80 CJ-5 repair/rebuild

Looking good, I have two more tubs if you need more practice.

 

Well, that's the plan after this one is is completed. I'd like to try my hand at a much older rig. I have to do SOMETHING to justify all the tools I've bought.

 

Excellent Weekend!
I finished work on the passenger side, flipped the tub and started on the drivers side. I changed my methods slightly this time. instead of cutting out ALL the rust and then replacing it, I took it one section at a time. This kept the tub from bending or sagging, and also gave me more original metal at each stage for new metal placement.


Also, I started on the outside of the tub, instead of the floor pan. This seemed to really help getting the pan the right size and with the proper curves. One problem on this side was the edges of the old gas filler indent was rusted out, so I had to patch in a BUNCH of little pieces to build up the area. Lots of welding, lots of grinding.



I changed how I did the rear fender rust, as well. I replaced a much smaller strip, and did NOT lap the new over the old. I find I get a much better patch if I butt weld the pieces and do a LOT of tack welds.


I also got the floor pan in and it went MUCH smoother than the passenger side. Nothing like a little experience to help things along


I gave the pan the initial bends and side lip, then just started beating on it and cutting excess metal out until it fit. I think I got a much stronger pan while at the same time drastically cutting down on the time it took. Of course, I had to replace the rear support just like the other side.


Another shot:

 

keep up the good work

 

Well, with both sides and floor pans pretty much done, it was time to turn my attention to the rear of the Jeep. I got lazy (and frustrated) at this point, and instead of carefully cutting out all the spot welds, I broke out the sawsall and proceeded to do major damage. Not that it mattered. Once the Bondo fell off, so did the tailgate.


Luckily, the rear deck needs to be replaced anyway, so cutting it out didn't hurt anything. However, I didn't think the rear fenders were in this bad of shape, so now I need to decide if I even want to keep them at all. I'd have to cut out the new metal I put on them to join to the sides, but I may have to.


The tailgate itself is a total loss. I'm not EVEN gonna try and replicate the original. It seems a stupid design to begin with, and pretty weak for hauling anything. I'm gonna use square tubing and sheet metal. Original? No. Better? I think so. 8)

 

nice!

great job...

 

Well, it's been a while since I posted anything. I've been puttering with the Jeep off and on, but I had a few other projects that took priority.

I got the new tailgate on. It's not original in design, but I really like the clean look it gives.


Funny thing was that the two sides didn't end up being the same height. Not sure why, but oh well. Also, I was off 1/8 of an inch in total width, whcih I didn't discover until I had stitched the tailgate to the rear deck.


I also finally got around to finishing the rear corners. I had left a small chunk on each side open because I flanged the sides, but couldn't keep that up on the corner. So these were butt welded.


And here is the nearly complete tub. I have to add the internal side braces in, and re-attach the main floor brace, but the cosmetic metal is finished.


Just another view of the tub.


Rear deck braces:


Firewall all cleaned and primered!


Next is the frame and body mounts. I am going to have to replace some of the frame, and strap other sections. Honestly, it should be replaced, but I can put that off until one becomes handy.

 

awsome job!!!

 

I just noticed that your using flux core wire. What model Lincoln are you using? Wire size?

 

I'm using .035 wire from HF, and I'm not sure what the model is of the welder. It's my father-in-laws. Mine from HF is WAY too hot for the sheet metal. I like the many different settings on the Lincoln, but I'd be stuck if it was my only welder. The highest setting on it isn't high enough to weld heavy stock like I can with my HF rig.

 

Thanks guys. It seems like this project will never end. I've discovered that the more you do on a Jeep, the more you WANT to do. I mean, what's the point of putting a new tub on a rusted out frame? And if you have a new tub AND a new frame, don't you really NEED that 401 you've been dreaming about????
R)

 

My Miller 185 does good on the thicker stuff but I have an awful time on the thin stuff. I was thinking of getting a 110 volt unit for the thin stuff. Maybe use the Co2 with it. I amusing the Argon/Co2 mix on the Miller.

 

try using thinner wire .24/.21 with the miller 185 and use gas instead of flux core .You can use a lower temp.

 

Both of my machines are 110 units, but I can do 3/8 stock with my HF unit with no problems. Of course, the duty cycle is to low for serious work. Since I don't have the tools to work with thicker stock, the little boxes work great for me. I mean, this morning I had to weld a broom handle back together, and patch up an old wheelbarrow. Not exactly heavy material.

 

Well, it's done. I haven't posted in a long time because there didn't seem to be a lot of action on the thread here, and I couldn't justify the time keeping up a thread on two sites.
All in all, I am very happy with the way it turned out. I like the look of the satin black paint, and I'm very glad I left the welds rough and uncovered. The whole point was to make it look as low-key and functional as possible, and I think I got it.