fits correctly. Tomorrow I will send it off to get water jetted and hopefully have them back by Friday.

 

[BC CJ]

Nice work. I love to see people fabricating thier own parts!