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Forest Service 3A

Discussion in 'Builds and Fabricators Forum' started by garage gnome, Jan 10, 2014.

  1. Mar 11, 2021
    givemethewillys

    givemethewillys Been here since sparky ran it. 2022 Sponsor

    New Kent, VA
    Joined:
    Jun 21, 2005
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    From what I understand, the original track kick brackets follow the round 6-bolt shape. When they switched to the flanged axle in '70, the bolt pattern changed to a more square 4-bolt shape. The new brackets are backwards compatible, but the old ones aren't.
     
  2. Mar 11, 2021
    garage gnome

    garage gnome ECJ5 welder

    Western MA
    Joined:
    Jun 19, 2009
    Messages:
    3,083
    Finally got the front swap done. Just have to make up one more brake line over to the passenger side.

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    I have been using nickel copper brake line. It is so nice to work with. My Eastwood brake flare tool makes a perfect flare every time.

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  3. Mar 17, 2021
    garage gnome

    garage gnome ECJ5 welder

    Western MA
    Joined:
    Jun 19, 2009
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    3,083
    Finally finish up the rear disc brake swap. I also wired up the parking brakes. Now all I have to do is bleed the brakes and try it all out!

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    And I swapped the master cylinder from a drum-drum to a disc-disc one.

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  4. Mar 18, 2021
    garage gnome

    garage gnome ECJ5 welder

    Western MA
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    Jun 19, 2009
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    Finally got Ted back on his tires and I can't wait to take him for a test drive! I could override the brakes just by hitting the pedal once. If I pumped them up, I could stall him. I think I have to bleed them again. As for the parking brake, I love it! The best parking brake a jeep could ever have!
     
    jeepstar likes this.
  5. Mar 19, 2021
    Steve's 70-5

    Steve's 70-5 Active Member

    Louisville, Ky
    Joined:
    Nov 12, 2009
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    1,381
    If you used the remote reservoirs, they leak. I would put a piece of stainless steel between the reservoirs and what you mounted them to. Bend the SS to move any leaking brake fluid away from any painted surface.
     
    Steamboat Willys likes this.
  6. Mar 19, 2021
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor

    USA
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    Oct 25, 2006
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    5,798
    Is the Ford Fusion rear brake really the holy grail of rear Ebrakes for early jeeps? I have such high hopes.
     
  7. Mar 19, 2021
    garage gnome

    garage gnome ECJ5 welder

    Western MA
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    Jun 19, 2009
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    I didn’t use the remote reservoirs.
     
  8. Mar 19, 2021
    garage gnome

    garage gnome ECJ5 welder

    Western MA
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    I’m really impressed by them. The road to my house has a really steep hill, I’d say a 15-20 percent grade. The parking brake held perfect.
     
    47v6 likes this.
  9. Mar 19, 2021
    Jeepsterjim

    Jeepsterjim Member

    Lincoln, CA
    Joined:
    Apr 25, 2019
    Messages:
    401
    Nate
    I also have the Fusion E-brake set up but lack how to wire the darn things up. Can you post how you wired yours up? Thanks, Jim
     
  10. Mar 19, 2021
    garage gnome

    garage gnome ECJ5 welder

    Western MA
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    You need a 6 pin dpdt switch and you cross the two outer terminals. Some people do two switches, one for each side. I only did one switch. This is the switch I used. I swapped out the on-off-on label for a on-off one to represent the way to engage and disengage the parking brake. I’m going to add a 10 amp automatic reset circuit breaker so it will pop when the brake is fully engaged. My parking brake switch is the farthest one of the left in the aluminum panel of switches.

    Baomain Momentary Toggle Switch DPDT (ON)-Off-(ON) 3 Position 6 Screw Terminal 125VAC 20A with Rainproof Cap: Amazon.com: Industrial & Scientific

    And this is how you wire the switch to reverse the motors. If your calipers have the pigtail off them, cut the factory plug off and connect your wires there. I temporarily wire nutted some wires on until I figured out which one did which. Then I made up a nice harness and soldered all the connections together. These butt connectors are your friend. As for the hoses, the sae 3/16 brake nuts did screw into them and tightened down. I don’t know if the stock ford hoses are standard or metric thread

    https://www.amazon.com/Connectors-H...uPWNsaWNrUmVkaXJlY3QmZG9Ob3RMb2dDbGljaz10cnVl

    Google Image Result for https://forum.allaboutcircuits.com/proxy.php?image=http%3A%2F%2Fwww.hunt101.com%2Fdata%2F500%2FDPDT_switch.jpg&hash=f3fa88b9bb5daca3b03218505c1d7a6f
     
    Last edited: Mar 19, 2021
    bigbendhiker and Fireball like this.
  11. Mar 19, 2021
    73 cj5

    73 cj5 Not ready for the junkyard yet

    Clinton, Mississippi
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    Jan 10, 2014
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    2,137
    Stock ford hoses are 10mm banjo and metric thread on the other side. I posted the connector diagram and it lists positive and negative wire colors and gauge.
     
    47v6 likes this.
  12. Mar 20, 2021
    Jeepsterjim

    Jeepsterjim Member

    Lincoln, CA
    Joined:
    Apr 25, 2019
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    401
    I have the hoses and the e-brake wiring looms. Both L&R wire looms are the same. Thanks for posting how you wired yours and the parts!
     
  13. Mar 20, 2021
    Jeepsterjim

    Jeepsterjim Member

    Lincoln, CA
    Joined:
    Apr 25, 2019
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    401
    I also have a flanged d-44 out of a '71 cj-5. Did you have any trouble with the rotors and wheel studs?
     
  14. Mar 20, 2021
    garage gnome

    garage gnome ECJ5 welder

    Western MA
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    I drilled the holes out to 5/8”
     
  15. Mar 20, 2021
    garage gnome

    garage gnome ECJ5 welder

    Western MA
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    Last edited: Mar 20, 2021
  16. Jun 21, 2021
    garage gnome

    garage gnome ECJ5 welder

    Western MA
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    I am very impressed by how much flex I am getting out of Ted with the rear leaf springs in the front. My RTI ramp score is about an 820, whatever that means. The right rear and left front are tucked in the fender wells nicely.

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    dozerjim, 73 cj5, Clayton and 8 others like this.
  17. Dec 22, 2021
    garage gnome

    garage gnome ECJ5 welder

    Western MA
    Joined:
    Jun 19, 2009
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    One last final mod for ole Ted. The mighty Go Devil still isn't quite powerful enough in my opinion, so it is time to say goodbye. I have been planning on a TDI swap for the past year. About a year ago, I picked up a 1998 VW Jetta. Why a 98? Well it has an AHU engine which is a little more swap friendly than the later ALH. The AHU has a nearly flat back of the head. The only thing back there is a heater hose connection. The later ALH has a cam driven vacuum pump on the back of the back the head. So the firewall has to be severly modified to make it fit. I want everything on my jeep to me bolt on and reversible. To this point, it all has been.

    I already swapped on an ALH intake, the AHU one points to the "rear" of the engine. And I did the timing belt.

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    The "back" of the engine.

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    Over the summer, I was scrapping a bunch of jeeps. I saved half a frame so I can drop the engine in along with a spare T90 and steering box. Once I get the engine mounts figured out, the rest is easy peezy. Now why am I using a t90 in my jig and I list a T18 in my signature? Well, if you remember back, I modified my T18 to bolt up to the L head with a T90 bell housing. I also left my engine in the original location. So by using the t90 in the jig, everything should line up when I go to put it in Ted.

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    After a bunch of measuring, internet searching and talking with other people who have done the swap, I gave my buddies the drawings for the crankshaft adapter and bell housing adapters so they could cut them out on their water jet. I have the crank adapters mostly done. Just have to counter bore them and face them off. Yes, I am making two sets of adapters. One for my jeep and one for a friend unless someone else needs measurements, I can get them. I can also cut more parts out in the future for anyone else who wants to do the swap.

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    73 cj5, blalp!, jeepstar and 2 others like this.
  18. Dec 22, 2021
    Howard Eisenhauer

    Howard Eisenhauer Administrator Staff Member

    Tantallon, Nova...
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  19. Dec 22, 2021
    garage gnome

    garage gnome ECJ5 welder

    Western MA
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    Almost forgot to post some disturbing pics of how I move junks around and pull their engines. :twist: And just an FYI, it is a real PITA to pull the engine wiring harness out!

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  20. Dec 26, 2021
    garage gnome

    garage gnome ECJ5 welder

    Western MA
    Joined:
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    Crankshaft adapters are all done. I used my friend's rotary table for the counter boring. So much easier that way.

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    73 cj5, mortten, dozerjim and 2 others like this.
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