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'57 CJ5: Updating The Old School

Discussion in 'Builds and Fabricators Forum' started by AlexCold, May 28, 2016.

  1. May 28, 2016
    AlexCold

    AlexCold Member

    Joined:
    Nov 4, 2015
    Messages:
    140
    Hey all,

    I've been lurking around for a while now. I purchased a '57 CJ5 from a snowbird who's owned it since '57. He was from Portland, Oregon and brought this CJ down with him in '97 to do some desert wheeling.

    [​IMG]

    Looking over the Jeep when I bought it, you can see the evidence of a bunch of old school tricks/mods of the day. But now that I own it, it's time for an update.

    Sweet custom shift knobs!
    [​IMG]

    I plan to keep this a very simple and classic wheeler. I want to make smart thoughtful updates to improve performance without taking away from the classic Willys.

    Engine:
    The 225 v6 was swapped in by the previous owner. He didn't do a terrible job. So far it's running fine. The carb has been rebuilt and really just needs some distributor work to bring the idle speed down.

    Transmission:
    The original T90 is still there and looks to have been rebuilt. Still looks good to my eyes, so I think just a reseal will keep it from leaking. I hope to find a 4 spd to replace it eventually. I'm going to use a hydraulic clutch with an external slave. Going to all hanging pedals.

    Transfer Case:
    The D18 also looks good. It has an Overdrive that I need to diagnose if it's still good. I drove it plenty prior to my dismantling, and it worked great and didn't give me any issues. Routinely drove around 60mph and it didn't seem to mind.

    Axles:
    Front is a Dana 25, I believe. Looking for a reasonably priced Dana 30 to replace it. The positives are that it already has the 5.38 gears I want and a Powr-Lok. Unfortunately the powrlok cross shafts looks to be toast. The only place I seem to find a replacement is Herm's.

    [​IMG]

    Rear is the venerable Dana 44, also with a Powr-Lok. This one looks great when I pulled the cover off, so a reseal and fresh fluids and I'm good to go.

    Suspension:
    Lopping everything off and swapping to YJ springs. Already ordered new hangers from Barnes4x4 and going to order Superlift 1.5" springs. I want to keep this as low as possible. Currently has some 10 leaf springs that seem to give it 4-6" of lift, plus shackles. The ride is stiff and there's no travel at all. Considered pulling springs from the pack, but I still think they would ride rough. With the YJ spring conversion, I'm hoping to gain some wheelbase as well.

    Brakes:
    I plan to copy Meiser's work, utilizing the Samurai brakes all around. Parts are cheap and it just makes sense to me. Currently the brakes were upgraded to the 11" drums all the way around and they actually stopped the 33's really great. Again a hanging pedal w/ a new master.

    Tires:
    Ordering 35x12.5R15 Wrangler MTR Kevlar's this weekend. I'm going this big just because I know that if I order 33s, I might kick myself and be upset I didn't go bigger. Get it done now and be done with it. The dana 25 won't be happy but that's just more incentive to find the dana 30. I have some Mickey Thompson fake beadlock wheels that I might use, since the current steelies look pretty old.

    Interior:
    This will involve a lot work. Purchased some new PRP low back seats. I'm gong to cut the floor out since it's rusted and make room to fit the seats and gain some leg room. I'm also adding a mount for my son's car seat. A new roll cage will also be built to tie it all in. The current cage is actually pretty good for as old as it is, but I want to tie this new one into the frame.

    [​IMG]

    The stock under seat door is in great shape, so It's a shame not to use, so I'm going to move it to the rear bed area and make a small storage area for gear under the floor. The rib spacing match the rear perfectly. Something I haven't seen before.

    A fuel tank will be fabbed for under the seats. Looking to get 15-20 gal.

    Current state of the cab.
    [​IMG]

    This is going to be a process for me. I'm not new to fab projects, but I haven't built a vehicle from home before (or by myself), and I'm still collecting tools. I've only done this kind of work with a full fab shop at work (I'm an engineer). A friend is selling me a Miller 185, and I need to wire my garage for it, plus more outlets (panel is just on the other side, so easy). Which isn't a big deal as it's all new learning experiences for me.

    I plan to finish the vehicle for EJS in 2017. That's this CJs 50th [correction 60th] birthday and I think it would be cool to drive it there, wheel around with like minded folks, and drive it home. I intend to drive this vehicle a lot.

    I've still a lot to learn about Jeeps and wrenching, but I love this hobby and I'm thankful I finally have the resources to start working on my own projects.

    EDIT: Sept 2016

    New Plan-
    Narrowed WT Dana 44 Front
    Isuzu Dana 44 Rear
    T18 - Wide Ratio
    D20 - Transfer case - twin sticked
    225 Dauntless V6
     
    Last edited: Sep 19, 2016
    ITLKSEZ likes this.
  2. May 28, 2016
    Dphillip

    Dphillip Member

    Omaha NE
    Joined:
    Nov 25, 2008
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    322
    Looks like a great foundation to start. What kind of YJ springs did your order to clear the 35's? We go to EJS every year, hope to see you there. Won't your rig be 60 next year?
     
  3. May 28, 2016
    chris423

    chris423 Sponsor

    greeneville tn
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    Dec 30, 2014
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    Welcome from Tennessee . Look like a great foundation !
     
  4. May 28, 2016
    AlexCold

    AlexCold Member

    Joined:
    Nov 4, 2015
    Messages:
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    You are correct, it will be 60. Keep thinking 50 because it was EJS' 50th last year.

    I'm going to use 1.5" Superlift springs. I want to make this as low as possible, I even considered running stock YJ leafs but couldn't find any locally. That and I'm cheap and the Superlifts are 70 a piece on Quadratec.


    Thank you! It's really not that bad and you don't see early CJs out here (SW AZ) ever.
     
  5. May 28, 2016
    SKT

    SKT I Like CJ's...

    Location
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    .
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    Nice '5 - looking forward to your progress!

    .
    .
     
  6. May 28, 2016
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
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    :watch: Subscribed.

    I like the rear toolbox idea! That box is an underutilized resource IMO. I plan on narrowing mine in my build.

    Spring over or under?

    Looking forward to the progress! Sounds like a solid plan.

    Just a heads up... Your steering is going to suffer big time with 35s on stock axles, especially if your wider YJ springs get mounted any wider than your frame. If it's legal in your area, you might want to think about something a hair wider, like Toyota, Scout, Wagoneer... unless it's not an issue for you. Limited steering is a huge pet peeve of mine.

    Carry on. (y)
     
  7. May 28, 2016
    AlexCold

    AlexCold Member

    Joined:
    Nov 4, 2015
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    Thanks! Me too.

    I haven't seen it before on any other builds but I figure it's better than just tossing it away.

    Keeping it spring under. I'm slightly worried about that as well. I'd really like to get waggy axles but stuff is really hard to find out here due to it being snatched up ASAP by anyone in the know or by rust belt folks looking for clean parts.
     
  8. May 28, 2016
    AlexCold

    AlexCold Member

    Joined:
    Nov 4, 2015
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    So I'm getting the BFG KM2 due to the fact they'll cost $20 less than the wranglers after rebates.


    ....and new steelies.
     
    Last edited: May 28, 2016
  9. May 29, 2016
    Dphillip

    Dphillip Member

    Omaha NE
    Joined:
    Nov 25, 2008
    Messages:
    322
    I hope the springs you have in mind have enough lift to clear the tires. Quadratech has a tire chart that indicates you need three inch lift springs with fender trimming to clear 35 inch tires on a CJ. I sure like your plan to keep it low as possible, many advantages to that.
     
  10. May 29, 2016
    AlexCold

    AlexCold Member

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    Well, they're 1.5" lift for a YJ, internet forum musings say they should add an extra 1-2" on a CJ, so maybe 2-3" of total lift. I'm also not shy to cutting fenders to make them fit. I'm pushing the rear back a bit (not sure how much yet) so the rear is getting cut anyways.
     
  11. May 29, 2016
    AlexCold

    AlexCold Member

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    All I was able to do yesterday was clean up the shop (tools and parts everywhere) and layout my cuts.

    Where the floor steps up into the bed area, there is a lot of room between the step and the cross-member. Can anyone come up with a reason not move the step back up to this area and include this wasted space into the cab floor like so? (sweet photobucket paint skills)

    [​IMG]
     
  12. May 29, 2016
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
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    I can't think of any reason not to, if your floor space is more valuable than bed space.

    I know you said you are going to 35s with minimal lift, and that you are moving the axle back some. FWIW, I've found that 33s (depending on the brand) are as big as you can go without moving the axle back without the tire rubbing the body section (seam) in the lower right of your photo at full-stuff. (Just for a point of reference.)

    If you plan on tying your main roll cage hoop into the frame, you might want to plan on it going through this area. Just a thought while you are moving things back; might as well plan for everything at once.

    Looking forward to living vicariously through this!
     
  13. May 30, 2016
    scott milliner

    scott milliner Master Fabricator

    Seattle Wa.
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    33X12.5X15's are the biggest tires I can fit under my Jeep. Even with this size I rub the front springs and ride the rear fender edge when crossed up.
     
  14. May 30, 2016
    scott milliner

    scott milliner Master Fabricator

    Seattle Wa.
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    Do the mean SOA springs?


    This is 3.5" SUA YJ Springs.
    [​IMG]
     
    Last edited: May 30, 2016
  15. May 30, 2016
    PeteL

    PeteL If it wasn't for physics, and law enforcement... 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Hills of NH
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    Your son may not need a car-seat by the time you get this done! :D
     
  16. May 31, 2016
    AlexCold

    AlexCold Member

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    I do plan to move the axle back to prevent this problem, from measuring yesterday, I believe 2.25-2.5" will put the tire in a good place.

    I expected as much, seeing as the 31s rub right now. But really I just want to see a low early cj5 with 35s. If a flat fender can do it, so can this CJ!

    Nope. That's what I read on the internet but maybe not this forum. But looking at that photo, doesn't that look closer to 5-6" of lift? Just going off of my Jeep as a reference.

    Shots fired!
     
  17. May 31, 2016
    AlexCold

    AlexCold Member

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    Did actually work on the CJ this weekend and ordered tires and springs.

    [​IMG]
    It looks like it's meant to go there.

    The rest of the floor is coming in pieces. You have to be a lot more creative when you do things at home and don't have a plasma torch. Sawz-all, jigsaw, and cutting wheel all were out there to get it out. I think I'm going to keep the step in the floor as it's the right height for the seat.
     
  18. May 31, 2016
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
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    That looks awesome. What are you going to do about the crossmember underneath? Go behind it?
     
  19. May 31, 2016
    Alan28

    Alan28 Well-Known Member 2022 Sponsor

    Châtillon en...
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    Before all changing, you can use your Jeep as it is, collect all what you need for transformation and... action.
     
  20. May 31, 2016
    AlexCold

    AlexCold Member

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    Once I cut the opening for the door, I'll decide how to work with/around it. Currently, as it sits, I think this actually fits behind the cross-member (over the axle). Unfortunately the previous owner also welded in a piece of c-channel to support the receiver tube he also added. This either needs to go away, or I can use it as a way to compartmentalize the new storage area.

    Too late now, but I did drive it for 6 months prior to changing anything but fluids. There was a list of things I didn't like, hence part of the rationale of this project. The 35s were just because I'm crazy.
     
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