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1965 CJ5 Rebuild

Discussion in 'Builds and Fabricators Forum' started by JeepDriver, May 5, 2008.

  1. May 21, 2008
    JeepDriver

    JeepDriver Member

    Paradise, NL, Canada
    Joined:
    Sep 12, 2005
    Messages:
    278
    Small update.

    Front axle is cleaned up and ready for rebuild. I don't like working on greasy stuff :) My new rear cross member arrived and has been welded in place. New shackles, bushings, u bolts, engine mounts, center pins for the springs and transfer case bushing have arrived as well. Next up on the list is replacing all the bushings and rebuilding the spring packs.

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    Totally unrelated.

    Here is the tiny shed I am building this thing in. It was for my woodworking tools but is pulling double duty as the wife says only clean stuff is allowed in the garage on the house.

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    And this folks is why my neighbors hate me :beer::beer:

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    mike
     
  2. May 22, 2008
    jjber_70

    jjber_70 Wicked Willys Pickup

    NOR*CAL
    Joined:
    Sep 8, 2007
    Messages:
    9
    I love your pictures keep them coming! Great project my uncle has the exact same year cj as you and he did boulder mountain in idaho last summer with it, we are going again this july but this time im bringing my big green willys pickup to show up his CJ!:twisted:
     
  3. May 23, 2008
    JeepDriver

    JeepDriver Member

    Paradise, NL, Canada
    Joined:
    Sep 12, 2005
    Messages:
    278
    Lots of progress today.

    Springs all done with new center pins, bushings and clean and painted. Ready for install.

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    Steering box and column reinstalled

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    Crossmember and skidplate reinstalled

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    New engine mounts and hardware ready for install

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    And installed

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    Front axle back in

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    Rolling chassis once again

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    Body in the shed and ready for repairs

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    Mike
     
  4. May 23, 2008
    Brian P

    Brian P Member

    Clarkdale Arizona
    Joined:
    Nov 24, 2007
    Messages:
    650
    Keep up the good work :) Looking good!
     
  5. May 29, 2008
    JeepDriver

    JeepDriver Member

    Paradise, NL, Canada
    Joined:
    Sep 12, 2005
    Messages:
    278
    It's been a little while. Started working on the body tonight.

    Here you can see the horrible patch on the pass. side.

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    And what was under it. Not as bad as the patch was.

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    Started cutting out the rest of the pass. side.

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    Going to have to replace both lower rocker panels, pass floor pan and patch up a bunch of small holes.

    Also the PO cut the hell out of the rear fenders to fit 36's.. I am going to make new pieces to weld in here and fix the radius of the openings instead of buying new side panels.

    [​IMG]

    Mike
     
  6. May 30, 2008
    bardp

    bardp Power Steering

    Concord, NC
    Joined:
    May 24, 2006
    Messages:
    69
    Another CJ, Mike? Boy you work fast. If you need any help when moving the body around just let me know.
     
  7. May 31, 2008
    JeepDriver

    JeepDriver Member

    Paradise, NL, Canada
    Joined:
    Sep 12, 2005
    Messages:
    278
    Bardp,
    I regretted selling the last one so much I just had to get another. They are so easy to build that it is actually relaxing.

    Mike
     
  8. Jun 1, 2008
    JeepDriver

    JeepDriver Member

    Paradise, NL, Canada
    Joined:
    Sep 12, 2005
    Messages:
    278
    Did some metal work today and replaced the drivers side floor pan that was rotted.

    Started by cutting out this

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    Ended up with this when all cut out

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    Rebuilt the support brace for the floor and side panel

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    Made up a piece to replace the part I cut out.

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    Finished the bend for the foot area and welded in those pieces.

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    Cleaned up the welds and ended up with this

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    Shot a coat paint to keep it from rusting in the humidity.

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    New rocker panels and passenger panel are supposed to show up on Tuesday. :beer::beer:

    Mike
     
  9. Jun 1, 2008
    jayhawkclint

    jayhawkclint ΜΟΛΩΝ ΛΑΒΕ

    Oklahoma City, USA
    Joined:
    May 18, 2006
    Messages:
    2,622
    Man, that's nice work on the floor pan.

    I agree with you about building these earlies; downright therapeutic.
     
  10. Jun 4, 2008
    JeepDriver

    JeepDriver Member

    Paradise, NL, Canada
    Joined:
    Sep 12, 2005
    Messages:
    278
    A little work done yesterday and today

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    Mike
     
  11. Jun 5, 2008
    canuckCJ

    canuckCJ Member

    Channahon, IL
    Joined:
    May 6, 2006
    Messages:
    98
    nice metal work. I'm certainly jealous. :p
     
  12. Jun 7, 2008
    JeepDriver

    JeepDriver Member

    Paradise, NL, Canada
    Joined:
    Sep 12, 2005
    Messages:
    278
    Cleaned up the engine last night and this morning.

    [​IMG]'

    It was supposedly rebuilt a few years ago.

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    Engine getting ready to go back in the chassis.

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    Back in and painted. I let it sit in the 100 deg heat today for 4 or 5 hours. The paint is baked on now. :beer:

    [​IMG]

    [​IMG]

    Mike
     
  13. Jun 8, 2008
    willys59cj5

    willys59cj5 Sponsor

    Gilroy, CA
    Joined:
    Jun 1, 2005
    Messages:
    660
    Nice job! You are flying along for only one month. Wish I worked that fast.
     
  14. Jun 8, 2008
    SUCKYJUNK

    SUCKYJUNK Painter

    New Lothrop, MI
    Joined:
    Mar 16, 2008
    Messages:
    79
    Nice progress!
     
  15. Jun 8, 2008
    JeepDriver

    JeepDriver Member

    Paradise, NL, Canada
    Joined:
    Sep 12, 2005
    Messages:
    278
    Started rebuilding the hat channels today. I was looking to buy some but the budget is tight and I decided to build my own. These might not be optimal but they will do. I used 16ga sheet to form the channels. I used a cut off wheel to score the metal and then formed it using a piece of 4" channel and a body hammer. This allowed me to make C-channel the right size and I cut 3/4" strips for the base of the hat. I spot welded the strips and then butt welded the channel to the strip. It is turning out ok. Very time consuming but I have more time than money:)

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    Mike
     
    Last edited: Jun 8, 2008
  16. Jun 9, 2008
    djbutler

    djbutler Sponsor

    Rio Linda CA
    Joined:
    Nov 5, 2007
    Messages:
    727
    Mike,
    Great job on the metalwork! It looks like you started with one a little further gone with rust than mine was, but it's coming along just fine.
    I just updated my thread on Don's '69 rebuild. I've just finished doing a lot of the same stuff you did, so I know just how much work it is.
    At the rate you're going, you'll be wheeling before I am!

    Don
     
  17. Jun 9, 2008
    JeepDriver

    JeepDriver Member

    Paradise, NL, Canada
    Joined:
    Sep 12, 2005
    Messages:
    278
    Thanks Don. I saw your thread and you are by far more skilled than I am with the metal work. It is fun and the time flies when you are working on them so it doesn't seem like that much work.
     
  18. Jun 10, 2008
    JeepDriver

    JeepDriver Member

    Paradise, NL, Canada
    Joined:
    Sep 12, 2005
    Messages:
    278
    I showed everyone earlier in the thread why my neighbors hate me. Now....this is wy my wife hates me

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    Mike
     
  19. Jun 12, 2008
    JeepDriver

    JeepDriver Member

    Paradise, NL, Canada
    Joined:
    Sep 12, 2005
    Messages:
    278
    Ran out of flux core wire so no welding tonight. I cleaned up a few more parts and had a bunch of stuff arrive form Jeepdoc.

    Manifold laid back in place

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    Parts (new front and rear axle diff cover gaskets, new exhaust gaskets, water pump gasket, clutch and brake return springs, wheel cylinder rebuild kits and other asst goodies.

    [​IMG]

    Also cleaned up some other parts and pieces due to the lack of welding wire.

    [​IMG]

    Mike
     
  20. Jun 20, 2008
    JeepDriver

    JeepDriver Member

    Paradise, NL, Canada
    Joined:
    Sep 12, 2005
    Messages:
    278
    It's been awhile since I posted last. I got sidetracked with bathroom remodels and writing yearly performance reviews for my team at work. I have made some progress but it has been slow. I managed to start on the passenger side floor and get the exhaust manifold reinstalled. I had to drill and tap a broken exhaust manifold stud and that was not alot of fun.

    Floor cut out

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    Manifold and Valve cover reinstalled with new gaskets

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    Mike
     
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