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The Blue Lemon: musings and hopeful progress of my '75 CJ-5

Discussion in 'Builds and Fabricators Forum' started by Leftlane, Jun 2, 2013.

  1. May 12, 2014
    jowwo

    jowwo Member

    Colorado
    Joined:
    Mar 11, 2012
    Messages:
    73
    Congrats. It sounds sweet!
     
  2. May 12, 2014
    tymbom

    tymbom Member

    Siskiyou Co.
    Joined:
    Jun 13, 2012
    Messages:
    814
    Yeah that sounds good! Thats the kinda progress that helps build motivation
     
  3. Jun 22, 2014
    Leftlane

    Leftlane Member

    Joined:
    Apr 12, 2013
    Messages:
    73
    I've been knocking out the little stuff by devoting a few hours each weekend to the Blue Lemon.

    Decided to stick with the factory clutch bell crank setup even though I know if I put time time and money into a hydraulic setup it would pay off in the long run. So I measured and took a stab at a mounting solution for the bell crank pivot on the engine side. The Lakewood bellhousing has three pre-drilled holes that made for the pickup point.
    [​IMG]

    The lower clutch rod was too long in factory form. I used a die to thread the base which allowed just enough adjustment. Don't get a chance to do this too often and it always amazes when it works :)
    [​IMG]
    [​IMG]

    To make the pivot pickup point, I used these pieces - one of which was some sort of 0.25" angle iron piece that was bolted to the frame under the passenger seat which appeared to do nothing in my Jeep's current configuration. So I recycled it. The bolt holes in the original part conveniently now serve as a clutch return spring mounting location.
    [​IMG]
    [​IMG]
    [​IMG]

    After getting everything installed and making adjustments as if it was a factory setup (which it definitely isn't, but I had little else to go on), I was happily surprised when I fired the motor, engaged and disengaged the clutch pedal, and actually saw the output tail shaft stop rotating and then start rotating. I was sure I was going to have an issue with the throwout bearing length. I may still have an issue as I haven't driven it, but hope springs eternal.

    With the clutch sorted, I could then turn my attention to the steering shaft. I picked up a replacement Borgeson unit for intermediate without power steering.
    [​IMG]
    I feel like it should be installed the opposite direction of how I have it, but for some reason in that configuration the splined collar doesn't seat all the way up the steering column shaft. That creates movement in the steering wheel that bugs me too much. I'm going to have to keep my eye on that rubber dust boot as it's only a couple fingers away from a hot header.

    Now with the steering shaft in, I can make it look like a proper jeep by installing the driver's fender, grill, and even the radiator that's been sitting around the garage for months waiting for me to accidentally pierce it with something sharp.
    [​IMG]
    [​IMG]

    I turned my attention to the gauges. Nothing really worked when I bought it except the oil pressure and volt readout. I picked up some new Stewart Warner gauges and made a cover for where the speedo was. I'm going to replace that with a 3 3/16" tachometer and some led's for left/right turn and high beams. Still much more to do in this department. Since good ground is a big deal, I did use a terminal barrier strip for multiple ground wires and then ran a larger gauge wire from it to a bulkhead bolt that then gets picked up on the battery side of the firewall and run to the negative terminal. I'll have a lot of problems on this Jeep for sure, but bad grounds ain't gonna be one of them.
    [​IMG]

    Lastly, yesterday I spent time painting and putting new Moog U-Joints (369's) in both drive shafts.
    [​IMG]
    [​IMG]
    [​IMG]

    I got the driveshafts installed. Even though I was out of time and the Jeep is blocked in the garage by our popup camper, I had to know. I moved some wheel chocks a foot on either side of wheel, fired her up, and proceeded to drive it 1.5' forward and then enage reverse and drive it that same one and half feet backwards! Woo-frickin'-hoo! :D Like Mac says - I'm gonna have me some fun!

    https://www.youtube.com/watch?v=YeVyXFN1OTY
     
    Last edited: Jun 23, 2014
  4. Jun 26, 2014
    rons75

    rons75 Member

    Joined:
    May 7, 2014
    Messages:
    87
    I had to rework the clutch linkage on an old 7 i had back in the day. No money and parts availibility make for interesting ideas! lol
     
  5. Jun 26, 2014
    rons75

    rons75 Member

    Joined:
    May 7, 2014
    Messages:
    87
    Oh, nice job by the way. Cool Jeep
     
  6. Jun 29, 2014
    Mike C

    Mike C Member

    Austin, TX
    Joined:
    Feb 19, 2007
    Messages:
    743
    Great looking Jeep! Looking forward to more updates.
     
  7. Jun 29, 2014
    Leftlane

    Leftlane Member

    Joined:
    Apr 12, 2013
    Messages:
    73
    As always, thanks for the comments. Nice to know folks are reading along.

    I drove the Jeep this weekend. Just out of the garage and to the middle of the driveway, but that's still driving. No pushing. No letting gravity do its thing followed by a quick throwing of a wheel chock hoping it will stop the momentum. Nope - this rolling was all Jeep propelled... well, Jeep body, Chevrolet motor, Jeep trans, and Ford carburetor, but why split hairs.

    Got the under-bite-looking front push bumper reinstalled. Got the skid plate back on. Did some wiring behind the dash. Still need to get a tach and install it. Put the glovebox back in. Put the new bikini top on that matches the seats. Little stuff. Much more little stuff to go.

    [​IMG]
    [​IMG]
    [​IMG]

    Just some of the things that remain:
    - take to exhaust shop - have my Dynomax bullets currently sitting in my garage installed :)
    - take to alignment shop - see how bad caster is on this 2.5" BDS kit, take home, add shims, repeat trip to alignment shop
    - buy and install tachometer in place of where original speedo was, also install high beam, left and right turn indicators
    - install seat belts when they come in (I went with Retrobelt lap belts to match the interior)
    - chase down hazard blinkers bugs in a couple of the lights
    - get some sort of rocker panel protection
    - take off of non-op status with the state
    - re-insure it with my car insurance company
    - other stuff I'm sure I'm forgetting. I've got it all written down in my notebook in the garage. Time for a beer now :beer:
     
    Last edited: Jul 9, 2014
    SKT likes this.
  8. Jun 30, 2014
    rusty

    rusty Well-Known Member

    norfolk,va
    Joined:
    Dec 16, 2006
    Messages:
    1,652
    You have done a great job on the Jeep. Nice to see it moving under it's own power. Sweet!!!
     
  9. Jul 9, 2014
    Leftlane

    Leftlane Member

    Joined:
    Apr 12, 2013
    Messages:
    73
    My Allstar fan spacer came in today unexpectedly (they had told me it wasn't going to ship until the 16th). I've been waiting on that part to finish up the cooling system. So, I installed a new 17" steel fan, 3 1/2" spacer, and Omix-Ada fan shroud.

    I really liked the Allstar spacer because I can install it and then install the fan. I don't have to juggle a screwy fan/spacer-loosely-assembled gizmo while trying to run in some overly long bolts. This made installing the fan easy.

    The less easy part was I took a guess that I'd be able to make a fan shroud for a CJ5 with an AMC 304 V8 work. This radiator is a Jeep 3-core radiator that I had a local radiator shop swap sides for the inlet and outlet since Chevy is opposite Jeep. As such, the Omix shroud's cutouts to allow for the hoses were on the wrong side. So I took a cutoff wheel and made quick work of that. I was happy to see that my fan is pretty well centered up in the hole and there's plenty of space around the fan and just the right amount between the fan and radiator (or so I believe).


    [​IMG]
    [​IMG]

    And I may have gotten a little carried away making a radiator overflow catch bottle:
    [​IMG]
     
    BobH likes this.
  10. Jul 10, 2014
    73 cj5

    73 cj5 Not ready for the junkyard yet

    Clinton, Mississippi
    Joined:
    Jan 10, 2014
    Messages:
    2,137
    Nice radiator over flow. Jeep looks very good.
     
  11. Jul 10, 2014
    rejeep

    rejeep Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Rochester, NY
    Joined:
    Nov 5, 2009
    Messages:
    1,691
    Quick question... Your borgeson steering shaft...
    is that installed correctly?
    mine only fit well with the slip joint more toward the gearbox (power) if that makes a difference
     
  12. Jul 10, 2014
    Leftlane

    Leftlane Member

    Joined:
    Apr 12, 2013
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    73
    I don't think mine is installed correctly (I mention this earlier in the thread), but it doesn't snug up the steering column splines tight enough when installed in the manner you describe. When in that position, I can pull on the steering wheel and get it to move ~1/8-1/4" which bothers me too much. In the position I've got it, there's no steering column shaft play at all, which "feels" better, but may be entirely wrong.

    I've seen another thread where someone machines their own thicker spacer and doesn't use the spacer provided by Borgeson. I suppose I could go that route.

    The only problem I think I've got when using the shaft in this position is the rubber grommet is too close to the headers for my liking. Maybe I'm missing something?
     
    Last edited: Jul 10, 2014
  13. Jul 12, 2014
    Leftlane

    Leftlane Member

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    Apr 12, 2013
    Messages:
    73
    alignment and exhaust begins

    I flat towed the Jeep to a local alignment shop to have it baselined knowing that I likely had a caster problem. I did. Here are the current specs:

    Caster, Front Left: 0.15°
    Caster, Front Right: 0.00°
    Toe, FL 0.04"
    Toe, FR: 0.04"
    Camber, FL: 1.25°
    Camber, FR: 1.20°

    They set the toe, and the camber was just fine where it was. The caster will need a shim, so I ordered 5° Specialty Products breakaway shims - which seem to be what most folks are using - p/n 80999. Hoping I don't need to buy another set of spring U-bolts once I get those shims in there, but I'm expecting to have to since I prematurely lopped off the extra threads on the u-bolts after installing the skid spring plates. Gack.

    While those shims are en route, I hooked it back up to the pickup and towed it to a muffler shop just down the street. It's currently there awaiting a full 2 1/4" dual exhaust inside the frame rails which will exit the rear sides. I'm going with Dynomax 2 1/4" bullet mufflers - p/n 24235. These:
    [​IMG]

    I'll take photos and a video when I get it back next week.

    Since I'm getting long in the tooth, I'm betting that the sound will start to wear on me after a while, but I can't resist at least trying them out for a spell. I can throw on a set of turbo mufflers in the future. I've always enjoyed the raspy nature of glasspacks. Witness the perfectly good exhaust I took off my Suburban after I got it back in 2012 -> https://www.youtube.com/watch?v=zs0cYD6y9Bg

    In the meantime, here's the newly installed Retrobelt lapbelts (in all four seating locations):
    [​IMG]

    Reconfigured gauges on the dash. Notice the missing speedometer, replaced with an SW 3 3/8" tach and led turn signal and high beam indicators on a plate I made and painted to match the factory paint code:
    [​IMG]

    Dirtworx bumper with the tire carrier swung out for reference purposes:
    [​IMG]

    Thanks for the comments and playing along. This has been one of my most fun (if not expensive) projects - and I haven't really done anything with paint and body (and don't plan to).
     
    Last edited: Jul 12, 2014
    SKT likes this.
  14. Aug 4, 2014
    Leftlane

    Leftlane Member

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    Re: alignment and exhaust begins

    Got the exhaust installed. Been working out the bugs in the Jeep over the last weekend or two by driving a mile here or there, then driving a couple miles there or here... rinse and repeat until I'm comfortable going 50 miles or so one way. Not there yet.

    As promised: video. As expected: too loud. In fact, I was compelled to pull out the Sound Level Meter in the video and take some readings. Yikes. I'm finally at the age where quiet wins out over "good" sound. That and I feel for my neighbors. These do sound good, though. It's hard not to rip through the gears and not have a poop-eatin' grin on my face. I tried to get video of driving, but my Canon video camera kept shutting down due to harsh vibration. I'll have to borrow a friend's GoPro to get the video I want before I haul this sucker back to the exhaust shop to cork her up.

    [video=youtube;XVLnLG6bm5Q]https://www.youtube.com/watch?v=XVLnLG6bm5Q[/video]

    I installed 6° steel shims in the front. That ought to bring caster to right at +6°. I will say the Jeep tracks much better - but it wasn't a slam dunk. There is still some sort of wandering in the steering. At this point I'm suspicious of a tweaked frame or spring mounts or ?? I used Warrior Products 2" steel shims, which I had to grind down to the 1.75" width of my springs. While I was in there, I replaced the rear aluminum shims you saw me install earlier in this thread with these same 6° WP steel ones. I was never happy with the goofy way I made do with a nub for a center pin. This time, I ordered up Rancho 3/8" center pins all the way around and pinned/bolted the shims permanently to the spring pack. Much sturdier.
     
  15. Aug 23, 2014
    Leftlane

    Leftlane Member

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    The End of Phase I

    Went back to the exhaust shop and had them quiet down the Blue Lemon. Like front row at an AC/DC concert, it sounded wild and got your heart pounding, but I was good for about 10 minutes. However, not before I took this ride-along video with the race bullets just so I could remember the tune:
    [video=youtube;bW058fTVKBA]https://www.youtube.com/watch?v=bW058fTVKBA&list=UUY9ifk5fEqaGkuhhCqdoG5A[/video]

    The new mufflers are Apex XLERATOR turbos. Much more livable but still with a good rumble at idle. I can actually hear the drivetrain whine now (you know, the M*A*S*H sound).

    Meanwhile I addressed the other issue - rich smelling exhaust. I ripped into the Autolite 2100 to find 51F jets. I got a set of 48F's and put them in the carb. It seems to be leaner without the unburnt fuel smell. Put about 70 miles or so on the Jeep today. It performed good. I'm learning its nuances. Also installed RAM mounts for a my iPhone (with Speedometer app showing) and that excellent RAM cup holder.

    The cheapo Jegs manual choke cable was giving me grief, so I ripped it out. Not happy with it. I wonder if those Lokar cables are smooth in the full range of motion. That Jegs cable basically was an on/off switch as it required so much effort. Anybody got manual choke cable recommendations from personal experience?

    I'm calling this the end of Phase 1. I've got a running Jeep. I occasionally take it to work. It fires up first shot. Good oil pressure. No leaks. All the gauges, lights, and signals works. Holds temp at 190° all day long. Pretty happy overall.

    Phase 2 might include stuff like:
    • family cage
    • heater
    • rocker protection
    • Warn winch (really like the 8274 series; feels right for this vintage Jeep)
    • perhaps I'll try my hand at making some steel half-doors
     
  16. Aug 24, 2014
    73 cj5

    73 cj5 Not ready for the junkyard yet

    Clinton, Mississippi
    Joined:
    Jan 10, 2014
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    2,137
    Sounds good and looks great as well. Kudos to you
     
  17. Aug 24, 2014
    jowwo

    jowwo Member

    Colorado
    Joined:
    Mar 11, 2012
    Messages:
    73
    Phase 1 looks (and sounds) like it turned out pretty well. Congrats!
    It looked like in a couple of spots in your vid that you could see the steering wander. That's about where I have my wifes cj5 five at with everything new, 2 degree shim and now just a little bit of wander. It's pretty fun on a rutted road eh? Mine seems to be at the steering gear, even though that's new and the shaft is rebuilt, you can still grab that steering shaft and rock it back and forth.
    Anyway, now on to phase 2.;)
     
  18. Aug 24, 2014
    rusty

    rusty Well-Known Member

    norfolk,va
    Joined:
    Dec 16, 2006
    Messages:
    1,652
    Very nice. You have done a great job on it. Looking forward to more. Nice !!
     
  19. Aug 24, 2014
    Long&Low

    Long&Low Active Member

    Geauga County, OH
    Joined:
    Dec 13, 2009
    Messages:
    1,212
    Man, Mine is only a four cylinder, I wish it sounded half as good....
     
  20. Aug 25, 2014
    Leftlane

    Leftlane Member

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    Apr 12, 2013
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    73
    Thanks! I'll do my best keep the thread alive with more pics and videos at interesting stuff (to me, at least) takes shape.

    Yeah, you saw it. That's where I'm at with 6* positive caster! At 0 degrees it was terrifying. Not sure what to look at next. Was thinking maybe my frame is tweaked a bit or maybe there's just 40 year old slop in the original steering box? Turning right with varying degrees of steering input feels okay, but turning left with varying degrees of input gets differing results that then make me have to saw at the wheel a bit to get ahold of it. Also, on deceleration (before applying brakes), it heaves to the left and requires more sawing at the bus wheel.

    Thanks for the complement. I actually enjoy the sound of the 4 banger, believe it or not. To me, it's a sound that goes well with the whole audio/visual Jeep package. If I ever did another "universal" type Jeep, it would likely be a 4cyl fuelie YJ. I'm liking the square headlamp grills more and more.

    I have to fess up to a user-error on my part regarding the comment I made about the Jeg's choke cable. I got it to work well yesterday, but it took some work. My problem was it is a 6' cable and I only needed about 3'. So before throwing it out and ordering a different style, I cut it short with a cutoff tool and then carefully, using a Dremel, cut off the metal jacketing around the solid moving core-cable a few inches back. The much shorter length and straighter run I took the second time around translated to a very smooth choke operation.

    I'm also still futzing around with the carb. The fuel smell is gone, but so is some power. Could be too lean - not sure. The smart thing would be to put it on a dyno somewhere and actually measure fuel/air ratio. What I'll probably do, knowing my typical M.O., is just order one size up (49's) and try that. :/
     
    Last edited: Aug 25, 2014
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