Build Thread Sons '74 CJ5 Project

[Colo Dean]

My oldest is turning 16 and wanted a Jeep. Picked up this ole girl for 2k. Mechanically everything seems to be sound. Needs some body work which I'm not the greatest at. Told my son if he wants a perfect Jeep, save up and buy a new one. This is a 40 yr old girl and is going to have some character in her. This is how she sat when we brought her home.







The plan is to strip it down and repaint fixing as we go. Will be a metallic black. It came with a soft top that is in ok condition and a bikini top that is pretty good. It has a AMC 258 i6 / 4.2l I-6 which will be staying tied to a granny low 4 speed. For now I think she will be staying mostly stock. Just starting this post but will update repairs/mods to date and continue with our progress enjoying working on something that doesn't require 40 computers and an engineering degree to look under the hood.

Thanks for following along.

 

[Colo Dean]

Once home we began looking into the electrical system. Had a couple lights that were not working. Cleaned a few connections and replaced wire nuts with better connectors and heat shrink and we had lights again.

Springs seemed to sit a bit crooked so we replace all spring and shackle bushings.

Checked and greased all u-joints, steering components, fluid levels.

She has a decent amount of cancer so we decided to start working on that. Both front fenders were rusted where it is two-ply metal behind the wheel. Cut that out and replaced with 16ga sheet metal. I am not a body man by any means so it is not going to be show room quality, but still did not turn out too bad. The hood looked like it had been caught by the wind and was creased where it hits the windshield. Fixed those creases as best we could. Grill cleaned up pretty decently. Now have the front clip hanging from the rafters. The oldest is getting pretty good at running the sander.





He decided that if it is not going to be painted, it will be bed lined. Fire wall is done and working on the cowl now.


Rocker panel will need patched along with the floor pans




The support for the floor has been eaten away so that will be replaced with 3/4" x 2" tube.

Brown Santa came and delivered new sheet metal along with some poly body bushings.


Brother in-law is a welder and will burn in the new panels for me once we get it all cut out and back to good metal. Hoping to have that done in the next couple weeks.

Had a bolt that holds the cover over the wiper motor that was frozen. Took it to a machine shop to have it removed and re-threaded. Everything went good until they set it down and broke the glass. The glass was fairly pitted and was on the possible to-do list, guess that got moved up.....

While disassembling the front clip, figured may as well have the radiator cleaned out along with the heater core. Couple leaks fixed and those are now good to go. Also found a couple cracks in the frame that are now fixed up.

I think this pretty much takes us up to where we are now. Plans are to finish repairing the floor pans and body work. Hoping to have the body work done before summer is over. Then really want to get rid of the points and thinking of going to the HEI. Also want to move to the GM alternator. Dont have the funds for a new wiring harness but would like to do that as well. Have to see what the budget looks like. Also need to take care of the rear main seal leak.

 

[mtnwhlr]

 

[Colo Dean]

So we have the floor cut out and found the support for the firewall was pretty much gone. Managed to get a new support piece made and tacked in along with a new vertical support piece for the lower "A" post. While creating this piece, found the triangular support for the floor had cracked. Quick run to HF for a soda blaster made quick time of cleaning it so it could be welded back together. Then mother nature decided to pay a visit and dumped everything she had on us. For some reason the brother in-law didn't want to weld in water so that pretty much ended the day for us. Got a quick shot of the removed floor section and the tacked in new support.

Hoping the weather will be good next weekend and we can finish the floor. For now will keep sanding down the rest of the passenger side and getting it ready for paint.

 

[Colo Dean]

Since we couldnt finish thr floor due to the rain, had the oldest start sanding down the rest of the passenger side to prepare for paint. Once he got to the rear quarter, we found bondo city.




Found enough good metal to leave the outline and cut out all of the bad area.


New patch mocked up. The sheet I had was a little narrow so I will have to fit a small triangle to finish it.

Next will be a patch around the tail light. Hoping to save the mount behind it since it is still solid at least from the rear. Once apart if its rusted out will make a new mount.

Debating on installing flush mount LED taillights. Nice and out of the way but not original.

Here's looking for good weather this weekend so we can burn some metal.

 

[Colo Dean]

Well we got a little further, the drivers side had a bit more rust than I thought. Had to cut out everything under the seat but didn't have to go up under the dash as far as the pass side.

The drivers side floor is cut out, ready for new metal. Glad the support was still in good shape and we dont have to fab this side.



While looking things over we found one of the frame mounts just behind the step up piece(not sure what its called) where the floor meets the bed was rusted. No way to get to it without removing the tub. Hadn't planned on going this far but looks to be the only way to do it right. The oldest had his friends over to take it off and put it on a couple dollys.

I guess it does make some things easier. Plenty of room to get to the bottom of the tub to repair sections and redo the undercoating . My fathers shop has a wash bay so we can de-grease the chassis and make sure there are no other little cracks to fix.

Seems like ya have to fix 5 things before you can fix the thing you started on. Will all be worth it once its done.

She looks a little barren without the body





Thanks for watching

 

[Colo Dean]

So I haven't updated in a while, have managed to get some work done as the with the tub off, been getting the frame cleaned up and a couple cracks welded up. Have most of it shot with rust preventative and a primer.




Since the son wants a "zombie-ish" color to go with the black, we found something that I think will work out. Painted the brackets for the rear bumper to see how its going to look. Plan to shoot the outside of the frame rails with it and bed line the inside of the rails.


Have also managed to get some work done on the tub. The drivers floor is now replaced, had to use a couple pieces to get it all replaced. My welding is not at a pro level so I welded both sides just to be sure. Doesn't look pretty, but its solid. Interior will all be bed lined so once that is done, you will never see any of it. Had to build a new piece for the "A" post where it had rusted and a new patch under the cowl. I think I now have everything welded up on the drivers side. Also have the passenger floor in just need to finish welding it up.




Slow but sure, its coming along.

 

[defibvt]

Looks like it is coming along. I am watching this thread because my CJ is a 74 and we intermediate years need to stick together. I am hoping mine will be done updating the drivetrain in the next couple of weeks. Money Pit is the name of my thread.

 

[Colo Dean]

Thanks for following along Defibvt, agreed, not alot of intermediates running around, least not that I see often. Will check out your build as well.

Just got the passenger floor all welded and a new "A" post section welded in. Son finished cleaning up the frame and we have it shot with paint, just need to spray clear coat and then he will start on the bed liner on the inside of the frame rails. Hoping to get the rocker panel trimmed and tacked up this week. Will try to get some pictures tomorrow.

 

[Colo Dean]

Got the floor pretty well finished now, have a little grinding to do and a few touch up welds most likely but both floors, both "A" posts and rocker panels are now in. Still need to weld up the pass rear quarter patch and the rear body mount supports and I think I will be done welding and patching the tub. Next will be flipping it over and sanding down to prep for bed lining.




Also managed to get the frame painted. Need to finish cleaning up a couple areas and we will get the insides of the frame and cross members bed lined.


Next on the to do list is bed line frame and under side of tub, build wiring harness for rear lights and be able to set the tub back on the chassis. Then start on the prepping tub for paint.

 

[Colo Dean]

Managed to get a little further this weekend. Had some help moving the tub back on the frame so I could tack the rear body to frame mounts where they belong. Took the tub back off and the oldest finished prepping the front half for bed lining. May need to remind him to watch for runs

The firewall had already been bed lined so a little extra isn't going to hurt anything. Will add a second coat once this has cured. Taking a while trying to keep the garage warmed up. Next project will be to finish cleaning the rear half and bed line it.

The short list now includes:
finish bed lining inside frame rails
attach new wiring harness to frame
remount rear brake lines and take care of a leak
mount fuel tank and design a skid plate for the fuel tank

Then I think we can finally put the tub back on the frame and make some room in the garage figure I can finish body work with the tub on and just use the movers dollies to turn it around when needed.

 

[Colo Dean]

So I made a list that had 26 things to finish before we can put the tub back on. We now have 8 left. Still working on bed lining the underside of the tub. Frame rails are now bed lined, new rear brake line is ran, extended breather hose for rear diff, bell crank re-installed, plugged holes on top of the t/c with oil pan drain plugs (didn't like the plastic plugs that were in there), fuel tank is re-mounted. Fuel line re-mounted although I don't like they used plastic line where it crosses over the shock mount and leads to the tank. Going to get new steel line and re-plumb that. Have a lead on a nice clean fuel tank but may be spring before I can get it so I didn't worry about cleaning this one up, had a bit of surface rust but nothing major may still buff some of it off. Ran new ground studs at the rear frame cross member for lighting needs, e-brake cables mounted, exhaust mounted until I can afford to have that re-done. Hope to lay out rear wiring harness tomorrow and have bed lining on the tub finished this weekend. Then hopefully................set the tub back on the frame. Nice to see parts going back on rather than coming off.

Couple shots of things going back together



Hoping next shots will be of the tub back on the chassis

 

[Colo Dean]

Looks like the moons have aligned. The bed lining is complete. The tub was set back on this weekend. Had to make new body mount washers as I could not find anyone that had them. Ended up using 1/4" steel flat stock and a 2" hole saw. Gained about a 1/2" body lift out of it since I used a washer above and below the new poly mounts. Looking like the skid plate for the fuel tank will be done another day. Need to find someone that has a brake.

Had to make a couple trips for bolts since someone measured the thickness of everything except for allowing for the nuts but we now have the tub back on. Still have a lot of body work to be done to prep for paint, but painting will have to wait to spring now.



Nice to have the tub back on and finally regain some room in the garage for a while.



New axle to frame bumpers will be here this week, need to get new shocks and I think all the work on the chassis will be complete. Then finish bed lining the inside of the tub and create the next list of things to do. The list seems like its going to go on forever.

 

[Colo Dean]

Have had some decent weather and got some more progress on the old girl. Mocked up a skid plate for the fuel tank from cardboard. Local Tractor Supply sells sheet metal. Any thoughts on what gauge metal this needs to be?



Also got a new 1/8" aluminum sheet for the new dash. Wanted to keep her mostly original but I think the dash will be one of the custom items.


Looking to get the Speed hut gauges and GPS speedometer. Over the freezing days, I managed to draw up a new wiring schematic that will clean up the rats nest of wires it had. Plan to run two new fuse panels w/relays. One that will supply Acc items and one that will supply Ign items to keep most of the load under the hood rather than under the dash. (sounds good in my head)

The tub is now bed lined. Oldest finished the drivers side today. Will still need a second coat but at least its now all one color and a big check mark off the list of things to do. Looks better in person than the picture, need more lights in the garage.......

Need to run wiring for the reverse switch on the Transmission then the rest of the tub sheet metal can get installed.

Trying to decide what to use to seal the Transmission cover to the floor. Factory used a putty like substance. Originally thought sticky backed weather stripping but wondering if plumbers putty would be a better option. Thoughts???

Also got the axle to frame bumpers installed and found a couple other bolts that didn't get tightened underneath. Once bed liner is cured things can start going back together inside the tub.

Thanks for following along with my slow adventure.

 

[defibvt]

Nice work!! Still waiting on mine from the shop.

 

[Colo Dean]

Well we got a little further, reverse switch is now wired and the floor is now in!!!
Have a couple spots to touch up with the bed liner but that part of the project is now basically compete. Also re installed the heater blower assembly and new heater hoses which allowed the battery box to be bolted back on again (needs some sanding dust washed out of it). Anyone know where to get or what a good replacement would be for the tubing that goes for the defrost duct? The large oval duct looks to still be pretty good condition. Reconnected the parking brake assembly. Glad everything seems to be working with that. Tore it apart because it would not originally hold and could not find a replacement that was any better. Found the little piece that engages the teeth was broke. Got that welded up and put it back together by drilling out the center of the factory rivets and bolting it back together. Seems nice and smooth and locks solid now. Also installed the dimmer switch.



Have to reform the hold down pieces for the shifter boots as they were a bit bent up originally then they can go back on. Sat the new dash piece up and started looking at the layout. Not everything is to proper dimension. Tax return is going to pay for Speedhut gauges with the GPS Speedometer.

Really wanted to have the gauges mounted towards the center with another piece mounted to the dash so they angled towards the diver but with the gear shifter going so close to the dash I don't think that will work. Still playing with different ideas on the layout. Father works for a tractor dealer that sells a water proof radio and speakers that I think will be great. Didn't have the speakers in stock but they said they were kinda small. Hoping they will be able to be mounted behind the dash and either drill holes or have louvers cut out for them. Radio is pretty far down on the list of things to do.

Next up will be getting the steering column cleaned up and ready to be installed. Looking at replacing the factory steering wheel with one of the grant wheels (little smaller for my gut to get in and out

) Anyone done this before? Looks like the install kits are designed more for a tilt column than the small diameter fixed columns. Make any difference?

Thanks for following along.

 

[defibvt]

I replaced mine. It was fairly simple if I recall but that was 8 years ago. I don't have a horn so I couldn't help you with that.

 

[Lumpy Grits]

IMHO-That skid plate should be at least 1/4" thick.
The OEM plate was a joke!
LG

 

[Colo Dean]

Thanks for the input guys, figure I could use an aftermarket horn button if needed.

Lumpy, thanks for commenting. Really wasn't sure what to use for the skid. Didn't have one when I got it and had nothing to base a new one on. 1/4" plate is readily available so may go that route instead of just sheet metal. On these lines, how much gap would you recommend between the skid and the fuel tank? My mock up had between 1/2 and 3/4 inch gap. That sufficient?

 

[defibvt]

Are you using a steel tank or poly tank? Make sure water has a way to drain away from the skid and not pool. Rust is not your friend.