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Made Room in the Shop and parked the CJ7and New Tub in the work area.
Now to start the Job 2011-01-26 |
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Started the Tub swap process today. Started by pulling the windshield
off the YJ tub. Ran into two fasteners that would not come out.
Even broke 2 Torx bits! Ended up drilling them out, fortuity no damage
to the windshield threads. Pulled the CJ's Hood, no problems.
Since the CJ's windshield hinges were broke, it's removal was fairly easy. Started pulling the fenders off the CJ, and again a stubborn fastener.
Then went to pull dash pad, and again two stuck screws, got one out but one
won't budge, and refuses to be drilled. Next moved to the make shift
cage removal, a sawzall and it's out. Then pulled the seats, and again
a stubborn fastener that had to be cut off. As for the 8 (of the 10) tub bolts,
well one came out, three broke off, and the remaining 4, well they aren't
holding anything so they will be cut out after the tub is off.
2011-01-27 |
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Completed day 2 of work on the Tub Swap. Started out by removing that
last screw holding the dash pad, then removed the dash. Spent quite a
bit of time disconnecting and removing dash items and wires (inside and
out). Once I was sure I had (almost) everything left connecting the
tub to the chassis I started by lifting the front, then the back. With
each lift checking for missed connections. Well, I missed a ground
wire, and two body bolts (the ones on each side of the fuel tank). All
this before lunch. Got the tub up about 6" and resting on blocks and
made one more check before using the engine hoist to remove the tub.
Well with only one hoist and doing it by myself, it wasn't that easy, but I
had it off by 1:00. I'll need a second hoist and probably an extra set
of hands to put the new tub on though. Next I tackled removing the old
stock 6 cylinder wiring from the engine side. Man what a mess.
I'll be spending some quality time with some almost to fine to read
schematics when I re-wire it. Next removed the brake and fuel lines.
I then went to the tubs and started the removal and preparing to transfer
items from the old tub, to the new one. Even though the new tub is a
YJ, I will with only adding one hole be able to use the CJ's heater.
There just won't be any defroster for the windshield. I'll have to do
a little work to get the battery tray to fit, and will also need to weld up
a few extra holes in the new tub. Tried to remove the old seat belts,
but new ones will be in order. 2011-01-28 |
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Only a half days work on the tubs today. This is the slow progress
part, cutting new holes, filling not needed ones. Also pulled the
pedal assembly out of the old tub and removed the brake booster/master
cylinder. I added 4 holes to the firewall, and welded nuts to the back
side to hold the CJ's battery Tray. I had to add one hole the the
battery tray for one of the YJ's studs. I also added the fan power
lead hole to the tub as well. I've also cleaned the battery tray and gas pedal.
After removing the left behind tub mounting bolts from the frame, I've got
to repair the rear frame for the as the tub mounts are rusted out.
This won't be a big deal as I had to modify them anyway for the YJ tub.
2011-01-29 |
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Another half day, and progress continues visually slow. Finished
cleaning and prepping the firewall. Pulled the chassis out and hosed
off the big gunk and stuff, this should help reduce the amount of dust and
dirt I spread around the shop when I clean the frame. You can see the
rear most tub mounts rusted out, no big deal, as I had to move them outboard
anyway. I did clean and paint the battery tray, booster/MC assembly and pedal assembly, as
well as cleaned up the heater assembly. It's amazing how many rocks
there were in the lower assembly. 2011-01-30 |
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Another days work. Drained and pulled the Fuel Tank, then started the
rear frame cross member clean up. Removed the rear facing extras, then
started measuring and cleaning to install new plates for the tub mounts.
With the condition of the area, I elected to to plate the area with a 1/8"
by 3" plate. I measured and pre-drilled the 1/2" and body mount holes.
I added a little metal to the frame rail so I'd have a flat area for the 3"
wide plate. I know the extra 1/8", will raise the tub in this area,
and I will do the same to all 10 mounts as I have three others that are in
bad shape and need to be patched. The gray primer is a weldable primer
I sprayed on both parts to help reduce the rust. I then started going
through the wiring harnesses. I've got a few odd wires on the dash
side that I'm not sure what they are, but the engine side is pretty good,
once I removed the computer harness. I won't have the engine side
complete until I get near the end, as there are several wires I won't need.
2011-01-31 |
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Completed the better part of a days work on the Jeep. With the power
continuing the flicker in the ice/snow storm, I held off on anything that
was power tool, or welder related. Didn't want to be in the middle of
something and loose power, and potentially have problems as a result.
I assembled the inner and outer firewall items (Heater, Accelerator Pedal,
Brake/Clutch Pedals, column pass-through, Battery Tray, Brake booster and
Master Cylinder, and the inner wiring harness and fuse block/connector.
His Farm Service Use Winch and Receiver Cradle came in, and I assembled them
as well. I'll fabricate a front receiver hitch so he can use it on the
Jeep as well as his Farm Service Truck. Then came the disassembly of
the dash, and last today, I stripped most of the dash paint.
2011-02-01 |
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Only just over a half days work today. Spent 4 hours cleaning ice and
show off the driveways and digging two neighbors out. I finished
stripping the paint from the dash and glove box, and cleaning up the rust.
Nest for them will be to weld shut the extra holes, and then paint. I
also finished cleaning the rear 2/3's for the CJ's frame, and as soon as I
get to town will pick up a new 1-5.16" hole saw and finish repairing the
mounts and then give it a coat of paint. I have discovered, that I
will need to add a new hole the the tub firewall for the speedometer cable,
and will need to fill in the YJ's defroster duct passage points and provide
three more dash mounting screw holes. 2011-01-02 |
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Just under a half days work today after doing some part chasing this
morning. I enlarged the previous hole above the wiper switch that was
used for a push button started, to now house the cigarette lighter.
This should help clean up the under dash area where it normally resided.
Got a good coat of primer on the dash and glove box door. I also got a
coat of paint on the frame, and started re-installing the fuel cell, turned
a 180 degrees so the filler is on the correct side. The large diameter
washers I need enlarged to repair the body mounts will be machined out this
weekend, until they are welded in place I can't finish painting the frame.
The exhaust is painted in BBQ/Stove High Temperature paint. 2011-01-03 |
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About a half of a days work, after a grocery run. I finished mounting
the fuel tank, it should work out OK turned this way. Once the new
hoses arrive, I will have to make a connector and ensure their routing when
I mount the tub. I placed the first coat of paint to the glove box
door inner side. This should give us a good idea of the colors.
Last, I started the brake lines. The rear axle is complete, and I've
ran the line to the right front wheel. Next will be the main rear
line, but I won't be able to connect it to the proportioning block, until
after I get the tube mounted, as I will need to rout the lines into the tub
to install the Brake Shut-Off Valve. I've also started a punk list, of
all the things left to do. I will compile it and post the link to it
at the top of this column,
it was longer than I expected. 2011-02-04 |
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Well, we got about 3-4" of snow, that I had to clean off the thick sheet of
ice on the driveways. So about a half days work, not moving as fast at
this stage of the job. Finished the front brake lines, and ran the one
main line for the rear. You know, there are two brake lines I hate,
3/8" & 3/16". Bending the 3/8" is just never pretty or easy, and I
have the most difficulty getting a good double flair on a 3/16" line.
Why can't everything use 1/4" lines? The final brake lines will have
to wait on me picking up a couple more lines, and setting the tub. I
also ran the 3/8" supply, and 1/4" return lines for the fuel system as well.
Oh, before you say anything, the one rear brake line on top of the exhaust
support, will be mounted though it when I'm done. I need to puck up a
couple of brake hose retainers, and get rid of my temporary zip ties as
well. I've now pulled the
lines back off, and given them a first coat of paint, see if that will help
slow the rusting problems. 2011-02-05 |
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Short day today. I picked up the washers from a local friend of a
friend who opened up the ID on a lathe to 1.032" Thanks Richard M. for
the fine work. I reinstalled the brake lines after having given them a
coat of paint last night, then I gave the dash it's first coat of paint.
2011-02-06 |
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Another days progress. Pulled the rear differential cover and drained
the ugly smelly fluid. Cleaned the surfaces and installed new gasket
and fluid. I welded the tub mount washers to the frame. Finished
all but three brake lines, one to the MC, and the two to the tub Brake
Shut-Off Valve. Installed the fuel lines to the engine, and figured
out how I'll mount the fuel pump. I gave the rear of the frame it's
final paint. I pulled the windshields wiper motors and started the
swap process. I fabricated the rear bumper fastener plates for inside
the rear frame cross member. And last but not least, I had aggravation
with the grab handle. Apparently between the 1st (old style) can of
paint I used for the first coat, and the second (newer style, but exact same
brand/kind) can of paint something changed. The second coat caused
bubbling and it lifted the 1st coat and primer! I had to re-strip and
clean it, and start the painting over. 2011-02-07 |
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More work completed. I mounted the fuel Pump and connected the final
lines. I also re-wired the pump and ran the line to the front harness.
I completed swapping the wiper motor over to the YJ Windsheid.
Fabricated the rear bumper mounting pads, they are gray because they are
painted in weldable primer. Wet sanded the dash and glove box in
preparation for the next coat of paint, had to remove a few imperfections
(don't know why). Discovered in addition to the center three mounting
points I had to address, I also had to address the upper two on each side.
The outer upper corner required that I adjust the hole in the dash.
the next hole in I had to drill and will use a nut on the back side. I
fabricated some fillers for part of the YJ defroster duct area, and
installed threaded connectors for the dash and welded it to the Tub.
Since I had the duct, and a little space I fitted the CJ's defroster to what
was left of the YJ's opening. It won't work well, especially with a YJ
windshield, but it's there. Last but not least, I re-painted the dash
and glove box. 2011-02-08 |
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Good Progress today. Fabricated a new tunnel shifter cover. Will
still need to cut the shifter holes, but will do that later when I know the
correct locations. Well, with the aid of a 2nd Engine Hoist (Thanks
LaVelle H.) I lifted and set the YJ tub on the CJ this morning by myself.
It went on easy and with no issues (hopefully that's a good sign). I
pulled the rear wheels off so the hoist would slide in, and because I need
to measure, mark, and cut the wheel well openings to clear the 35's.
Pieced together a new fuel filler and vent hoses for the YJ filler opening
to fill the CJ's 180 degree rotated fuel tank. Should work out well.
Installed the fuel tank and axle vent lines onto the new tub. I also
removed and transferred the CJ's rear wiring harness to the YJ tub. I
then welded up two cuts and three cracks in the TJ tub I started the
installation of the CJ's Tail Gate onto the YJ tub. I've marked the
holes, and fabricated the backing plates needed to mount the hinges.
Still need to fabricate the strap brackets though. 2011-02-09 |
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After a quick part run I finished the tailgate mounting plates (flange nuts
welded to a 1/8" strap) and figured out how to "fish" them into place and
bolt the tailgate on and in place. still need to complete the
latch/cable plates tough. I may cut the old ones off the old tub and
see about re-suing them, or fabricate new ones. I finished connecting
the fuel filler hoses and bolted the tub in place. Had to bias the tub
to the rear to keep the clutch rod from touching the header, but everything
sets pretty good. After a lot of measuring and planning, I've planned
the tub wheel well trim lines. I'm 2" larger than the tires and right
up against the inner panels, just about as large as you can get with out
extending the wheelbase. I started on the front receiver mount that
will hold the portable winch. I've still got to weld the additional
plate but it looks like it should work out. 2011-02-10 |
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Another day of great progress. I removed the old tailgate latches from
the CJ tub, and welded them into the YJ tub. The tail gate lines up
nicely, and latches nice and snug. It turned out better than I thought
it might. I finished welding the extra plate to the front 2" reviver
hitch. I then cleaned the front portion of the frame, and painted
both. The winch looks kind of weird setting up and out like that, but
should work well. I picked up the two remaining brake lines this
morning and routed them through the tub mount plate and up through the
floor. The Brake Shot Off Valve arrived in the mail today, and I'll be
able to plum it in to these lines now. I finished connecting the brake
lines to the master cylinder and installed the clutch rod boot. And I
repaired the grill body mount area, and should be able to install the grill
tomorrow. Starting the engine side wiring harness as well, so I think
(hope) I'm on the down hill stretch, but still waiting on the new ignition
switch, hope it comes off back order soon. 16 days into the Job, 92
actual hours. 2011-02-11 |
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About 3/4 of a good days works today. I finished the cleaning of the
Grill, and installed it onto the frame and reconnected the radiator and
installed the grill support rods. Assembled the dash and installed it
into the tub. Still waiting on the new headlight switch know, but
everything else is there. The new Spedo, had one less dash light, but
everything else is OK, so for. The fuel gauge works! Won't know
if the temperature sender is compatible until it's running again. I've
installed the old ignition switch, but it is bad, but can make it work for
testing. Everything else on the dash works. Finished chasing
some of the engine side wires, and all looks good. the only problem so
for is the horn button doesn't seem to work. I can now finish the
engine side wire termination, and then install the hood so I can start on
the front fenders. With the grill on, I re-test fit the winch, and
will be able to move it back 3" so it doesn't stick as for out, but looks
good mounted that high. 2011-02-12 |
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Just over a half days work. I completed the Engine side wiring clean
up. Now to get some wire cover to swap it in. Still need to
connect the start relay, but will need the finders installed to do that.
I routed the Holley Pro-Jection harness into the tub, but not sure where
I'll mount the controller. I installed the hood and windshield.
I don't recommend the stainless steel hinges, the 90° bend isn't sharp
enough. The wipers work, but the park function doesn't. I know
the wiper motor was not tight and partially open, so I suspect something is
wrong in the motor. I also fabricated the Parking Brake valve bracket
and lines, and once dry can install it as well. 2011-02-13 |
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A short day, but not by much. It is Valentines Day ya Know.
Installed the Brake Shut Off Valve and the last two brake lines. Then
proceeded to use my new pressure bleeder to bleed the lines. Well that
didn't work, can't get a good seal to the top of the master cylinder.
Don't know why. Did operate the brake pedal and found some leaks.
One set a union I forgot to tighten, the other two, well the last two brake
lines. The ones going to the brake shut off valve. I have double
flaring, especially those 3/16" lines. Tried tightening the ends, but
that did not stop it. So I pulled the line sand grabbed the last two
brake lines I had and bent new ones, cut and re-flared. Well the ones
seems to have some out OK, the other, well 4 flairs later and I gave up, the
line was getting too short. So I'll get a new brake line and perhaps a
new flaring tool. I cut the shifter openings out of the tranny cover
and installed it, not too bad of a fit. Now to just find the right
shifter boots. I spent most of the day fitting and welding the BTF
Front Tube Fenders together. they came out pretty good for my first
set of tubes. A lot of welding, and a little tweaking. I tried
to re-use the old inner fenders, but they won't work. So I'll
have to pick up some sheet metal and fabricate some new panels.
2011-02-14 |
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Well, only just over a half days work today. Had a lengthy parts run
and had to pickup and haul one of the son-in-laws vehicle so he could fix
it. Installed the new ignition switch, and then the steering wheel.
Managed to get two good brake flare jobs done, and installed the last two
brake lines. I also managed to get the brake bleeder to work, and
bleed the brakes. Still have a couple of small fitting leaks at the
shut off valve, will pull the valve and check the fittings. The left
front brake caliper bleeder screw is stuck, big time, but got most of the
air out, and the pedal feels good. I finished cleaning and wrapping
the engine side wiring and have decided where to mount the fuel injection
module. So I figured I'd see if she would run. Well, not the
first crank, be she does run! I only have 6 volts at the coil, and
that wasn't enough to power the fuel injection, so I'll have to make sure
there aren't any problems and run the fuel system off another switched wire.
In the side view picture, the wheels are just up against the axles, and the
jeep is still on jack stands. Basically the main items left are the
front inner fenders, rear wheel well opening, and install the seats and
belts. 2011-02-15 |
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Well a nice long day today. This morning I mounted the fuel injection
unit under the dash, cleaned up the remaining lighting and tach feed wires.
With the exception of mounting the dimmer switch the dash side is done.
Discovered the 6 volts at the coil was because the previous owner or Jeep
used a resistor wire in the harness. So I pulled a new wire from
another switched source in the engine bay and feed the fuel injection from
it. I had to undo my harness to add the new wire, but it came back out
just as nice as it was when I finished it yesterday. Engine starts and
runs just like it did before I started this tub swap, great. This
afternoon and evening I fabricated the inner fenders for the BTF Tube
Fenders. I was pleased with how they came out, and that they almost
match each other. In an effort to ensure maximum tire clearance, I
left the headers exposed. This was based on frame and spring pack rub
marks. The rear panel on both fenders is a separate panel, and is left
off during installation so that you can access the fender to tub bolts.
I filled the non-welded portion of the seams, as well as the tube to plate
in the inner fender well areas. 2011-02-16 |
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Another good days work. I tackled the rear fenders. I re-marked,
cut, bent and primed the larger wheel opening to accommodate the 35" tires.
It went easer than I expected and I was very please as to how it turned out.
The rear of the wheel well is opened up to a 18.75" radius, and is the most
you can go with out moving or affecting the rear panel in the wheel well.
This is very close to the rough cut opening that was on the CJ's tub I
removed. I then mounted the seats, and seat belts. I took the
old T18's back-up light switch, and used a newer switch, and a nut I shaved
to the right thickness, to make a replacement functional switch. It
came out pretty good, and works. Essentially the old switch's plunger
activates the new off the shelf switch. I started the painting of the
front fenders and had a surprise visitor. By brother, Darrell (the
Jeeps owner) came up and stopped in to check up on the work.
Thankfully he was nicely surprised. 2011-02-17 |
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With Darrell here, I only spent a couple of hours on it. Basically
installing the fenders after last nights painting. Brakes still aren't
right, and the MC leaks out the top. So I'll be replacing the MC and
re-bleeding the brake system. I'm down to a true punch list of misc
items to complete the job, they are:
- Change Brake Master Cylinder
- Fix NPT fitting brake leak at Brake Shut Off Valve
- Install Front Fender Side Lights
- Fix any Issue related to blown Fuel Gauge/Back-Up Light Fuse
- Install New Ignition Key Assembly
- Install Winch Power Leads
- Install Horn, and Fix Horn Button
- Install wire ends to Rear Dome Lamp Leads
- Fabricate Hydraulic Clutch Pass-through Plate and Install
- Install Fuel Injection Wire Loom Firewall Close Out Plug
- Touch up any of my Painting
Well, not too bad of a final list. I've now spent about 138 hours over
22 days doing the tub swap. 2011-02-18 |
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Darrell and I spent a few hours Saturday taking care of a few things, but
spent most of the time trying to figure out the front Flasher Issue.
It too me about an hour, but I finally figured out other than a loose
connection at the harness bulk head, the replacement Crown Automotive
Parking and Turn Signal Lambs were incorrectly wired when they were
fabricated. They had swapped the park/turn leads. Once I
corrected the wiring on the lights, everything worked great. Today I
finished up a few more loose ends, and cut the back off the old tub.
I'm now down to needing to replace the Brake Master Cylinder (hopefully this
fix's the brake issue) and installing the missing horn parts in the steering
column. So I'm now waiting on parts, the MC is supposed to be here
Tuesday, not sure how long it will take to get the horn/steering parts.
2011-02-20 |
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A few more hours of work, while parts lasted today. The steering wheel
is all back together, except for the horn button, hope to have those parts
tomorrow. I installed the hydraulic clutch close out plate I made and
painted yesterday. I also finished the winch wire and mounting.
Now if parts arrive tomorrow, I will install the new Brake Master Cylinder.
2011-02-21 |
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Installed the new Brake Master Cylinder, un-stuck the front calipers,
adjusted the rear pads, and she now has good brakes. Also discovered
that the temperature sending unit in the 304 isn't compatible with the CJ's
Gauge, so I'll install the correct sending unit to fix the fuse problem.
I installed a temporary horn button while I wait on the horn button spring
that I had to order. Also the brake shut off valve leak is
fixed. Now to do some paint touch up and deliver it to my brother.
2011-02-22 |
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Spent a good days work fabricating the rear bumper. Tomorrow I'll
clean and paint it. 2011-03-03 |
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Installed the freshly painted bumper, and took Darrell's Jeep to the MIJC
Annual Inspection Event. Had a great time, and a good start for what
is hopefully a great year of wheeling. 2011-03-05 |
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Darrell now has fresh paint on the Jeep. Time for some new padding on
the bars and a few decals. 2012-08-14 |
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Darrell has named his Jeep, and now has decals made and installed.
2012-09-19 |
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Darrell installed the rear fender flairs, the roll bar pads and a bikini
top. Only things left is the "Jeep" decals and painting the wheels. 2012-12-14 |
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