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1962 Jeep Willys Build

Discussion in 'Builds and Fabricators Forum' started by jeepstar, Oct 29, 2017.

  1. May 10, 2018
    55_Willys_CJ5

    55_Willys_CJ5 Nephews Visit 2017 2024 Sponsor 2023 Sponsor

    Southern California
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    Glad to read the rebuild resolved your fuel issue.
     
  2. May 15, 2018
    jeepstar

    jeepstar Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sheboygan
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    Hoping to install the ballast resistor and the new distributor tonight. If all goes well i can tackle the new muffler install as well. Im not holding out hope for getting those old nuts off the manifold flange studs. Been soaking them the past few days in P.B. blaster. Praying i dont have to buy a new manifold
     
  3. May 15, 2018
    jeepstar

    jeepstar Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sheboygan
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    20180515_162316.jpg

    Short of buying a new manifold, what are my options? PO welded the nut to the flange...
     
  4. May 15, 2018
    jeepstar

    jeepstar Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sheboygan
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    20180515_162938.jpg Problem solved. I ordered a new manifold.
    But now my other problem. One that I can't fix off the top of my head. These two bolt heads snapped off. It's the top Center one and the right one closest to the firewall.
     
  5. May 15, 2018
    Oldriginal86

    Oldriginal86 Member

    Pasadena, Md.
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    Nov 5, 2014
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    589
    On a positive note they aren’t broke off flush. Drive a nut onto the stud and weld it on. Then use your favorite method for removing tight bolts.
     
  6. May 15, 2018
    sterlclan

    sterlclan Member 2022 Sponsor

    exploring the...
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    I weld a washer then a bit mash some canning wax into the stud while it’s hot wait a little and wind it out. Lacking canning wax use a crayon.
     
  7. May 15, 2018
    Jrobz23

    Jrobz23 Member

    Northern, WI
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    Oct 3, 2016
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    I had the same two freeze. I did get the top one out but had to cut, drill, tap the rear.
     
  8. May 16, 2018
    dozerjim

    dozerjim Member

    western New York
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    Nov 22, 2010
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    x2....:waiting:
     
  9. May 16, 2018
    masscj2a

    masscj2a Member 2023 Sponsor

    Ware, Mass
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    I easy out them with heat. Usually grind them flay and center punch and drill them out. Takes a little time, but if you progress through the drill sizes and get down to just a little thread left, they spin right out. Just did it on my F Head, the distributor hold down bolt snapped off. Good luck.
     
  10. May 17, 2018
    jeepstar

    jeepstar Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sheboygan
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    Almost ready to install this! My other jeep needs some attention...but its registered and almost ready for the maiden voyage!
     
  11. May 17, 2018
    jeepstar

    jeepstar Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sheboygan
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  12. May 22, 2018
    jeepstar

    jeepstar Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sheboygan
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    20180522_173607.jpg 20180522_190804.jpg
    Done...new muffler..check

    I used an oxy/map gas torch to get the embers glowing hot, and then I tried to turn the studs out with a vice grips. no luck. then I tried to weld a nut to the stud. no go. the nut kept breaking off the weld. or the stud would break farther down the shaft. I ended up just building up gobs of weld on the stud shaft itself and using it as the "nut". then, with a little finesse of the vice grips and a lot of muscle power combined with a steady stream of curses, I managed to turn them out. I ran a tap through the hole to clean it up for insertion of the new bolt.

    the 2 studs that broke are actually in the water jacket, and I think that is the reason these two bolts were stuck and broke.

    while I got the new muffler on, I bumped the old fuel pump, which disturbed the gasket. so when I went to start it up, fuel was spraying everywhere. now I need to add fuel pump gasket to the list of things to get ASAFP. maybe by next winter she will be road worthy.
     
    Last edited: May 23, 2018
    tripilio, 73 cj5, Jrobz23 and 4 others like this.
  13. May 23, 2018
    ojgrsoi

    ojgrsoi Retired 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Weatherford, TX
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    Idk what it sounded like before but you will enjoy the quiet when you're done. Putt putt putt....
     
  14. May 23, 2018
    jeepstar

    jeepstar Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sheboygan
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    just ordered the fel-pro 5019 fuel pump gasket. hopefully I can come home next week to it sitting in the mailbox or on the front porch.
     
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  15. May 31, 2018
    jeepstar

    jeepstar Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sheboygan
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    Granted, im not a shipping magnate, but REALLY?!!

    20180531_174453.jpg
     
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  16. Jun 4, 2018
    jeepstar

    jeepstar Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sheboygan
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    Spent two hours fabbing a battery mount on the firewall. Once it was done to my satisfaction and mounted in the right place I decided to take apart the previous owners disgusting work of sheets of Steel and plywood sandwich together. To my surprise there was a brand new original battery tray under all that crap. lesson learned.
    20180604_143926.jpg
     
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  17. Jun 5, 2018
    jeepstar

    jeepstar Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sheboygan
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    all right, updated checked off "to do list"
    1. muffler system. the muffler is done, I picked up an International Harvester muffler to replace the muffler that came in the kit. the wife wanted straight pipes, I detest loud vehicles, so we compromised. it sounds good when you step on it.
    2. battery is properly mounted
    3. fuel pump gasket has been replaced, no more leaks
    4. installed the electronic distributor and a new ballast resistor last night.

    tonight's list entails:
    1. install new plugs/wires
    2. replace the coil. while hooking up the electronic distributor I noticed a large bulge in the coil. when I touched it the cap popped off and the oil was leaking out. this cant be good, right? so ive got a coil to pick up on the way home tonight.
    3. check and ensure timing is right since its all new ignition systems throughout.
    4. cut out the sidewall of a tractor tire for the body to frame bushing mounts. I was going to use some 1" spacers I had made from some thick rubber we have at work, but decided against that.
    5. test drive it on the trails at my house after its all said and done tonight.
     
    Last edited: Jun 5, 2018
    Jrobz23 likes this.
  18. Jun 11, 2018
    jeepstar

    jeepstar Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sheboygan
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    jeep is almost all ready mechanically. motor purrs like a kitten, the muffler is as loud as a tractor, and its reliable as all get out now.

    I am going to redo the brakes this week/weekend. going to put on 10" drums on the front and also all new wheel cylinders as well. a 10" drum is 50 bucks at a FLAPS, and 18 bucks on rock auto. hard to compete with that price difference. I was going to do the disk brake conversion on the front, but I will wait till winter to do it. I just want the wife to be able to drive it safely to and from work this summer.
     
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  19. Jul 8, 2018
    montanacj

    montanacj Member

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    Jul 11, 2012
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    Nice build thread, where did you source your floor pans from ?
     
  20. Jul 8, 2018
    jeepstar

    jeepstar Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sheboygan
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    Rock auto
     
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