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Slow Build Of A 1970 CJU.

Discussion in 'Builds and Fabricators Forum' started by Broylz, May 15, 2017.

  1. May 15, 2017
    Broylz

    Broylz Member

    Gallatin, TN
    Joined:
    Oct 9, 2012
    Messages:
    238
    I have decided to start a build I have had in my mind for a long while now. It will be a slower build but I figured I would start my build page to keep myself motivated and to set goals so I don't procrastinate yoo badly.

    This is what I'm starting with...
    [​IMG]

    I ended up with a good running full size bronco with no title but it has a low mileage 302 and a T19 transmission plus the reverse steering box I have been wanting to use as well. I traded into this bronco for about $400 bucks.
    [​IMG]

    I also found a set of narrow track wagoneer dana 44s which are being torn down to rebuild as well.
    [​IMG]

    And also in the last pic you can see a stack of 2x4x1/8" tube which will become a new frame.

    I am calling this build a CJU (CJ Unlimited) as I have done the following rough sketch of a 4 door cj6 which I plan to be the final result of all of this.
    [​IMG]

    Now I have seen several other 4 door attempts but they have all been stretched monsters the length of crew can duallies and I am hoping to fit mine into the same overall size of a cj6.

    My goal is a weekend trail cruiser for my family to fit in plan a cooler in the back. Will not be used on hard core rock trails or anything extreme but looking to build a safe family cruiser which will have the modern power brakes and steering. I do currently drive my cj5 daily to work so the new frame and drivetrain will keep down time to a minimum.

    I have never built anything on this scale before but have played around with welding and sheet metal and such on smaller projects so this is a big learning curve for me as well. I have a few good friends who have much more experience I can lean on ad I need to but it will mostly be done all in my suburban 2 car garage.
     
  2. May 15, 2017
    Broylz

    Broylz Member

    Gallatin, TN
    Joined:
    Oct 9, 2012
    Messages:
    238
    The plan for now is to tear the bronco down this week and get the motor, wiring harness and ecu, transmission, and steering box all sorted out in the garage and part out or scrap the rest of the bronco.
     
  3. May 15, 2017
    Focker

    Focker That's a terrible idea...What time? Staff Member

    WA
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    Aug 18, 2014
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    7,540
    I'll be watching. :watch:
     
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  4. May 15, 2017
    Broylz

    Broylz Member

    Gallatin, TN
    Joined:
    Oct 9, 2012
    Messages:
    238
    Results of day 1...
    [​IMG]

    Have a cherry picker lined up with a buddy after work tomorrow.
     
  5. May 15, 2017
    Walt Couch

    Walt Couch sidehill Cordele, Ga. 2024 Sponsor 2023 Sponsor 2022 Sponsor

    cordele, Ga.
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    Mar 29, 2007
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    That small chair for your small observer I presume.
     
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  6. May 15, 2017
    Broylz

    Broylz Member

    Gallatin, TN
    Joined:
    Oct 9, 2012
    Messages:
    238
    Yes. My 3 year old daughter likes to "help". She also thinks I should paint it red so she can have it... we will see
     
  7. May 16, 2017
    homersdog

    homersdog Tulsa, Ok 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Tulsa, OK
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    Broylz likes this.
  8. May 16, 2017
    Broylz

    Broylz Member

    Gallatin, TN
    Joined:
    Oct 9, 2012
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    238
    This Indian Mahindra model is very close to what I have in mind.
    [​IMG]
     
  9. May 16, 2017
    givemethewillys

    givemethewillys Been here since sparky ran it. 2022 Sponsor

    New Kent, VA
    Joined:
    Jun 21, 2005
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    this is going to be cool....
     
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  10. May 17, 2017
    tymbom

    tymbom Member

    Siskiyou Co.
    Joined:
    Jun 13, 2012
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    814
    Cool project!
     
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  11. May 25, 2017
    Broylz

    Broylz Member

    Gallatin, TN
    Joined:
    Oct 9, 2012
    Messages:
    238
    Finally got the motor out. This is very slow work after my normal job and alone plus family time... I'm sure a few of you can relate.

    Anyway...
    [​IMG]

    [​IMG]

    Now to take the pedals, master cylinders, steering box and any other small part I want to trip over for a bit out of the bronco and get rid of it. Then onto my frame build
     
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  12. May 26, 2017
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
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    Aug 13, 2015
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    Just found this thread. Subscribed. :watch:
     
  13. May 30, 2017
    Broylz

    Broylz Member

    Gallatin, TN
    Joined:
    Oct 9, 2012
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    238
    Got what was left of the bronco sold this weekend. refilling the welding gas tank and trying to figure out if the 4.5" angle grinder will be my best option for cutting the tube to start the frame build.

    Engine is on the stand and no longer on the hoist. have decided after reading this weekend that i am going to try to find a dodge NV4500 and bolt that to a Jeep Dana 300 as the adapter from the NV4500 to my ford 4 speed bellhousing will be the cheapest way to get through the adapters.

    Also scored a set of GT40P heads, intake, MAF meter, and factory manifolds off of a 99 Mercury Mountaineer for $140 last night. then i read that my engine is a roller block with a flat tappet cam in it so i will be doing a roller cam conversion too. will see when i pull the heads and check the bores if i need to just rebuild the whole motor or not. have at least on broken head bolt that ive found so far...

    Im stoked to keep the momentum going. i know it will slow down after a bit but i'm riding the wave while i can.
     
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  14. May 30, 2017
    tymbom

    tymbom Member

    Siskiyou Co.
    Joined:
    Jun 13, 2012
    Messages:
    814
    I wouldn't try the 4.5in angle grinder to make frame cuts. You want to be as accurate as possible... Harbor fright sells a cheap band saw that can used after a little work truing it up, or a chop saw would be better... Precise, Accurate cuts...
     
  15. May 30, 2017
    Focker

    Focker That's a terrible idea...What time? Staff Member

    WA
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    Or...Cut over your measurements and then grind to the lines.
     
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  16. May 30, 2017
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
    Joined:
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    6,656
    An angle grinder is what I use for anything that needs any amount of precision. "The separation is in the preparation." Get yourself a good angle finder and a speed square. Mark (scribe) all four sides of the tubing before you start. Make certain all four corners of your scribes intersect at the same point of the tubing. If they don't, your cut won't be square. Use good lighting. Err on the side of "too long" and go back to clean it up with a grinder if you need to, like Focker suggested.

    Without spending big bucks on a good carbide saw, I've found this to be a very effective method. A 14" abrasive saw is great for general cutting, but there is so much flex and deflection in the wheel, it's hard to get accurate, consistent cuts.
     
  17. May 31, 2017
    Broylz

    Broylz Member

    Gallatin, TN
    Joined:
    Oct 9, 2012
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    Looks like I can gain access to some large horizontal bandsaws at work after hours. Looking into that today. This would be the most effective I would think.
     
  18. May 31, 2017
    Broylz

    Broylz Member

    Gallatin, TN
    Joined:
    Oct 9, 2012
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    238
    Also, pulled the heads last night because after finding a broken head bolt and the valve covers loose, it made me question the integrity of the internals. Lucked out. Bores are nice and shiny with good cross hatch marks. Time to order bolts and gaskets to get the motor sealed back up and put aside.
     
  19. Jun 12, 2017
    Broylz

    Broylz Member

    Gallatin, TN
    Joined:
    Oct 9, 2012
    Messages:
    238
    got the motor broke down and awaiting a cam swap and new gaskets throughout. have a 4x4 AODE on the way and it will be getting a stock type rebuild before going in.

    also started cutting the steel for the frame. using a 4.5" angle grinder so im going slow an taking my time. researching the 4link geometry as well to get it set up correctly.

    as i stated originally, its slow progress but still making steady progress.
     
  20. Jun 21, 2017
    Broylz

    Broylz Member

    Gallatin, TN
    Joined:
    Oct 9, 2012
    Messages:
    238
    [​IMG]

    This is my most current rendering. I had the tub dimensions and took my own frame measurements. The windshield, top height and front end are rough guesses visually. It is shown with a 107" wheelbase with cj6 length tub and 37" tires.

    Few ideas running through my head. Let me know your thoughts.

    1. I could make it a permanent hard top and add a/c but that would negate the open air driving I enjoy.

    2. I would have to use a B pillar from an XJ or something to allow the doors to close without a visible b pillar.

    3. I could suicide the rear doors and have the fronts latch into them like an extended cab truck and then I would have a large opening when the doors are removed with no b pillar.

    4. I don't mind having the solid permanent top if the doors and rear windows and tailgate hatch could be removed. Easy enough to do but I would keep the d pillars, rear corners, solid with the roof. Would likely have the roll cage up pretty tight to it for support as well as maybe sandwhiching the top between the cage and a roof mounted basket. Idea is a family oriented overland expedition type rig.
     
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