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'65 Rubicon Rig

Discussion in 'Builds and Fabricators Forum' started by timsresort, Dec 27, 2020.

  1. May 26, 2021
    timsresort

    timsresort Member 2022 Sponsor 2021 Sponsor

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
    Messages:
    636
    Looking at the intermediate shaft made me feel like I probably could have skipped this rebuild, and I knew it has been trouble-free and quiet, but Murphy's Law made me do it, mostly because it does not get any easier. The shaft and thrust washers are not bad, for 32 years. And a testament to a good rebuild, and clean oil.
    [​IMG]
    I have to get the front housing on first, so I cleaned it, disassembled, installed new shifter seals, bearing and front output seal, reassembled.
    [​IMG]
    Prepped the front of the housing for installation.
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    Bolted it up, now I can get to the main shaft installation.
    [​IMG]
     
    fhoehle, Rich M., Fireball and 2 others like this.
  2. May 26, 2021
    Mr Vaughan

    Mr Vaughan Fly by the seat of your pants

    Central City, NE
    Joined:
    Oct 20, 2020
    Messages:
    1,279
    lucky...

    [​IMG]20210514_161045 by Levi Vaughan, on Flickr
     
    timsresort likes this.
  3. May 27, 2021
    timsresort

    timsresort Member 2022 Sponsor 2021 Sponsor

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
    Messages:
    636
  4. May 28, 2021
    timsresort

    timsresort Member 2022 Sponsor 2021 Sponsor

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
    Messages:
    636
    Following the Novak instructions, installed the main shaft, gears, bearings, snap ring. Tapped in the rear race to firm it all up.
    [​IMG]
    Took a shot at figuring the initial shim pack, I was way off. Ended up at about 65 thou. Has 2 thou end play, on the low end, but within Novak's recommendation.
    [​IMG]
    And now the fun starts. Gooped up the needles and spacers with this assembly lube, placed them inside the intermediate gear, the lube really made this easier, it's super sticky and will dissolve quickly. Stuck the thrust washers into the case, held the gear inside, and slid the shaft through. Pretty slick, only had a washer slide down once. The Novak shaft has grooves for O-rings for better sealing.
    [​IMG]
    Installed the lock plate on the shaft, and the cover. I hope this is going in this weekend, then the tub back on.
    [​IMG]
     
    CJeep5, locrwln, Norcal69 and 5 others like this.
  5. May 29, 2021
    timsresort

    timsresort Member 2022 Sponsor 2021 Sponsor

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
    Messages:
    636
    Back at it this morning after a worthless trip to pick and pull. They have started leaving the vehicles on the ground, on the axle, no stands, don't allow jacks. Dumb. Anyway, since I am not using the driveline parking brake, I got out my box of yokes to find a 1310 yoke that is not the companion flange style. This adds about an inch of driveline, and the 60 takes an inch out, so maybe it will work out.
    [​IMG]
    I also need the front 1310 yoke, as i don't trust the tiny stock yoke. Found one in serviceable condition.
    [​IMG]
    Rear yoke on, also tapped and sealed the little shift fork caps that are unique to the 20 case.
    [​IMG]
    Front yoke on, played with the levers to make sure everything shifts. I am leaving the detent out that prohibits 2-low.
    [​IMG]
    An easy stand-up install! Like 5 minutes, and that's a good accomplishment and stopping point for the day.
    [​IMG]
     
    duffer, Muzikp, fhoehle and 10 others like this.
  6. May 30, 2021
    locrwln

    locrwln New Member

    Carson City, NV
    Joined:
    Aug 17, 2020
    Messages:
    21
    Yeah, not sure what’s up with PnP and the vehicles no longer being on stands.

    Jack
     
    timsresort likes this.
  7. May 30, 2021
    timsresort

    timsresort Member 2022 Sponsor 2021 Sponsor

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
    Messages:
    636
    Shock mounts. This will be a lot easier with the tub off. Some 2" box and some 4" angle are what I'm playing around with.
    [​IMG]
    Summit cheap shock studs, cut the 5/8" threads off and will extend them to go through the box tubing.
    [​IMG]
    Drilled the tubing to accept these, and welded.
    [​IMG]
    I'm adding some gussets to reinforce the cantilever, which is needed to get the shock out away from the frame.
    [​IMG]
    Clamped it up, it sits about 4" back from the body mount, where there is a little triangle of space below the body. I need all the length in the shocks that I can get, or it won't droop to its potential.
    [​IMG]
    Burned them in and painted. One more step to getting the tub on. Tomorrow.
    [​IMG]
     
  8. Jun 1, 2021
    timsresort

    timsresort Member 2022 Sponsor 2021 Sponsor

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
    Messages:
    636
    A few clean up items, wiring to the rear, and a rear brake line, flared and clamped to the frame.
    [​IMG]
    And now, the moment I want to get to. I stole a pair of tires off the 3B so the front would roll, and put dollies under the rear, since the rear end is now 2 weeks over due. The plan is to lift the tub and roll the chassis under.
    [​IMG]
    While I am strategizing on the best way to not drop anything, I had a quick Memorial Day BBQ. I wanted to test out this small grill I got, it flat packs the size of an IPad. Hey, us short wheelbase guys need all the room we can get. Short answer is, it works great.
    [​IMG]
    The plan worked well with just a hoist and a few extra hands.
    [​IMG]
    This opens up a lot of work, mostly assembly instead of fabrication. I am excited to get to this step, and now I have more room, and less parts laying around. Now if the rear end would show up...
    [​IMG]
     
    Rubicloak, Ol Fogie, Muzikp and 5 others like this.
  9. Jun 2, 2021
    Jay's WWII Jeeps

    Jay's WWII Jeeps Member 2021 Sponsor 2020 Sponsor

    Napa CA
    Joined:
    Mar 14, 2018
    Messages:
    152
    Whats with the big change? Aren't you an original Coors guy???
    Jeep looks good by the way!!!
    Jay
     
    timsresort likes this.
  10. Jun 2, 2021
    truckee4x4

    truckee4x4 Grant Kaye 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Truckee CA
    Joined:
    May 30, 2008
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    1,262
    Congrats - major milestone!
     
    timsresort likes this.
  11. Jun 2, 2021
    timsresort

    timsresort Member 2022 Sponsor 2021 Sponsor

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
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    I know! I must have missed a payment during graduation, the Banquet truck just went on by...
     
    Jay's WWII Jeeps likes this.
  12. Jun 6, 2021
    truckee4x4

    truckee4x4 Grant Kaye 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Truckee CA
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    Tim - is it acceptable to weld through/place the Loctite under the weld-thru primer? I can't quite tell from your pic but it looks like you removed the Loctite around your plug holes. I’m getting ready to do a bunch of plug welds and I can’t seem to completely get the rust off the old metal that will be mated to the fresh panels….?

    I found an answer from Loctite to the question at HomeDepot.com:
    Screen Shot 2021-06-06 at 7.43.54 AM.png
     
    Last edited: Jun 6, 2021
  13. Jun 7, 2021
    timsresort

    timsresort Member 2022 Sponsor 2021 Sponsor

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
    Messages:
    636
    Sorry for the delay, I was on the road this weekend. No, I have not removed the Loctite at the welds. It welds fine, surprisingly. Before Loctite, I would clean the spot weld areas if there is still rust, then coat with the Loctite, then plug weld. Also the stuff needs rust to work, so I usually just knock off the loose stuff, then apply.
     
    Fireball and truckee4x4 like this.
  14. Jun 10, 2021
    timsresort

    timsresort Member 2022 Sponsor 2021 Sponsor

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
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    Quick after-work 1-beer job today. Front calipers from Autozone, mostly because I could hand them some ratty cores. Not bad at 25 bucks each, and I picked up pads also. Interestingly, the left caliper was coated, the right I had to paint. (Application- '76 K5)
    [​IMG]
    Easy install, with all new hardware. I put a little brake grease on the wear points.
    [​IMG]
     
    Last edited: Jun 10, 2021
  15. Jun 12, 2021
    timsresort

    timsresort Member 2022 Sponsor 2021 Sponsor

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
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    Doing maintenance today on my 3B ahead of a run next weekend. This is why I get underneath every once in a while. Spotted this ujoint cup about to leave. That could have been bad.
    [​IMG]
    On the advice of my brother, I decided to fix this with what is in the jeep. The only cheater tool I used was the floor jack. And if I had really wanted to make this Rubicon reality, I would have put it out in the sun, had 6 friends hanging around, and had several Coors first. All fixed, ready to go. I think Woody just missed having attention.
    [​IMG]
     
    Fireball likes this.
  16. Jun 13, 2021
    timsresort

    timsresort Member 2022 Sponsor 2021 Sponsor

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
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    Back at it on a Sunday. Started disassembling the grill. The plan here is to use the Commando grill I got from my brother, mostly for the wide radiator benefit that has been shown on other builds.
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    The grill I got from Sam has marker lights that were field installed in the wrong location, so I placed the 2 grills face to face to mark the correct location.
    [​IMG]
    With the correct location marked, it's just a hair off!
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    For the pilot hole, I used this great little carbide hole cutter I have for work, used for entering conduit into electrical panels.
    [​IMG]
    Then the Greenlee hydraulic hole punch, makes a clean hole.
    [​IMG]
    Next I made some patch slugs with my throatless shear. It's pretty cool for cutting 16 GA in any shape.
    [​IMG]
    This will work fine. But it's too late in the day to put boots on for welding, so I will hit it this week after work.
    [​IMG]
     
  17. Jun 23, 2021
    timsresort

    timsresort Member 2022 Sponsor 2021 Sponsor

    South Lake Tahoe CA
    Joined:
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    I got distracted and took the weekend off to go into the Rubicon for some R and R. Pulled into the Tahoe staging area, noticed the new improvements, a new kiosk with signage and maps.
    [​IMG]
    Looking closer, I'm on the board. A photo from a few years ago at Buck Island with me pulling a trailer. Pretty cool.
    [​IMG]
    A nice quick trip in, and for father's day, Sam and I had our sons with us. This was at Observation, maybe an hour in.
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    Met up with some friends, had a nice spot on the river, and relaxed. Camp was quiet, and we heard the messed up show was up to the west. That's fine, they can have it.
    [​IMG]
    River front camping was great. The most activity we had was welding a receiver hitch on a buddy's jeep.
    [​IMG]
     
    Rubicloak, locrwln, dozerjim and 8 others like this.
  18. Jun 24, 2021
    timsresort

    timsresort Member 2022 Sponsor 2021 Sponsor

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
    Messages:
    636
    Good news today! The rear end is here, and it is from Currie.
    [​IMG]
    Got it home and off the trailer, and opened. The specs:
    61" wide, offset housing
    Dana 60 high pinion Iron Rock Jock
    Detroit Locker
    5.38 gears, reverse cut
    35 spline (1-1/2") semi float shafts
    Torino big bearing ends, 3" x 3/8" wall tubes
    5x5-1/2" lug pattern
    Currie cast cover, with dipstick, I discovered.
    Under-diff skid plate
    [​IMG]
    Here you can see the high pinion, that really helps straighten the driveline. It also has great ground clearance, with the tilted casting.
    [​IMG]
    Bottom line, I realize this is overkill for a V6 jeep. But....with 37's, never having to worry about a broken axle shaft again is priceless. And I don't have to carry spares. And, I have tried to build a HP 44 for this price, and it's the same, or more. So why not go to a 60?
     
    melvinm, CJeep5, locrwln and 6 others like this.
  19. Jun 25, 2021
    Jay's WWII Jeeps

    Jay's WWII Jeeps Member 2021 Sponsor 2020 Sponsor

    Napa CA
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    Mar 14, 2018
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    I see inspector Henry likes it!! Can you post a pic of the drivers side spring mount in relation to the pumpkin?
    Thanks
    Jay
     
    timsresort likes this.
  20. Jun 25, 2021
    Fireball

    Fireball Well-Known Member 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Pullman, WA
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    Feb 9, 2018
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    :drool;
     
    timsresort and Downs like this.
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