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Don's '69 CJ5 rebuild

Discussion in 'Builds and Fabricators Forum' started by djbutler, Mar 2, 2008.

  1. Mar 2, 2008
    djbutler

    djbutler Sponsor

    Rio Linda CA
    Joined:
    Nov 5, 2007
    Messages:
    727
    Hello all,
    I'm finally posting some pictures of the rebuild project I'm working on. Here it is as I brought it home... View attachment 21490 It doesn't look to bad, until you look close.
    First thing I started on was the floor around the SM465. The PO had butchered it with tinsnips, there was just a hole with about 1/2 inch of clearance around the SM465 case. I ended up with this.. View attachment 21491 I read Scot Milliner's post about how he sectioned a pan from a THD 350, I used an original center top cover and sectioned it. You can see the corners of the original cover, I used 18 ga sheet metal to fill in the rest.
    I used a torch and wire brush to remove the bedliner material from the floor, and saw how many rust holes were hidden like this one.....
    At that point things sort of snowballed out of the original scope of what I planned. The more I looked the more I found. There were patches on the right quarter where the original spare tire mount was and over each tail light panel. The patches were just lapped over the rust holes and covered over with bondo. After I cut off the patches to see what was underneath, I should have taked a 'before' picture of the right quarter area. It had a hole over most of the internal corner brace. I cut out the rusty metal and put in a flush fitting patch of 16 ga, then sectioned the corner brace using new metal. Here is how it looked after grinding down the welds....
     
    Last edited: Mar 17, 2008
  2. Mar 3, 2008
    trickpatrick

    trickpatrick Done? LOL

    North Idaho USA
    Joined:
    Nov 29, 2006
    Messages:
    838
    The AT pan is a good idea.

    Lookin good.
    I noticed the bra right off.
    Id have that off right away:rofl:

    Keep that on and this bumper sticker would make you cringe.
    Maybe you have seen it.

    Barbie called and she wants her jeep back:)

    Seriously though keep up the work and make her yours.
     
  3. Mar 3, 2008
    drexotic

    drexotic Happy now?!?!?

    San Diego
    Joined:
    Jan 7, 2007
    Messages:
    419
    Nice sheet metal welding! I wish I could make sheet metal welds that look that nice.
    I see your using a Lincoln welder. What model is it and what settings / wire are you using?
     
  4. Mar 3, 2008
    djbutler

    djbutler Sponsor

    Rio Linda CA
    Joined:
    Nov 5, 2007
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    727
    The welder is the WeldPak 175 HD from Home Depot, $599. Using .030 carbon steel wire, 50% argon/C02 shielding gas. The settings on the chart for 18 ga are a little hot, get burn through unless I move right along, I'm using the "B" step heat setting and about 3.5 on the wire speed setting. I don't know exactly what that comes out to in Amps or in/sec, I just experimented with it until it behaves like I want.
    It was Scott who came up with the sectioned AT pan idea, I used the stock top cover and sectioned it. That way I got the angle transition to the front piece that covers the upper part of the bellhousing.
    Oh, yes the BRA came off right away. Should have seen the peeling paint/rust underneath it.

    I'm still trying to figure out how to upload photos that will show full size in the posted message, instead of as thumbnail size. Anyone know the trick to that? :?
     
  5. Mar 4, 2008
    djbutler

    djbutler Sponsor

    Rio Linda CA
    Joined:
    Nov 5, 2007
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    727
    Ok, I think I found the answer to my own question about the photos. I put some on Photobucket, here are a couple to test with (I hope). This should be the right side taillight panel after I got the PO's patch off. I have trimmed it to be a rectangular hole to fit the patch easier.
    [​IMG]
    Here is the left side.
    [​IMG]
    Hopefully I can show the 'after' pictures next week.
    The large round hole is where the PO cut out the panels to mount some aftermarket taillights, I plan to patch these back in and use the stock taillights. The stock lights mount in the lower of the two smaller holes that show in the right side panel. Does anyone know what the upper set of the two small holes were for? Backup lights maybe?
     
  6. Mar 4, 2008
    drexotic

    drexotic Happy now?!?!?

    San Diego
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    Jan 7, 2007
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    Great! I have the same welder! Nothin' like learning from the experienced!
    Thanks!
     
  7. Mar 5, 2008
    djbutler

    djbutler Sponsor

    Rio Linda CA
    Joined:
    Nov 5, 2007
    Messages:
    727
    Here are some pics of today's progress. I worked on the right side tail light panel,
    [​IMG]
    Here is a view of the new patch I cut and fit to fill the hole left by the PO installing a non-stock tail light. I decided to stop for the evening at this point, I don't weld too well with a couple of :beer: in me.

    [​IMG]
    This is a view of the whole tail light panel. After fitting a patch where the body mount brace was and straightening the tail panel, it was obvious that the quarter panel still needs some work.

    [​IMG]
    I marked out one more patch to fix the lower curve of the quarte panel. I decided it would be easier to patch in new metal rather than try to stretch and move the metal so far.

    [​IMG]
    The straight edge tells the tale.
     
  8. Mar 10, 2008
    djbutler

    djbutler Sponsor

    Rio Linda CA
    Joined:
    Nov 5, 2007
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    727
    Here's an update with some more pics.
    [​IMG]
    The metalwork on the problem right corner is done. This oblique view shows a lot of heat discoloration from doing stress relieving of the welded patch in the lower curve. Next comes sandblasting to remove all the rust, some more hammer and dolly work, then fill and paint.
    [​IMG]
    Here is a rear view of the corner with a straight edge to tell a better tale now.
    [​IMG]
    Here is a side view of the corner with a straight edge to tell a better tale now.
    [​IMG]
    A look at the left corner showing the holes needed to patch this side. It won't be near as much work as the right side was, the corner curve is relatively undamaged. The rectangular hole on top of the wheelhousing is where the roll cage mounted, the wheelhouse top panel was badly weakened by rust.
     
  9. Mar 11, 2008
    bkd

    bkd Moderator Supreme Staff Member 2022 Sponsor

    K-Town Tenn.
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    Apr 29, 2007
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    3,294
    keep the posts coming....quite an impressive display of metal work skills :beer:
    Jim S.
     
  10. Mar 14, 2008
    djbutler

    djbutler Sponsor

    Rio Linda CA
    Joined:
    Nov 5, 2007
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    OK, here's some progress done Thursday evening. I got the left corner metal work started, fitted a patch of new metal where the PO cut out a hole for non-stock flush mounted tail light.
    [​IMG]
     
  11. Mar 16, 2008
    Huntman

    Huntman HIGH ROLLER

    Apex, NC
    Joined:
    Jan 19, 2007
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    Very nice progress so far, keep us posted!!!
     
  12. Mar 17, 2008
    djbutler

    djbutler Sponsor

    Rio Linda CA
    Joined:
    Nov 5, 2007
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    OK, here's more progress from Sunday afternoon.
    [​IMG]
    This is a view of the patches tacked into place on the left rear quarter.
    [​IMG]
    Here is the left wheelhouse showing the patch installed where the roll bar mounting plate trapped mud and caused a rustout.
    [​IMG]
    A rear view of the tub mounted on the stand.
     
  13. Mar 17, 2008
    jayhawkclint

    jayhawkclint ΜΟΛΩΝ ΛΑΒΕ

    Oklahoma City, USA
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    Don, you are my hero.
     
  14. Mar 18, 2008
    Huntman

    Huntman HIGH ROLLER

    Apex, NC
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    i wish i had a stand like that when i did my tub. looks good keep up the work!
     
  15. Mar 19, 2008
    djbutler

    djbutler Sponsor

    Rio Linda CA
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    A member here, Tommy B posted the plans for the stand on this site. I spent about $220 for new materials and a couple of weekends to put it together, it's been well worth it.
     
  16. Mar 19, 2008
    Brian P

    Brian P Member

    Clarkdale Arizona
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    Impressive! Great metal work :tea:
     
  17. Mar 19, 2008
    juffer

    juffer Juffer

    Netherlands
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    Jun 16, 2007
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    215
    Hello,

    It seems to be the same color like mine. Do you have the code? I am doing a paint yob next month.

    Thanks in advance
     
  18. Mar 28, 2008
    djbutler

    djbutler Sponsor

    Rio Linda CA
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    Nov 5, 2007
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    No, I don't have a code plate remaining on my CJ. I found a color chart of 1969 factory colors, and this looks like the Kaiser Jeep color called Spruce Tip Green. I'll find a link to the website showing the colors and post it.
     
  19. Mar 28, 2008
    djbutler

    djbutler Sponsor

    Rio Linda CA
    Joined:
    Nov 5, 2007
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    727
    More progress pictures on the metal work.
    [​IMG]
    I started on the bad hat channel under the gas tank. This is a look at the hat channel after I drilled out the spot welds.

    [​IMG]
    The floor panel is exposed, showing the rust through.

    [​IMG]
    I cut a patch from new 18 gauge metal and tacked it into place, viewed from below.

    [​IMG]
    View of the patch metal from above.

    [​IMG]
    Finish welding is ground smooth, but a problem is apparent. The side panel buckled from weld shrinkage.

    [​IMG]
    A closer view of the buckle. More hammer-on-dolly work as the welds were cooling would have prevented this.

    [​IMG]
    Here you can see the buckle from above, looking at the inside of the side panel.

    [​IMG]
    I decided the problem called for a pull with the Porta-Power. I set a length of I-beam inside the cowl reinforments as a strongback, and used a piece of 1/2 inch plate as a base on the other end.

    [​IMG]
    A view showing the flex in the I-beam with the pressure on. After putting a pull on the shrunken weld patch in the floor, I used some reheating on the weld combined with hammer-on-dolly work to stretch the weld and relieve the buckle.

    [​IMG]
    A view of the side panel after pulling the buckle smooth. Control of shrinkage and warping is probably the toughest part of this whole project.
     
    Last edited: Mar 30, 2008
  20. Mar 28, 2008
    drexotic

    drexotic Happy now?!?!?

    San Diego
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    Don . . .
    How'd you like an apprentice for a couple of weekends?
    Again I am impressed with your work!
     
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