1. Registration trouble? Please use the "Contact Us" link at the bottom right corner of the page and your issue will be resolved.
    Dismiss Notice

Cjtj Build Thread

Discussion in 'Builds and Fabricators Forum' started by 1947cj2a, Oct 31, 2020.

  1. Jan 17, 2023
    1947cj2a

    1947cj2a Member

    PNW
    Joined:
    Nov 11, 2017
    Messages:
    223
    To me it looks like the door is bolted right to the windshield frame and that meets up pretty good with the corner of the top. I will have to do a little more research. I like the top, it has big windows, the door side glass rolls down at some point it was insulated.

    Its a Kemco All Steel Cab Ser No. F 2A 3A 300A
     
  2. Jan 17, 2023
    1947cj2a

    1947cj2a Member

    PNW
    Joined:
    Nov 11, 2017
    Messages:
    223
    so the w.f. is at 15* relative to the cowl but it measures at 68" from the top of frame to top of tailgate. the 15* sounds about right according to the nets but it should be closer to 66.5" which if it was it would make that fit worse. as it would be leaning back even more.

    Edit
    I wonder if its a 5 top
     
  3. Jan 17, 2023
    Fireball

    Fireball Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Pullman, WA
    Joined:
    Feb 9, 2018
    Messages:
    5,690
    A 5 top would have perfectly straight sides since the windshield is the same width as the body. It looks like yours angles in a little over the door openings so it would have to be for some sort of flatfender.
     
  4. Jan 17, 2023
    Stakebed

    Stakebed Member

    Lake Co....
    Joined:
    Aug 2, 2022
    Messages:
    670
    @1947cj2a I really like your wheel color. Just read the whole thread.
     
  5. Jan 17, 2023
    1947cj2a

    1947cj2a Member

    PNW
    Joined:
    Nov 11, 2017
    Messages:
    223
    thanks! I was actually going for a more red color but its grown on me.
    Edit,
    picking up the doors from a buddy that was storing everything. will see how they all fit.
     
    Last edited: Jan 17, 2023
  6. Jan 28, 2023
    1947cj2a

    1947cj2a Member

    PNW
    Joined:
    Nov 11, 2017
    Messages:
    223
    [​IMG]
    Went to the paint store and got a sample color matched in Krylon direct to metal oil based paint. I think its pretty close. Since I dont plan on adding body filler i was just going to paint with the Krylon. I have a pretty good idea of how its going to turn out but then again not going for anything special. the body has so many dents that i would have to bondo the whole thing and at that point i wouldnt want to take it out into the woods.

    [​IMG]
    I am also going to give a shot at making my own seat covers. the brother in law has a sowing machine as the mother in law so i am going to see if i can borrow it. Thinking of just making slip on covers and adding some 1" high density foam.

    [​IMG]
    Started on the cage. 1-1/2 x 0.120" DOM tubing. made three hoops. two will go to on the rear fenders and one will go across the windshield frame. with some tie bars. Thinking of attaching the front hoop to the dash, similar to the way my TJ is. Also picked up some three point belts from the Pick and Pull from a WJ. If i am going to have a cage I am going to have seat belts.

    [​IMG]
    and finally took it for its first drive. I promptly ran out of fuel down the street from the house, dog was not amused. and this is where the problems started.
    it started acting like a carburetor when starting off from a stop i had to feather the throttle. I suspect its the fuel pump?
    the other issue is that the clutch got progressively worse and now wont go into gear. even with the rear tires on jack stands and in gear i can push in the clutch and the tires wont spin.

    [​IMG]
    The throw out bearing is coming out i think its at about 1/2" of throw. however i can not spin it when the pedal is not depressed. it also spins when the engine is running but not engaged and i can not slip in any feeler gauges between it and the clutch fingers.

    I was planning on taking the body to paint so I will be investigating it further once that happens. I will call Tilton Eng. and see if they have any ideas for trouble shooting.

    [​IMG]
    I really wanted to do an external slave cylinder with a clutch fork but due to the two big pumps on the side of the transmission I was not able to. I did contemplate cutting them off and re welding the case in the very beginning
     
  7. Jan 29, 2023
    Fireball

    Fireball Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Pullman, WA
    Joined:
    Feb 9, 2018
    Messages:
    5,690
    Make sure you have some slop in the clutch pedal when it's released. It almost sounds like it's not returning the clutch master cylinder all the way to release the pressure.

    The Jeep looks fantastic by the way.
     
  8. Jan 29, 2023
    1947cj2a

    1947cj2a Member

    PNW
    Joined:
    Nov 11, 2017
    Messages:
    223
    Thanks!
    I am pretty sure i had free play in the clutch, I also have a physical stop on the peddle as Tilton says no more then 1" of travel on the master cylinder. In the picture above you can see some pitting/scarring on the slave/throwout bearing. that might have something to do with it.

    Also for that brief time it did run it was great, i had a smile on my face the entire time even with out a windshield in 40*. tons of power and very responsive, steering was tight and easy to turn even at a dead stop. once i get the last of the bugs figured out I know it will be a very capable/versatile vehicle.
    I also need to re think my shocks, I dont think the JK ones are going to cut it. its a very bouncy ride.
     
    blalp! and Fireball like this.
  9. Feb 12, 2023
    1947cj2a

    1947cj2a Member

    PNW
    Joined:
    Nov 11, 2017
    Messages:
    223
    I was out of state on a job assignment so not much work the week before. I was able to figure out the high idle and stuttering. Apparently the computer needs a VSS signal (vehicle speed sensor) pretty much i need to hook up the speedo signal some how. So iam thinking if there is no after market solution for a pass through cable adapter to electronic connection for a ChyrCo computer I have two options.
    One use a TJ/XJ wheel type build a bracket and have it driven or spun from the E brake drum. If i have to use the Dodge one build a bracket but modify the ring that Dodge uses from the rear differential once again make it fit on the e brake drum. I dont need it to give me accurate speed i just need to satisfy the signal.

    I did get the cage all done. just need to finish welding once i pull it all apart for paint. I build the cage so it should fit underneath a hard top if I ever go that round. I do plan on welding or bolting up some sheet metal as a bikini top. I also plan on installing some three point seat belts.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
    This will all get trimmed ground down once its off and finished welded. I really couldnt come up with a good way to attach the cage to the dash. I could have done with out the front hoop but wanted to be able to run the sheet metal as a bikini top. plus more protection is is always good.
    I also made plates on the back side on all attachment points.
     
  10. Feb 19, 2023
    1947cj2a

    1947cj2a Member

    PNW
    Joined:
    Nov 11, 2017
    Messages:
    223
    [​IMG]
    It might look like I am just starting this build but it was time to take it all apart again.
    Fix some oil leaks in the running gear, trouble shoot the clutch, come up with a VSS to keep the computer happy, and paint the body

    [​IMG]
    Hopefully I will never have to do this again

    [​IMG]

    [​IMG]

    [​IMG]

    I had Herm rebuild these and put them all together for me many years ago. once I added oil to everything it started to leak right away. leaked out of the seals on the PTO, from mating surfaces anywhere where it could leak it leaked. I cant blame him since all these sat for so long.
    I had pretty good success on my 5 when I resealed it many years ago. The only place it leaks from is from the one spot on the oil pan where i pinched/tore the gasket
     
    blalp!, dozerjim, ITLKSEZ and 4 others like this.
  11. Feb 27, 2023
    1947cj2a

    1947cj2a Member

    PNW
    Joined:
    Nov 11, 2017
    Messages:
    223
    [​IMG]
    color matched up pretty good.

    [​IMG]
    It turned out about as well as can be excepted...really close to original Picket Gray
    Still need to paint the fenders, hood, W/F, tailgate a few other small things

    [​IMG]
    installed transmission with out bell housing to triple check the clearance from bearing to clutch. made some small adjustments.

    [​IMG]
    started reinstalling running gear after re sealing, cut a hole in the bell housing to help trouble shoot in the future. Got as far as re installing the O/D unit and realized something is missing.

    [​IMG]
    Missing oil scoop.
    at least I only put a couple of miles on it, it was still packed with assembly lube, and i am glad i took it all apart to re seal. this could have been expensive.

    Also cleaned up the wiring a little bit and found my VSS sensor wiring, glad i didnt cut that one out.
     
    jeepstar, vtxtasy and Fireball like this.
  12. Mar 5, 2023
    1947cj2a

    1947cj2a Member

    PNW
    Joined:
    Nov 11, 2017
    Messages:
    223
    Finished painting everything, on Saturday i drove down to Daryls and picked up the missing oil scoop for the OD unit. I ended up canceling the check i sent for the gaskets. I think I am done sending checks... Made my own gaskets for the PTO and PTO adapter and figured out what oil seals the PTO output shafts needed. Took Sunday off from working on the Jeep and took the wife and dog for a Sunday drive on the ferry to Poulsbo WA then to Port Townsend WA, it was nice to take a brake.

    [​IMG]
    Painted, starting the reassembly

    [​IMG]
    OD unit back in, PTO ready to go in. home made gaskets.

    [​IMG]
    Maritime museum in Poulsbo WA

    [​IMG]
    Matching color scheme to the 2A...
    [​IMG]
    Light house in Port Townsend WA built in 1879 I think, before WA was a state.
     
    Last edited: Mar 5, 2023
  13. Mar 30, 2023
    1947cj2a

    1947cj2a Member

    PNW
    Joined:
    Nov 11, 2017
    Messages:
    223
    [​IMG]

    [​IMG]
    Before I left for my work trip, a couple of weeks ago i was able to finish up the windshield. I took the frame to a local glass guy and for 250 he cut new glass and installed it. I think it was a pretty good deal seeing as glass alone online was in the 150 not counting shipping and my time and then buying tape. To me it looks like it has a slight tint.

    [​IMG]
    I came back from my work trip on Saturday, been busy with getting ready for EJS but today I was able to put the body back on. Slowly but surly its getting closer.
     
  14. May 6, 2023
    1947cj2a

    1947cj2a Member

    PNW
    Joined:
    Nov 11, 2017
    Messages:
    223
    got some work done the last couple of days
    [​IMG]
    installed seat belts

    [​IMG]
    made a cover for the pto

    [​IMG]
    made some cup holders and a cell phone tray

    [​IMG]
    made some heater vent holders and a thing for the heater to move heat to different areas

    [​IMG]

    [​IMG]
    installed VSS with a short piece of speedo cable

    [​IMG]
    went for a drive

    [​IMG]

    and still having issues. it still idles at 1050. Plugged in a factory jeep VSS and spun the gear and the RPMS come up, plugged in the new VSS spun it with a short piece of square rod and the idle comes up. So I dont think its the computer. back to square one.

    and the clutch stopped working again. its loosing pressure/sucking air. looked around when trying to re bleed it and found the culprit.
    [​IMG]
    Its leaking on the bleed hose between the crimp for the bleed fitting and the steel braded line.
    any one know if you can get a field fitting for this type of hose?
     
    Rich M., 47v6, Fireball and 2 others like this.
  15. May 7, 2023
    Norcal69

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

    Northern California
    Joined:
    Sep 6, 2014
    Messages:
    3,562
    If you cut the hose end off you can see if it’s rubber or PTFE lined hose. Looks like -3 AN hose, the replacement hose end should use a “olive” that goes under the steel braid and over the inner liner.
     
  16. May 7, 2023
    1947cj2a

    1947cj2a Member

    PNW
    Joined:
    Nov 11, 2017
    Messages:
    223
    I emailed the manufacturer to find out what kind a hose they use. If I can use a compression fitting that would be great.
    I don't want to cut the hose right now as it's some what keeping the oil in
     
  17. May 7, 2023
    1947cj2a

    1947cj2a Member

    PNW
    Joined:
    Nov 11, 2017
    Messages:
    223
    [​IMG]
    solved the high idle issue...missing o ring on number one injector. found it by spraying some starting fluid...

    [​IMG]
    from 1050rpm to normal

    [​IMG]
    mounted the license plate
    all thats left is
    shifter boots
    bikini top of some sort
    and the leaky clutch bleed hose
     
  18. May 20, 2023
    1947cj2a

    1947cj2a Member

    PNW
    Joined:
    Nov 11, 2017
    Messages:
    223
    I got the clutch issue resolved, waiting for a field fitting to come in hopefully it will be ready to roll to eastern WA for the Memorial Day.

    [​IMG]

    [​IMG]

    Got the new seat covers from Big Willys Jeep. they fit great, i like that they have front pockets and I got the optional rear pockets. this way I can stuff a jacket in there on trips. I really wish they made something for the rear seat just to get it to match.
     
  19. Oct 1, 2023
    1947cj2a

    1947cj2a Member

    PNW
    Joined:
    Nov 11, 2017
    Messages:
    223
    I havnt done much. for many reasons. but now that I have a little extra room to shuffle vehicles around my garage has opened up a little bit. I couldnt keep the old Dodge car out side so during the winter months when its not driven i always had a blocked space. Anyway, back to the CJTJ

    [​IMG]
    I was having issues with a fuel surging issue, the thing would fall flat on its face. two things, i dont have a surge tank and I didnt install a pressure regulator. it was a pretty big oversight on my part but i assumed that the 2.5L didnt need it since it didnt have a return to tank line. however it still has a pressure regulator on top of the pump in the tank. so I ordered one, and holly fuel mat to deal with potential issues.
    I also ordered a new master brake cylinder. I should have done this from the get go. remote mounted reservoirs should make my life easier.

    [​IMG]
    Some time ago I also got the new foam for the rear seat to match the fronts.

    So things really left
    Paint a few things,
    noticed a good amount of loose body mounting bolts, this could have been as simple as i forgot to tighten or they loosened up after first driving it.
    need to fix some minor light issues. currently i have the running lights wired so when you pull the head lights on the running lights also stay on. i believe they should turn off.
    hi beam indicator light looses ground
    finish shifter boots.

    I think thats it for now...
     
  20. Nov 15, 2023
    1947cj2a

    1947cj2a Member

    PNW
    Joined:
    Nov 11, 2017
    Messages:
    223
    I have been plugging away when I get a chance to work on this. Wish I had more time to work on it but work has actually had me busy.

    [​IMG]
    Drilled out a bigger hole in the bottom of the tank

    [​IMG]
    Made a ring to weld to the bottom of the tank which would allow a cap with a -6 AN fitting to get bolted on. Welded the inside lip to keep fuel from leaking out

    [​IMG]
    cap with the -AN fitting, welded to a bent SS 1/2" line which is threaded to the fuel mat. this all gets installed into the tank.

    [​IMG]
    Installed the fuel pressure regulator, its bigger then I like. I need to run the return line back to the top of the tank

    [​IMG]
    I couldnt find a center dump manifold or a header. I decided to cut the factory manifold and rotate the collector and weld it back on. I do not do much cast iron welding. many options and opinions. in the end i went with SS filler rod. I have braze rod but from what gather thats more for fixing cracks not for something that will have some weight hanging on it. I thought about wetting the ends of the cut then welding that but decided to just go for it hope for the best.

    [​IMG]
    I have gotten as far as a quick test fit. next is to remove, and finish weld using pre heating and post slow cooling. I had to do this in order to gain as much room from the exhaust to the master brake cylinder.

    I have about a week left in Korea. will see how busy the holidays get though. maybe next year...
     
    Danefraz, Stakebed, Fireball and 6 others like this.
New Posts