CJ5 build up

Well here is my build thread. Its an 83 CJ5 that has been my trail rig for about 4 years its been through a few changes since I brought it home. As I find things I don't like I change them, that's how this build has gone since day one.
Last Nov I went on a snow run with a few buddies, towards the end of the trail there was a long steep down hill once I went over the edge it was nothing short of a bobsled course. I fought it the whole way down just trying to keep the back end behind me, just when I think I am in the clear a 4'' tall stump changed my direction and I hit the last tree on the hill.
So now here I am full in on this build fixing the things that have been bugging me but I was just to lazy to get to. Here is the build plan.

Fix the rust, crash damage, and paint it.
Build a new cage, bumpers, and fenders.
2.5'' lift using YJ spring and shackle reversal.
Tear down the engine to find an oil pressure issue that started last year.

Next winters plans are to install a 4.3 V6 and SM465.

 

This what it looked like when I got it from a friend.


Its last day in one piece.


After the Tree.


Firewall damage.

 

I cut out the rust and damaged area's and replaced them with pieces from Classic Ent. I also had to fabricate new lower's for the vertical pillars that run behind the side panel's and a small piece of the floor for the same area.


New sheet metal in place.


The drivers side had rust in the rocker panel and most of the floor.




New stuff welded in. I still have some work to do on the floor because the patch panel just wasn't big enough to fix everthing.

 

Nice work. I just went through the same type of repairs to the body a few months back. Still isn't painted.

 

Time to update my progress. I just spent the last week cleaning and painting the under side along with the new YJ 2.5'' lift, shackle reversal, and other misc parts.

Tore down


HD steering box mount and DOM tie rod and drag link.


Mountain Off Road shackle reversal.



Back on all fours.

 

Engine is out to find an oil pressure issue. Last year I lost half my PSI and am not sure why. the engine has less then 10,000 miles, I master guaged it, checked main bearings and replaced the oil pump but things stayed the same. Right now I am sitting at around 13-16 PSI at idle which is what the manual specs but I did have 30 PSI before this problem started. I ran it all last summer with out problems but I still feel uneasy about it. So out it came to get ran through again.

 

My first Jeep(and my primary Jeep) is an '83 CJ5. looks like your doing a great job!!

 

Thank you.


Any guys with more AMC experience have any idea's about the oil pressure ussue? I usually just throw a Chevy in the them but I am not doing that till next year. I am thinking bad lifter bleeding pressure? I just dont know until I get inside of it. I am hoping the problem wont be a mystery that cost more money then I want to spend on an engine I am not staying with.

 

I guess I could update this. I haven't done alot that is noticeable, mostly working out dings, filling, and sanding. I Built some new fenders then I smoothed them and covered them in tinted primer. The Color will be the new version of Hugger Orange. this weekend I started bending the cage but its slow going.

Welded with integrated inner fender.


In primer.

 

Nice job on the fenders!

 

cj5dave, is that 3/4" tubing/pipe around the edge? Great idea and work!

 

That is 1.25 .120 wall tubing with the skins done in 10g. I built them like most tube fenders are done then used the factory inner fender and spliced the two together.
Here is a pic of the skeleton before I plated them and welded the inner fender.

 

What kind of bender did you use and what primer?

 

I have a Pro Tools 105 bender backed with the Bend Tech EZ cad program and Velspare primer with a couple shots of my final color choice. I don't have the exact primer number but if ya need to know I can post it tomorrow, no problem.
Thanks for the kind words guys, it really encourages me to get this project done.

 

O.K. so the color we're seeing is the new hugger orange. I was thinking DAMN that primer looks GOOD!! I went out and spent about 4 hours washing out my '83 today to see what body panels I'll need... a LOT!! Your thread is a great encouragemant!

 

That is the primer you are seeing, its just color matched. Doing the primer this way provides an even color under the paint and with some colors it makes for a brighter top coat, and I also just like it. Take a look at Classic Enterprises for your replacement panels, that is where all of mine came from and I am fairly happy with them.

 

I worked on the cage this weekend things did not go smooth. My Bend Tech program came up with some goofy numbers that did not work out then my fix went even worse so I started over today and things worked out well so went with math and free hand. I love run on sentences. This is just a small portion of the cage but its the hard part, I wanted it to be tight to the body so that there would be more interior room. So far I am happy, this pic just shows the drivers side mocked up. More to come this week.

 

I now have the cage almost complete, just need a few gussets and weld it all together. Things would go faster if life didn't get in the way. It turns out my girlfriend has a real eye for bending tube. She has been there since the first bend and has been a big help. She comes from a family of artist and is a pretty good one herself, so she see's things that I look over and kinda coach's me when I am figuring out angles. Its a funny role change.

My newest rescue Blue Healer CJ cant wait for her first ride.

 

I like the cage work.