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1969 Cj5 Build

Discussion in 'Builds and Fabricators Forum' started by BMoney, Oct 18, 2021.

  1. Oct 18, 2021
    BMoney

    BMoney Member 2024 Sponsor 2023 Sponsor

    Orange County, CA
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    May 31, 2021
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    Hey Everyone,

    So I recently purchased a 1969 Jeep CJ5 and wanted everyone to be able to follow along in my rebuild process. Below are some photos of the original vehicle as it stood the day I bought it. The Jeep was started as a rebuild from a guy who got it from his late father about a year ago. The previous owner says that it ran when his father passed away but it hasn't been started in over a year. Jeep is complete with a motor and transmission. Fingers crossed that it runs once I get the electrical and body work taken care of.






     
    melvinm and timsresort like this.
  2. Oct 18, 2021
    BMoney

    BMoney Member 2024 Sponsor 2023 Sponsor

    Orange County, CA
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    Well I know I just posted a minute ago but I just got word that the CJ5 is out of paint and ready to be picked up. Since I am on a budget, single stage paint from my local Maaco was the way for me to go. Not looking for a show car but something that looks presentable from 10-20 feet away while I am driving down the street. Here are some photos of the finished paint work.




     
  3. Oct 18, 2021
    Fireball

    Fireball Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Pullman, WA
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    I'm not seeing any pictures.
     
  4. Oct 18, 2021
    BMoney

    BMoney Member 2024 Sponsor 2023 Sponsor

    Orange County, CA
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    May 31, 2021
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    How about now? Still getting used to the forum and how to post images.
     
  5. Oct 19, 2021
    Fireball

    Fireball Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Pullman, WA
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    Phots working now. Great looking Jeep!
     
  6. Oct 19, 2021
    fhoehle

    fhoehle Sponsor

    Harford Township, PA
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    Apr 11, 2012
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    Hey, I wish we had a Maaco! That looks great!
     
  7. Dec 27, 2021
    BMoney

    BMoney Member 2024 Sponsor 2023 Sponsor

    Orange County, CA
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    May 31, 2021
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    So in the midst of doing a bunch of home improvement projects I have dedicated Sundays to be the day I work on my Jeep. Two weekends ago I finally got alot of parts back from powder coat which included the hood hinges, windshield frame, seat frames, intake manifold, valve covers and rocker panels. I decided that it was time to start putting some of this on so I installed the rocker panels and corner guards along with the hood hinges and front end dressings. Here are some photos of my progress

    Rocker Panels and Corner Guards Before

    New Powder Coated Rocker Panels

    Grill Before

    Grill After Installing New Headlights and Turn Indicators, New Hood Latches and Footman Loops

    All In all a pretty nice day's worth of work. Up next is tackling some of the mess in the engine bay.
     
    melvinm and Fireball like this.
  8. Dec 27, 2021
    BMoney

    BMoney Member 2024 Sponsor 2023 Sponsor

    Orange County, CA
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    So here is the list of work that I plan on doing, please feel free to comment with anything you think I should do during the process that maybe I have overlooked, I am of course on a budget but I am doing all of the work myself (outside of the machine shop stuff). This isn't in any particular order of operation either, I know that I need to do bed liner before the seats and stuff like that.

    • Rebuild Top Half of Engine
      • Clean Existing Cylinders (Done)
      • New Water Pump (Done)
      • New (Used) Cylinder Heads (Done)
      • Powder Coat Valve Covers and Intake Manifold (Done)
      • New DUI HEI Distributor & Wires (Done)
      • Paint Engine Components (Pulleys, Fan, Fan Shroud, Headers, anything else that needs paint without me removing the entire engine) (Done)
      • New Radiator Hoses and Belt (Done)
      • New Thermostat (Done)
      • New Mechanical Fuel Pump (Done)
      • All new gaskets (Done)
      • New Spark Plugs (Done)
      • Mufflers and Exhaust (Done)
    • Interior/Body
      • Paint Exterior (Done)
      • Bed Liner entire interior of the tub (Done)
      • New Pedals and Steering Wheel (Done)
      • New Dash, Gauges and Switches (Done)
      • Install Seats (Done)
      • New Body Mounts (Done)
      • Re-install powder coated windshield frame and windshield (Done)
      • New side mirrors (Done)
      • New lights all around (brake lights, reverse lights, turn indicators, etc.) (Done)
      • Paint Bumpers (Work in Progress)
      • Install Fuel Tank (Done)
      • Run New Fuel Lines (Done)
      • Install New Seat Belts (Done)
      • New Roll Bar (Done)
    • Electrical
      • New Wiring Harness from Painless (Done), special thanks to
        @Tralehead for the help!
    • Brakes and Drivetrain
      • New Master Cylinder (Done)
      • Stainless Steel Brake Lines (Done)
      • Full Brake Inspection and Possible Rebuild of Drums
    • Steering
      • Rebuild Ross Steering Box (Work in Progress)
      • New Drag Link, Tie Rod Assemblies and Steering Bellcrank (Done)
    I am sure more will come up but my hope is to have my Jeep running and driving by Summer 2023, wish me luck!
     
    Last edited: Oct 10, 2023
    Fireball, supertrooper and jeepstar like this.
  9. Dec 27, 2021
    BMoney

    BMoney Member 2024 Sponsor 2023 Sponsor

    Orange County, CA
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    This past weekend was a day of cleaning the pistons and removing the water pump, fan, fan shroud and hoses.

    The piston heads cleaned up pretty nice but I need to go over a few of them one more time. My go to was gasket cleaner and a non-scratch scotch Brite pad along with a plastic razor blade scraper. After cleaning I lined each cylinder with a little bit of oil and turned over the motor a full crank to get the oil all the way down the cylinder wall.

    Pistons before cleaning

    Pistons after cleaning

    Up next will be removing the timing cover and inspection of the timing chain, gears and oil pump. The entire outside of the engine was covered in about 1/2” of mud/sludge that I am slowly cleaning and scraping off. The weird thing is there isn’t any of the mud/sludge on things like the alternator, distributor, wires, etc. I am seeing it everywhere that maybe where dirt and oil came in contact with one another.
     
    Last edited: Dec 28, 2021
    Fireball likes this.
  10. Dec 27, 2021
    BMoney

    BMoney Member 2024 Sponsor 2023 Sponsor

    Orange County, CA
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    A couple of weeks ago I pulled the valve covers off of the Jeep only to find a huge amount of sludge on the passenger side in the cylinder head where the rocker arms and valve springs are located. I decided to take the heads to a local machine shop for cleaning and resurfacing only to find out that both the driver and passenger side heads had a crack in almost the exact same spot on both heads. After a few panicked calls I found some replacements for pretty cheap through J&W in Adelanto.

    Driver Side Head

    Passenger Side Head

    I got my new heads just the other day and I am in the process of finding a good mechanic in Orange County to do a valve job and resurface the heads in preparation to start putting the top end of the engine back together.
     
    Rich M., blalp!, timsresort and 3 others like this.
  11. Jan 2, 2022
    BMoney

    BMoney Member 2024 Sponsor 2023 Sponsor

    Orange County, CA
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    Well I just pulled the stock headers and realized why the PO put a block off plate on the mechanical fuel pump and went with an electric fuel pump. Turns out that I have two of the same headers on the drivers side and passenger side. The drive side outlet was point towards the radiator and the passenger side was pointed towards the tub. The backwards driver side header basically interfered with having a mechanical fuel pump.

    So onto the web I went and ordered a set of Hedman Headers for the Dauntless.

    https://www.summitracing.com/parts/hed-69420

    Anyone installed these on their Dauntless V6? Anything I should be concerned with or is this a pretty straight forward install? I am hoping for no cutting of inner fender wells or anything like that.

    I will be painting them once I dry fit them and make sure everything will be ok with the install.
     
  12. Jan 3, 2022
    timsresort

    timsresort Active Member 2023 Sponsor 2022 Sponsor

    South Lake Tahoe CA
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    The stock cast iron manifolds are almost identical, and the drivers side does point forward, and misses the fuel pump. That was the stock configuration. There is a heat shield that protects the fuel pump. The only difference in the manifolds is the heat riser damper that is on the passenger side (I think).
     
    Lockman likes this.
  13. Jan 10, 2022
    BMoney

    BMoney Member 2024 Sponsor 2023 Sponsor

    Orange County, CA
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    So this weekend was filled with time for the family so I didn't get much done on the engine dismantle this weekend other than removing the passenger side exhaust manifold and muffler, the harmonic balancer, timing cover, sprockets and chain. To my surprise when I opened up the cover I found the reason that the PO had converted to an electronic fuel pump as the fuel pump eccentric for the mechanical pump was cracked and extremely worn. I got a new eccentric ordered (not cheap) and hopefully that will be here in time for reassembly next weekend. The plan for this coming weekend is to rebuild the oil pump, install a new timing chain and sprockets and install the new timing cover along with the water pump and pulleys.

    Photos of the worn fuel pump eccentric:



    Here are some progress photos of the engine prior to pulling the gears and chain.




    Any feedback on issues you see would be great, hopefully next weekend
     
    cj2atruck likes this.
  14. Jan 11, 2022
    cj2atruck

    cj2atruck Member

    Spokane, WA
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    Dec 12, 2020
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    64
    you might think about a Jet-hot coating instead of paint. I've got 30 year old Advanced Adapter headers that I have fixed three times, so going to order a new set and have them drop shipped to Jet-hot for coating in hopes of keeping them looking good for a few years.
     
  15. Jan 11, 2022
    BMoney

    BMoney Member 2024 Sponsor 2023 Sponsor

    Orange County, CA
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    I can't see spending $450 for Jet-Hot Coating when a can of header paint is less than $20.00. I could paint them and sand blast them and repaint them a number of times before it would make sense to do the Jet Hot Coating.
     
  16. Jan 11, 2022
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    You should be able to find somewhere local to you that can ceramic coat your headers for a few hundred dollars. That $20 paint might last a month….
     
  17. Jan 12, 2022
    truckee4x4

    truckee4x4 Grant Kaye 2023 Sponsor 2022 Sponsor

    Truckee CA
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  18. Jan 12, 2022
    BMoney

    BMoney Member 2024 Sponsor 2023 Sponsor

    Orange County, CA
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    Just got a quote and it is between $295-$400 to have them ceramic coated from Specialized Coatings in Huntington Beach, yikes!
     
  19. Jan 12, 2022
    supertrooper

    supertrooper Member

    moreno valley, ca
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    You might be better off returning the hedman headers and getting Advance Adapter headers that are already chromed or Samderson ceramic coated block hugger headers.
     
    Norcal69 likes this.
  20. Jan 31, 2022
    BMoney

    BMoney Member 2024 Sponsor 2023 Sponsor

    Orange County, CA
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    So I got a little work done on "Poppy" (Name bestowed upon her by my wife) this weekend. Timing Chain and cover put back on, harmonic balancer and pulley back on, heads put back on, rockers and push rods back in, intake manifold and valve covers also back on as well as a new mechanical fuel pump. Next weekend will hopefully be the water pump and pully, alternator, carb, exhaust manifolds, fan and radiator. Getting closer and closer to being able to hopefully start this thing back up.


    Anyone have any ideas on how to get the crankshaft bolt torqued to 140 ft/lbs as spec'd in the manual? I had a bear of a time and couldn't get it even with the vehicle in gear. I don't have any brakes right now so stepping on the brake pedal isn't really an option.
     
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