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Buffs 58 cj5 build

Discussion in 'Builds and Fabricators Forum' started by Lilbuff63, Jan 16, 2014.

  1. May 11, 2020
    Lilbuff63

    Lilbuff63 Member 2022 Sponsor

    Sonoma County Ca
    Joined:
    Jan 12, 2014
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    296
    Thank you! The two bolt holes up front line up with the existing rivet holes top and bottom on the frame horn. I drilled another hole on top at the back of the bumper through the frame and used a spacer to fill the gap. So with some minor modifications it works out well! It is a nice bumper!
     
  2. Jul 8, 2020
    givemethewillys

    givemethewillys Been here since sparky ran it. 2022 Sponsor

    New Kent, VA
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    Jun 21, 2005
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    I just noticed the rear arch openings on your jeep from your last video in November. Did you end up moving the axle back at all when you redid the springs? I'm at that point in my build, and trying to figure out if I should mount my shackle hangers in the stock location or move them back. I'm doing body work at the same time, so cutting into the body doesn't really matter either.
     
  3. Jul 9, 2020
    Lilbuff63

    Lilbuff63 Member 2022 Sponsor

    Sonoma County Ca
    Joined:
    Jan 12, 2014
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    These are the shackle hangers I used, I mounted them with the flat butted up against the rear crossmember so I believe they are a bit further back from stock. They are YJ springs and obviously longer shackles. 2FF763DF-0DF1-41B7-87DA-26B97F157924.jpeg
    I don’t have a true measurement how far back but the below picture is before the cut so to avoid rubbing and to make it look uniform I trimmed it.
    CFAA1EF4-82E3-4C8D-9198-47B1D8737EE3.jpeg

    This is how it sat stock with very old leaf springs.
    278A5245-18D4-42AF-B5E4-6E0B29950997.jpeg

    This is mocked up before adding weight.
    D9A0199E-F84B-4E94-83F4-FE8A86B729B7.jpeg

    And the final product.
    051EC9C7-4818-427F-81F0-CC8F737E9D05.jpeg
     
    melvinm, Danefraz, ITLKSEZ and 3 others like this.
  4. Jun 13, 2021
    Lilbuff63

    Lilbuff63 Member 2022 Sponsor

    Sonoma County Ca
    Joined:
    Jan 12, 2014
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    296
    Took a drive and did some wheeling yesterday and broke some stuff. My OD went out on the way there and then I snapped a rear axle shaft. A bit disappointed that these things failed under pretty mild conditions.

    Here is where the OD broke, where the shifting mechanism attaches to the gear set. FC24E476-78B6-4AD8-979C-85052788D71A.jpeg

    And here is the axle shaft.

    DB6F14F9-09AB-46A4-9B69-5BA2F211CE74.jpeg

    I have an email into advanced adapters and Herm to see about getting replacements. Both of these things only have 5,000 miles on them. Glad it happened now and not on the Rubicon.
     
    Danefraz, Fireball and Ol Fogie like this.
  5. Dec 16, 2021
    Lilbuff63

    Lilbuff63 Member 2022 Sponsor

    Sonoma County Ca
    Joined:
    Jan 12, 2014
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    Well, after I snapped an axle shaft prior to the Rubicon trip I decided to look into a better option. I called Rich at R&P 4wd to inquire about his full floating rear axle. I liked the bigger diameter of the 30 spline shaft and the fact that there wasn’t any grooves machined at the end of the outer splines. That always seemed like a weak point on my other setup. This is basically the same as the original Warn full floating axle setup from what I understand. 7E8BC2A4-FF0E-4173-8F85-9677B2AD3E03.jpeg

    The difference between the two, old and new. These are also a bit longer so no more bolt threaded into the end of the shaft like I was advised to do with my old setup.
    D1F4DF14-DA67-470E-96B1-F9049C64A5FA.jpeg
    AC921428-EE73-4814-8E4D-B59F159C9F39.jpeg
    And now I have locking hubs in the rear for easy flat towing.
    B9E548AC-204C-4D27-81F5-58B488C41F6E.jpeg

    Speaking of flat towing, two weeks ago I was up at our hunting club screwing around and decided it would be a good idea to peel out in the mud in 4 high. Turns out it was not a good idea, one good clunk and then it was barely catching the gears and making all kinds of racket! I was able to get back to the cabin in 4 low but it doesn’t sound good or always engage in other gears. I’m guessing I broke something in the xfer case. I keep on finding the weak points. Going up Saturday to tow it home and then I can dig into it.
     
  6. Jan 8, 2022
    Lilbuff63

    Lilbuff63 Member 2022 Sponsor

    Sonoma County Ca
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    Jan 12, 2014
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    I got a chance to dig into the transfer case after being home all week with a “cold” that is going around. It looks like I chewed up my overdrive and chipped one tooth on my intermediate gear. The output gears look good, I’ll inspect them further upon removal. Here’s some pictures of the damage:

    05C28486-085D-4FF8-BA22-965C30947B9B.jpeg

    FE412365-3328-4ED8-B313-96608C87021E.jpeg

    0CD5E21F-5E11-44C2-952F-25EBB08C125A.jpeg

    391C9E08-BEAA-4581-B952-224D510EA13E.jpeg

    I think I’m going to look for an intermediate gear and get a rebuild kit from Novak, I’ve needed to seal this thing up (if possible) anyway. I’ll get in touch with Advanced Adapters and look at OD rebuild options. I guess the Saturn OD isn’t meant for slinging mud in 4 high! I thought about ditching it but it sure is nice on the highway!
     
    Last edited: Jan 9, 2022
  7. Jan 8, 2022
    scott milliner

    scott milliner Master Fabricator

    Seattle Wa.
    Joined:
    Dec 17, 2002
    Messages:
    2,364
    Warn FF has hubs specifically designed to not come unlocked. They have set screws. FF use only.

    I broke one of these hubs, but I have never broken one of their axles.
    [​IMG]

    [​IMG]
     
    Last edited: Jan 8, 2022
  8. Jan 9, 2022
    Lilbuff63

    Lilbuff63 Member 2022 Sponsor

    Sonoma County Ca
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    Jan 12, 2014
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    Do you know if those are still available? I like the added assurance of the set screws for locking or when towing. Looks like they just modified a stock 30 spline hub.
     
    Ol Fogie likes this.
  9. Jan 9, 2022
    scott milliner

    scott milliner Master Fabricator

    Seattle Wa.
    Joined:
    Dec 17, 2002
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    Not sure, they sent me new ones when one broke.

    The part number for these Warn locking hubs is 36655. (30 spline)
     
  10. Jan 11, 2022
    cj2atruck

    cj2atruck Member

    Spokane, WA
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    Dec 12, 2020
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    64
    Herm the Overdrive Guy in Washington should be able to help you with the OD parts, as he rebuilds these as well as a ton of other CJ parts.
     
  11. Jul 16, 2023
    Lilbuff63

    Lilbuff63 Member 2022 Sponsor

    Sonoma County Ca
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    Jan 12, 2014
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    Couldn’t wait to get this project started, got the old box out. Took a little work to get the welds ground out due to @timsresort and @jonah doing a great job, thanks guys! Got parts ordered to go to Saginaw and ram assist.

    IMG_9058.jpeg

    IMG_9057.jpeg

    In the trash where it belongs! Had nothing but problems with the Ford reverse setup, that was my second box in 8,000 miles. Not to mention the inaccessibility of the power steering pump. Might be a good application in some setups, just not mine.
    IMG_9060.jpeg

    I have the advance adapters mount already here and 4 hole mount box will be here tomorrow. Going to order the ram today and then mock it up when I have the time (another camping trip with high school buddies next weekend).

    Edit: The U-joint at the steering column was shot as well so glad I’m tearing into this thing anyway.
     
    Last edited: Jul 16, 2023
    timsresort, blalp!, Muzikp and 8 others like this.
  12. Jul 27, 2023
    Lilbuff63

    Lilbuff63 Member 2022 Sponsor

    Sonoma County Ca
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    I’ve had a little time to work on the steering after work this week. Drilled a hole through the cross member for the shaft and it looks like a straight shot:
    IMG_9099.jpeg

    I also layed out the holes on the new box for ram assist. I referenced bleepinjeeps video on YouTube for locations of holes.



    IMG_9098.jpeg

    My plan is to prime the box with fluid and drill and tap the holes and let the fluid clean out the shavings and then flush again. I believe that is what @Norcal69 did and his worked great! I certainly don’t want to take apart a newly built box. I’m going to be helping Liam work on his Grandpa’s Jeep on Saturday and then I’ll be working on mine.
     
  13. Jul 28, 2023
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    You got this!
     
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  14. Jul 28, 2023
    Lilbuff63

    Lilbuff63 Member 2022 Sponsor

    Sonoma County Ca
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    Jeep to do:
    Steering
    Front Sway bar
    Fuse holders
    Junction block for battery
    Add a leafs in the rear
    Skid plate
    New oil pan
    Leaf spring bushings
    Rear axle seals and check bearings? (One rear hub is throwing grease/gear oil)

    Steering being the #1 priority
    Oh, and find another bikini top that I can wrap around my roll bar so I can join the windshield down crew!
     
  15. Jul 29, 2023
    Buildflycrash

    Buildflycrash More or Less in Line. 2024 Sponsor 2022 Sponsor

    Gulf Breeze FL...
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    I just added a row of snaps to my existing top and matched up to the rollbar.
     
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  16. Aug 1, 2023
    timsresort

    timsresort Active Member 2023 Sponsor 2022 Sponsor

    South Lake Tahoe CA
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    That summer breeze on the Rubicon can't be beat!
     
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  17. Aug 1, 2023
    timsresort

    timsresort Active Member 2023 Sponsor 2022 Sponsor

    South Lake Tahoe CA
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    I'm going to follow this, as I need a higher ratio box in the tux, and have always sent them out for porting, but if I could do it myself it would be great.
     
  18. Aug 1, 2023
    Lilbuff63

    Lilbuff63 Member 2022 Sponsor

    Sonoma County Ca
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    I’m going to drill and tap it this weekend and I’ll take videos of the process. Not sure about my videography skills but I’ll do my best!
     
  19. Aug 5, 2023
    Lilbuff63

    Lilbuff63 Member 2022 Sponsor

    Sonoma County Ca
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    We’re drilled and tapped! Went pretty smooth, less stressful than I expected. I have some videos, I just need to figure out how to edit them and put them all into one. IMG_9141.jpeg

    IMG_9143.jpeg
    I perimeter and plug welded a quarter inch plate to the frame to beef it up a bit and then welded the mounting bracket to it. Just a little more welding to finish up and then position the ram and weld that bracket to the axle tube.
    IMG_9130.jpeg IMG_9131.jpeg
     
    Last edited: Aug 5, 2023
    tymbom, 47v6, blalp! and 7 others like this.
  20. Aug 5, 2023
    timsresort

    timsresort Active Member 2023 Sponsor 2022 Sponsor

    South Lake Tahoe CA
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    Very nice. Can't go wrong with that set up. How did you cut the crossmember hole? I rigged a tubing notcher jig with a hole saw when I last did this.
     
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