Project...Kahuna 66 cj6

here;s some fun reading I found while your waiting on mine to be done
http://home.kendra.com/xjdlgill/converti.htm
Jim S.

 

finally got around to tearing down the 6 for upgrades. It took half the day to get the garage cleaned/organize enough to start . Wish it would go back together as quickly as it comes apart

I ordered the 3 1/2" yj springs from Bob Supplee, should be here next week. I'm gonna do a ubolt reversal when I'm doing the swap, I'll fab it all up here rather than purchase aftermarket. I also ordered a hydro clutch kit made by CNC out of San Diego
Looking forward to nights in the garage, bloody knuckles, obcene words., and the reward of building it my way
Jim S.

 

so we got the drivetrain pulled today, first shot are the 289 and the 302 side by side

second shot is the trans/TC/OD......you can see in the pics a couple problems we found.....one of the motor mounts was split in half, and the trans mount was seperated in 2 pieces

add them to the list of parts we'll need to purchase.....makes me wonder if that's been the problem w/ OD engagement all along. The TC leaks like a sieve, not looking forwardto rebuilding it
Jim S.

 

so I got the OD removed and the TC seperated from the trans. The TC whines badly so I thought I would replace it w/ the original low mile TC thinking the intermediate shaft would be in better shape. Problem.....the case I took off is a big hole, the original is a small hole ....it's never easy
Looks like the OD may need to go to Herm
Good news....my BDS 3 1/2" yj springs should be here in the next few days
What was I thinking!....seems like I just had this all apart!!!!!!!!!!
Jim S.

 

OK I tackled the holy grail this afternoon. After some convincing by a couple forum buddies I dis assenbled the Warn OD for inspection

It wasn't as bad as I had thought and the only parts I'm going to replace are the syncro dogs/springs and the gaskets
I'm also going to order a rebuild kit from Herm for my D18.....might as well do it all while it's apart
Jim S.
ps....I didn't tear the planetary unit apart completly as it all moves smooth as a babies behind

 

worked on pulling the springs/shackles while I'm waiting for parts for the OD and the TC. For those that did the Aug Rubicon trip.....I had to dig all the wood out of the U bolt skids from that last log on the way out R).
Take a look at the size difference between the new YJ 3 1/2" lift springs and the old CJ springs. Also put the old and nrw shackles side by side



I'm working on cutting off all the spring hangers from the frame now, I'll start fabbing the shackle reversal parts after that
Jim S.

 

R) I brought some of that log home with me too.

 

lots of stuff coming together, this is gonna be a busy thread for the next few weeks . I'm taking 4 days off next week and applying all the time off to getting the 6 back together.
I recieved the OD parts and TC rebuild kit from herm today. I had the square bed ubolts bent up yesterday for the ubolt flip. I also have the 1/2" flat stock for the ubolt plates. I bought new motor mounts and a trans mount earlier this week. I pulled the gas tank and skid and straightened them out from the damage done on the 'Con. I located a in tank fuel pump to feed the mighty 5.0, and will pick it up this weekend. The hydro clutch kit should be here any time.
Gonna have fun this weekend and next week!
Jim S.
ps....almost forgot....also had a metal supply bend up custom brackets for the shackle reversal and YJ spring swap

 

I got about half the brackets removed from the frame before I ran out of air for my torch. I worked on the OD, should have it finished tomorrow. Here are the brackets for the new Wrangler spring swap, I have a set of spring brackets (4) as well...the long brackets will go on the front for the shackle reversal

had a little excitement this morning.....I forgot to remove a oil/gas soaked rag before I started cutting w/ the torch, it went up like a bonfire...right under the front gas tank .....needless to say I'm glad my shop fire extinguiser works well R)....all in a days work, eh?
Jim S.

 

both sets are exactly 3" ID where the springs mount, the long ones are 8" long by 4" wide
the shorter units are 6" long by 4" wide.....they're both made from 1/4" plate
I've been using the metal supply shop for 10 years for my business needs....the owner won't charge me for any of my personal Jeep projects (I buy him a high end 6 pack every so often )....the material, laser cut, and brake work on these would've cost $175 otherwise R)
Jim S.

 

got the rest of the old hangers cut off and started on installing the YJ springs

played with the shackle angle and this is what I settled on....whatta ya'll think? I tried lining up top bolt and bottom bolt to come up with overall angle

the UPS guy stopped by and asked what the heck are you doin w/ those heavy springs I delivered?....I said grab a pair of gloves and I'll show you R)
Jim S.

 

finished the rear mounts this morning, I left the springs off for now because I'm short some bushings and sleaves. I'll get everything painted up and install the springs when the bushings get here.
I started on the front mounts. I had to modify the front a bunch to get the center far enough forward, as it is this should be 1 1/8" forward from stock.


Big thanks to sdcj6 (Ray) for his help here, plus I know where to go if it doesn't work R). I'll finish the other side tomorrow, but I'm not going to mount the springs until the motor/trans/TC are in place.
I also got a properly weighted flywheel and pilot bearing today. Brown Santa finally showed up w/ the hydro clutch kit as well

I feel for ya'll who are freezing trying to work in the garage, it was 75* here today
Jim S.