Build Thread Project Rot

[JAE]

So this past Memorial Day I convinced my wife that we needed an open top Jeep and I was lucky enough that she actually agreed on the condition that it be drivable since we already have 3 other full blown projects. We find one and go check it out. It looks rough but starts up and sounds decent but I wasn't able to do a good look over on it because of the weather conditions. Well after a 120 mile drive home in the thing in holiday traffic the weather had cleared up. I start looking over it closer and find that all the body mounts are destroyed, where most of the body mounts attach to the tub are crushed, one area is being held up by a piece of 2x4, the floor of the tub next to the drivers seat is not attached to the side of the tub anymore and that there's some decent holes rusted through the rear section of the frame. I then realize that what was supposed to be our new summer toy was now another project (#4), and that I was probably lucky that it didn't crumble out from under me on the drive home, oops.

On to the details. It's a 77CJ7 with the AMC 304 / GM Turbo 400 / QuadraTrac / 20 rear/ 30 front. A p.o. had installed a Rubicon Express 4.5" lift and 35" tires at some point that were somehow in decent shape. The lift and the tires are probably the only good parts on the thing.

The plan. I was trying to decide between if I wanted to patch my frame or just build a new one but I found a good deal on a decent used one so I'm going to pick that up and do some upgrades on it then swap stuff over. Unfortunately my t case doesn't have the low range option so I have to swap it, deciding between a np241 and a Dana 300 . Im leaning towards the 300. New t- case means new axles. Luckily I already have a 9" and matching Dana 44 already built but have sat for a while and need to be freshened up. As for the body I'm just going to buy a sheet of steel and start making patch panels.

It sounds so simple when I put it together like that, if only it was. I've never done a build thread before so hopefully it will help keep me on track and get this done. Especially since I told the wife I'd have it drivable again by next Memorial Day and I really just started working on it. And I know, it needs pics. I'll add some when I figure out how since I have to do this on my phone.

 

[Peanut Butter]

:ww: neighbor. Sounds like you have a good plan. Don't throw that QT away. I try to buy those for extra parts for my rig. You selection of axles is awesome and your lucky to already have them. ($$$$) I'd go with the Dana 300 myself. Used in the later year Jeep CJ's. Pictures are easy from my computer, not sure how that works from a phone, but get that figured out, we're like kids with comic books!

 

[JAE]

The day we brought it home


Getting ready to start stripping it down


And everything out

 

[JAE]

Someone had done a bad bed-liner job on it so I figured getting rid of that was a good place to start. What I have found so far is less than encouraging but I can tell you that a chisel and acetone or brake fluid helps take the stuff off.
Back section.

Passenger floor
That gray spot in the middle is Bondo and you can kind of see the seam between the two panels that had been tack welded in and slathered in Bondo along with most of the rest of the floor so far. I've also found a few small patch panels tacked in and covered up in various places.

 

[shum8]

Never underestimate the intelligence of a PO...... They can be very creative in ways to hide .

 

[JAE]

Sad thing is it probably wouldn't have taken that that much more work to do it right after the layers of primer Bondo more primer a full paint job and then the bed liner. Oh well I'll just view it as more practice for my other projects.

 

[JAE]

Some more of my fun finds
Earth friendly body mounts

Custom frame lightening holes

Easy swap tub?



Yup, still feeling lucky I survived the drive home in it.

 

[Lumpy Grits]

Thanks for doing the thread.
Might want to start looking for a frame.
Tap'n the frame rails with the ball end of a ball peen hammer, will tell you all the bad news.
Best of luck-
LG

 

[JAE]

I was toying with the idea of just building a new one but I found a replacement one in good shape I hope to pick up soon. That way I can make sure everything is in order with it while I work on the body.

 

[Peanut Butter]

Looking good. Do you have access to a good air compressor? I used a little air chisel on my truck bed to pull off some tar that was used. Made the job a lot easier. Are you keeping the lift? Looks like at least 33" tires.

 

[JAE]

I do have a compressor but no air chisel, the regular chisel has been working pretty good though. I'm keeping the lift on the rear but switching the front over to coils since the axles I'm swapping in are out of a 78 Bronco I had built and I kept all the suspension parts off of it. The tires are 35" Pro Comp mtr's which is the size I wanted to run anyways.

 

[Lumpy Grits]

Heat with a hairdryer. That really helps to release it, to be scraped off.
LG

 

[JAE]

I was thinking about trying a heat gun since looking around online people were recommending it for removing Bondo so was hoping two birds one stone.

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[Peanut Butter]

This is what I was talking about. Got it from HF.

 

[JAE]

I had pictured something different in my head. I'll have to look into that

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[JAE]

Thanks for the recommendation PB, I picked one up and it made life a lot easier except now I want a bigger compressor. My progress at this point, nothing super exciting but I keep telling myself every bit helps.
Front section

Driver floor

Passenger floor

And progress like this doesn't cost me anything but time which is a good thing.

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[Peanut Butter]

Thanks for the recommendation PB, I picked one up and it made life a lot easier except now I want a bigger compressor. My progress at this point, nothing super exciting but I keep telling myself every bit helps.

Forgot to tell you I have a big shop compressor, my bad! Even though it is slow going, sounds like it's helping you make some progress. With that in mind, rebuilds take time. Money, or life events, day to day chores, they all take time away from the rebuild. I'm going on 5 years on mine. total knee replacement and other health issues have been my greatest hurdle. Just as you might do an outline to write a paper, make a least of what you want done, prioritize them, and stick to that. As you cross things off, you'll feel like you're accomplishing something, and that's the big thing that make all of us tick. We need to see accomplishment, and we get impatient with that. The list will help. It will most likely get changed several times, but the items with lines through them will make you feel good. Keep posting, take lots of pic, and the members of this forum will help you maintain your momentum.

PS: You rust areas are very fixable. Replacement panels are readily available. I would suggest taking a hard look at what others have done in the build forum, may help some. Revealing what you have is a great starting point!

 

[JAE]

Thanks for the encouragement. I have a 29 gal compressor right now so it does ok, part of me just wants a bigger compressor. I'm getting my build plan together in my head so I can put it down on paper to help me stick with it. Not doing that is why my first build went from what was supposed to be a mild build to a ridiculous all because of finding a broken axle housing. I want to say that one took about 4 years. I would like to have it be able to move under its own power again by next Memorial Day even though I know it's a long shot.

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[Peanut Butter]

Thanks for the encouragement. I have a 29 gal compressor right now so it does ok, part of me just wants a bigger compressor. I'm getting my build plan together in my head so I can put it down on paper to help me stick with it. Not doing that is why my first build went from what was supposed to be a mild build to a ridiculous all because of finding a broken axle housing. I want to say that one took about 4 years. I would like to have it be able to move under its own power again by next Memorial Day even though I know it's a long shot.

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Be sure you take a hard look at the QT TC, unless you plan to replace it with something else. Lot of people put the cheep China made chain in them. If you use a made in the US chain from BJ's you'll have a good Transfer Case . I bought a couple extras so that I had parts and cases on hand.

 

[JAE]

I think I'm going to swap in a Dana 300 since my QT doesn't have the low range option and that is something I have to have so it'll probably be looking for a good home when the time comes.

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