Started My ECJ5 Build

A plate on the firewall is pretty mandatory..............but the real hot set-up is to do a brace coming down from the cowl to the pedal assembly behind the dash. I slot the two 5/16" holes so there is a little adjustment between the brace and cowl........totally stiffens the pedal assembly up.

 

Finished up my plate,used 1/8" and the holes through the cowl. I'll make a drop down bracket like Tarry used to tie it in. Thanks.


I'm running out of room to mount the ARB compressor and the engine PCM on the cowl.....

 

figured out the dimensions of the behind the axle fuel tank 14" x 24" x 14" = about 20 gallons. Perfect, can do away with the under seat tank if need be, or potentially use it as an secondary unit.

Need to cut and weld the brake and clutch pedals to obtain full swing..... coming together........

 

Are you making a tank or having one built? Make sure you leave yourself a little room around the tank. You will be glad you did.

 

Making one, I'm leaving some clearance in case I want to move the rear axle back 1 to 1.5", and leaving some side room to run the exhaust out the back if I decide to do that too.

 

Got the master cylinder, booster and pedals mounted and finished, and the hydraulic clutch master in and plumbed. Mounted the Wilwood proportioning valve and connected all the brake lines, they need bled though.

Made and pressure tested the new fuel tank, and made it 13"x13"x24", should be just about 17.5 total gallons. The fuel filler will be out the rear of the Jeep, not what or how I wanted it, but it will work.

Got my new plate steel for my new rear corner guards. Using 14 gauge plate, easier to bend to the 6" curve in the rear quarter. Will tie that into my Jamboree rack, that will fold down, and or swing to the side.

Decided on mounting the spare to the roof. I know, I know some folks are gonna hate it, and it'll make me top heavy, but the wider axles should offset that negative.

Got the dash back in, but I think I broke my headlight switch, need to order a new one from EZ Wire.

Picked up some more steel for the cross member for the AX5 and D300. Gonna pick up a spare D300 this week.

I need to post some pics......

 

Getting rid of the old cross-tube clutch mechanism was one of the best upgrades I've done. You will really like the hydraulic clutch. Are you using a slave cylinder or the hydro throwout bearing? If you are using a slave, who makes it? I had an issue with the Wilwood slave that was easily resolved.

 

Posi,
Engine and tranny are from a '92 YJ, so it's all the stock stuff for the clutch reservoir and the internal throwout bearing.

 

Ok, its been a few pages, so here's some pics:

Shifter comes in being very very close, slight off and slightly back:


Engine bay, MC, booster, clutch reservoir and proportioning valve:


What you say, power steering, well why not, the engine came with it, it'll make steering with the front ARB bearable:


Passenger side engine placement (2.5ltr fuel injection, '92 YJ motor)- gonna use an electric pusher fan in front of the radiator, has plenty of room


The makings of my fool tank:


My blinging grille:


More engine bay pics:

 

Completely forgot the interior hanging pedal pic.....



Turn your head to the left.

 

Finished the fuel tank up. Pressure tested it for leaks, got those addressed, added the filler and vent inlets, got the in tank fuel pump mounted and the two return lines thingees in place. Need to prime and paint it, mount it and make a skid plate.

 

OK, fuel tank installed and plumbed. Made new rear corner guards that come up about 3" over the lip were the hard top and tub meet.

Having issues getting spark and fuel pump to run. Need to figure out a way to bypass the Auto Shut down relay and the fuel pump relay........ she cranks over, but no spark and no fuel pump turning on.....

Dang.

 

OK, got the fuel pump to work. I forgot something when I made my tanking deeper than the stock YJ tank. I extended the in-tank fuel lines, but cut the lines and extended them with rubber hose. Well, since the metal to metal contact was gone, the ground was gone, no ground no fuel pump pumpee fuelee. Whoooppss. Fixed the ground issue, and she pumps, but, ran into another issue, the ninety degree tube bends that come through the mounting plate are cracked..... So, I'm gonna let it air out, and try welding the cracks, or will have to jerry rig up some 3/8" fittings and make a new mounting plate.

On a separate note, on the YJ fuel tank there are two vents with a real small diameter hose, where or what does that line from the vents connect to on a YJ?

 

Found out the vent lines go to the charcoal canister, gonna need a lot of hose, the canister is still on the YJ......

 

I anticipate putting the fuel tank back in, hooking up the plumbing, and turning it over and hearing it fire up early this week. My pants are full of ants.

 

I remember the feeling and it feels good!

 

I tried welding the cracks unsuccessfully, and then even tried Seals-All, no luck the tank's bulkhead fitting leak. Need to re-do that. Got fuel pump working, but not sure on adequate fuel pressure. She cranks, turns over, pumps fuel, but no go on the spark. Frustration level is entering the high range. Need to cool down, drink some beers, and approach this with a level head. Maybe its time to purchase an FSM......

 

You'll figure it out.

 

Well, direction change. Instead of pairing down and piecing this maze of wiring together, I'm going a different route. I'm gonna pull the EZ wire body harness and CJ5 dash out, and put the YJ Wrangler dash and body harness in. Since I already am using a YJ windshield, powertrain, it makes more sense. I'm gonna lose the retro cool look of the flat dash panel, and install the whole YJ assembly, heater, defrost ductwork, and all the related interior controls. So the plan now is to completely install a YJ driveline, dash and wiring into my CJ5. Basically giving up on the spartanness of the CJ5 for technology that is 26 years newer, this should be nothing more than re-connecting what I've cut out, and fitting the dash in place. I have been looking at the option for the past few weeks, and it seems to be the most practical. I'm not convinced I can make the 2.5 run and hare I wired correctly. If I had a long nose, I could pick up a Hesco harness and be done, but no one makes what I need for the 2.5 ltr, and with the 2.5ltr harness being re-worked twice in '92, I'm not convinced of my electrical knowledge to make it would, it should be now, butit just ain't sending any spark, and there is no reason it shouldn't be based on my knowledge.

Biggest hurdle here is getting it in right. I'm convinced I can do that, and I've been working on this for far too long without any road time not to get it done. I'll take lots of pics. I'll also be using the YJ steering column also. May as well.

Should have thought more about this at the get go, woulda been done by now.

I'll be having some parts for sale shortly.