1. Registration trouble? Please use the "Contact Us" link at the bottom right corner of the page and your issue will be resolved.
    Dismiss Notice

Cody's '66 Cj5 Build

Discussion in 'Builds and Fabricators Forum' started by Cody12, May 14, 2021.

  1. May 14, 2021
    Cody12

    Cody12 New Member

    Northern CA
    Joined:
    May 18, 2020
    Messages:
    17
    Hello everyone,


    I have been browsing the forum for the past year after the purchase of my first CJ5 in May of 2020. I was specifically looking for a CJ5 with the V6, and was lucky enough to find one in decent shape not too far from me. Although this jeep did spend it's life here in CA (or so I was told), it did spend some time on the CA coast, and was not used or taken care of for some time. Overall it's in pretty decent shape, we spent no time after getting it addressing some of the issues that it had. It runs great but there were some usual rust/bubba repair issues that I wanted to fix. The tub was a bit bouncy in the back when I test drove it and later we found out there were no bolts holding the rear of the tub o_O. Other than that, everything shifted as it should, and sounded great. This will not be a restoration by any means. It is mostly original with the exception of 31" tires and some small things here and there. It's got the T86, with dana 27 & 44 axles. I don't plan on swapping anything out or doing much changing, just cleaning up what is there and replacing anything that needs replaced.


    Although I have never owned a CJ5, my dad has a '57 and he has been helping me. It has been a fun project and it gives me an excuse to spend more time with him (plus he has all the tools and the shop) (y) When I got it, the plan was to just address the few issues we noticed on it, (wiring was not correct and several of the wires were either corroded or going nowhere, fuel line was routed with multiple pieces of flex line, there was some rust under the rear of the tub and the other usual places, and the radiator had several leaks and the outlet had been bashed in to allow room for the fan as they had a 2” spacer on it for the HEI). As we got more into it, we realized there was a bit more than we originally had thought but it would be better to do it right.


    The first thing we did was some tear down. Took the bumpers off and sandblasted them (there was even bondo in all of the bumper holes). They got sent off to powder coat and they turned out pretty good.

    IMG_1618.jpg IMG_1617.jpg


    IMG_2241.jpg

    IMG_2242.jpg

    Got to work on the gas tank, cleaned it out and gave it a quick sand and spray with some new paint. It was actually surprisingly clean inside.

    IMG_1742.jpg
    IMG_1745.jpg
     
    Last edited: May 14, 2021
  2. May 14, 2021
    Cody12

    Cody12 New Member

    Northern CA
    Joined:
    May 18, 2020
    Messages:
    17
    And the tear down on the engine/tub began..
    IMG_1739.jpg
    IMG_1748.jpg

    Here's some of the rust that came out of the rear crossmember :shock:
    IMG_1751.jpg

    After the engine was stripped, I prepped it for paint. I went with this greenish POR15 (if I remember correctly it is called Buick green) and I'm pretty happy with how it turned out. I just applied it with a foam brush which worked ok. I assume it goes on a bit smoother with a gun. Only took about 15 foam brushes from start to finish. Shot some black on the frame and firewall just to see how the contrast will be.
    IMG_1800.jpg IMG_1805.jpg
     
  3. May 14, 2021
    Cody12

    Cody12 New Member

    Northern CA
    Joined:
    May 18, 2020
    Messages:
    17
    Put a bit back on the engine (starter, alternator, carb, fan) but this is about when we decided that we should remove the tub so we can repair the rusted hat channel/clean and paint the frame. The underside of the tub does need some attention and will just be easier with the tub off.

    IMG_1813.jpg

    Fired up the forklift, and off with the tub.

    IMG_1848.jpg
    IMG_1850.jpg

    Then it was time for the frame to get painted. I cleaned it and used a needle scaler to get into the corners where some gunk had collected. It worked very well. This pic shows where the needle scaler had and hadn't been used.
    IMG_1854.jpg

    I bought a black tractor/heavy equipment paint from Tractor Supply and shot the entire frame and the axles.
    IMG_1884.jpg
    IMG_1906.jpg
     
  4. May 14, 2021
    Cody12

    Cody12 New Member

    Northern CA
    Joined:
    May 18, 2020
    Messages:
    17
    There was some additional work on the frame that I unfortunately did not get photos of. Put in a new master cylinder, replaced both rear axle bearings/seals, new wheel cylinders, new clutch bellcrank as the pivots were worn, reinstalled the brake lines and bled the brakes. Also put new shocks, and drained all the fluids.

    After the frame was buttoned up, my attention turned to the tub, which is where I am at currently. First thing I did was pull out the sandblaster again to get a better idea of what was hidden. I knew there were a few areas to address, as the paint had cracked and split due to the bondo splitting under the paint. When I got done blasting, it revealed where we would need to make some 18ga patches to get the tub even again. One of the PO's had just filled the gap with bondo.
    IMG_2151.jpg IMG_2155.jpg IMG_2144.jpg

    There was some poorly installed tail light panels that were riveted into the tub. They were loose and would rotate if you pushed on them. There was some rust back there too so we just cut them out and cleaned them up so they could be welded in.
    IMG_2147.jpg
    IMG_2148.jpg
     
    locrwln, 73 cj5 and FinoCJ like this.
  5. May 14, 2021
    Cody12

    Cody12 New Member

    Northern CA
    Joined:
    May 18, 2020
    Messages:
    17
    Then we cut the patch pieces to size and welded them in. I had never welded before so it was definitely a learn as you go type of deal. All I have is a flux core welder so it was not ideal but made it work. Luckily we had several flap discs to take it down smooth with the grinder :rofl:

    IMG_2215(1).jpg
    IMG_2216(1).jpg

    Also welded the wheel well cutout on the drivers side. One of the PO's had done the cutout and then bent some pieces to somewhat fit the space. They tacked a few welds and then used some bolts to hold it. This left a huge gap on the top and sides that allowed dirt/mud/dust to fling up on the back of the driver seat and onto the floor board under the tank.
    IMG_2232.jpg

    This is about currently where I am at with the tub. We are in the process of building a rotisserie to turn the tub upside down so I can patch the rusted hat channel. From what I can see, it looks like the factory wood is still in the hat channel so I'll have to cut out the rust and repair it. The rotisserie will also help when it comes time to paint. I haven't bought any paint yet but was maybe going to keep it white. Not sure yet. From what I can see, the jeep looks like it was originally spruce tip green? It's almost a teal color that you can kind of spot in some of the photos. Maybe someone else might recognize the color.

    Hopefully within the next week or two, the jeep will be upside down so I can get to work on the last of the repairs, then it's time to prep for paint and reassembly.
     
  6. May 14, 2021
    Buildflycrash

    Buildflycrash More or Less in Line. 2022 Sponsor 2020 Sponsor

    Gulf Breeze FL...
    Joined:
    Jun 5, 2007
    Messages:
    2,921
    Great thread. Good to see you only have moderate project creep so far. At this pace you can be ready for the Rubicon Run in Mid July.
     
    Muzikp and truckee4x4 like this.
  7. May 14, 2021
    homersdog

    homersdog Tulsa, Ok 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Tulsa, OK
    Joined:
    Jan 8, 2012
    Messages:
    2,014
    Your doing good work! A single barrel carb makes me think your engine came from an actual Buick, or a boat.
     
  8. May 20, 2021
    truckee4x4

    truckee4x4 Grant Kaye 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Truckee CA
    Joined:
    May 30, 2008
    Messages:
    1,320
    Nice work and great progress!
     
  9. May 20, 2021
    tymbom

    tymbom Member

    Siskiyou Co.
    Joined:
    Jun 13, 2012
    Messages:
    762
    Nice work!
     
  10. May 23, 2021
    Beach66Bum

    Beach66Bum 1966 Tuxedo Park Mark IV 2021 Sponsor 2020 Sponsor

    Big Island on...
    Joined:
    Oct 30, 2015
    Messages:
    1,361
    Great following along with your restoration!
     
  11. May 23, 2021
    givemethewillys

    givemethewillys Been here since sparky ran it. 2022 Sponsor 2021 Sponsor 2020 Sponsor

    New Kent, VA
    Joined:
    Jun 21, 2005
    Messages:
    1,820
    Great work so far!

    In looking at the original color that I can see of your jeep, I don't think it's spruce tip green; it looks too blue to me. My money is on empire blue, but it's hard to tell from the small pictures.
     
    Lockman likes this.
  12. Aug 24, 2021
    Cody12

    Cody12 New Member

    Northern CA
    Joined:
    May 18, 2020
    Messages:
    17
    Just a quick update on my progress - unfortunately I have not been able to work on the Jeep as much as I would like. Other things have gotten in the way the past few months and my progress has slowed. I have been able to put some time in recently getting to work on the tub. We concocted a homemade rotisserie with some material lying around and were able to get the tub turned over to address the floors. Sorry if the pics are small, I have been trying to figure out how to add large pics without getting the 'file too large' message.


    Cutting out the rusted and pitted driver floor board section. I will also replace the floor riser between the front and rear floor. I ran out of time so this is still a work in progress.

    IMG_2391.jpg

    IMG_2392.jpg



    Then proceeded to clean up the hat channels to address what needed to put replaced and what could be remedied.
    IMG_2393.jpg
    IMG_2394.jpg IMG_2395.jpg IMG_2396.jpg IMG_2397.jpg IMG_2398.jpg IMG_2399.jpg IMG_2400.jpg
     
    Last edited: Aug 24, 2021
    Muzikp, Buildflycrash and Fireball like this.
  13. Aug 24, 2021
    Cody12

    Cody12 New Member

    Northern CA
    Joined:
    May 18, 2020
    Messages:
    17
    Some more photos of the hat channels. The entire underside of the tub has some sort of undercoating applied that is a PITA to get off. It gums up any flap disc or sander so most of it I had to remove by elbow grease.

    I will be cutting out the floor under the channels and replacing. After that I will be cutting out the floor riser and also replacing the rear valence panel with new body supports as that whole area is covered in rust. I am still tossing around the idea of whether or not the rear should be replaced. It is bowed and there are a few spots where the rust has made it's way through. I figure I'm already placing most of the floors, so I should also do the rear.

    IMG_2402.jpg IMG_2403.jpg
    IMG_2401.jpg
    IMG_2405.jpg IMG_2404.jpg
     
    Muzikp and Fireball like this.
  14. Aug 24, 2021
    Lockman

    Lockman OK.....Now I Get It . 2022 Sponsor 2021 Sponsor 2020 Sponsor

    White City, NY 14617
    Joined:
    Dec 4, 2018
    Messages:
    2,322
    I concur......Empire Blue.
     
  15. Aug 24, 2021
    Buildflycrash

    Buildflycrash More or Less in Line. 2022 Sponsor 2020 Sponsor

    Gulf Breeze FL...
    Joined:
    Jun 5, 2007
    Messages:
    2,921
    I had 87 piles of rust about the same size from my rebuilding. Your doing great!! Keep at it.
     
  16. Jul 8, 2022
    Cody12

    Cody12 New Member

    Northern CA
    Joined:
    May 18, 2020
    Messages:
    17
    Wow, it's been almost 1 year of posting any progress. Unfortunately I haven't been able to spend the time or money I want on the rebuild. Between getting engaged, buying a house, and planning a wedding I have been very occupied. With that being said I have made a bit of progress and plan on getting back into it more in the next few weeks.

    I had contemplated about replacing the rear floor and rear riser. I honestly could have left it as it wasn't too terrible, but I figured I've already got the tub off so I fired up the cutter and went to town getting it out. Then placed an order with classic enterprises for a new rear floor, rear riser, and rear valence panel.
    IMG_2408.jpg


    Got everything cleaned up real nice with the grinder prior to fitting all the panels up. There were a few areas in the rear where I had a difficult time getting the floor to sit flush. With some more grinding I was able to fit everything up nicely and weld it into place.
    IMG_2497.jpg


    And the finished installation. Still a few more places I need to weld on but mostly done.
    IMG_2500.jpg

    This is basically where I'm at currently. I pulled the tub into the shop for the winter and now that the weather is nice, I plan on pulling it back out and finishing the front floor repairs and hat channel repair. I have been unable to touch it since November so I plan on getting back into it. I have a new driver floor panel on order so as soon as I get that it will be going in.

    My plans for the next 6 months:
    Driver floor repair
    Small passenger floor repair
    Hat channel repair
    Sandblast cowl area under dash
    Clean and prep for primer
    Primer & paint

    The hope is to have the tub painted and back on the frame before the end of the year. It's an ambitious goal for myself but I want to make some serious headway to getting this thing back together. Hopefully in the next few weeks I will have more progress to show. Here's to hoping :beer:
     

    Attached Files:

  17. Jul 26, 2022
    Cody12

    Cody12 New Member

    Northern CA
    Joined:
    May 18, 2020
    Messages:
    17
    Went to work on finishing the driver floor this weekend. First step was patching the floor brace that had rotted out.

    IMG_3148.jpg

    IMG_3149.jpg
     
    Muzikp and givemethewillys like this.
  18. Jul 26, 2022
    Cody12

    Cody12 New Member

    Northern CA
    Joined:
    May 18, 2020
    Messages:
    17
    Then patched the actual floor piece. I had bought the full replacement floor panel from Classic Enterprises but I didn't want to patch all the way up to the toe board. That section of floor is not rusting and I didn't want to make more work for myself than needed. The floor brace was very rusty. I cleaned it up with a wire wheel and coated it with POR15 metal prep, which completely transformed it to a usable metal.

    IMG_3151.jpg

    IMG_3150.jpg

    Then hit it with POR15 rust preventative. I'm happy with how it came out and I'll feel better knowing these will have some rust protection for the future. I do live in northern CA where it's mostly dry, but I wanted to do this for my peace of mind. I will also be coating each of the floor braces with Eastwood internal frame coating once I complete the floor repairs.
    IMG_3154.jpg
     
    Last edited: Jul 26, 2022
  19. Jul 26, 2022
    Cody12

    Cody12 New Member

    Northern CA
    Joined:
    May 18, 2020
    Messages:
    17
    Then fit the floor piece and welded it in. My welds are terrible and I'm still learning but the floor is plenty strong. Next step is fabricating the front hat channel pieces that sit on the toe board braces. I plan on getting some 16ga sheet and bending it to create my own channels rather than buying the entire set.
    IMG_3156.jpg

    IMG_3161.jpg
     
    blalp!, Twin2, Fireball and 3 others like this.
  20. Aug 5, 2022
    Cody12

    Cody12 New Member

    Northern CA
    Joined:
    May 18, 2020
    Messages:
    17
    This past weekend I was able to fabricate my own floor braces. I didn't want to buy an entire set of new braces due to the cost, so I decided I would just fabricate my own, attempting to make them close to the original.

    Drivers side bent and welded in. There is a crush sleeve in the bracing to prevent crushing.
    IMG_3171.jpg

    And coated with more POR15.
    IMG_3173.jpg
     
    Muzikp and Fireball like this.
New Posts