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Making My CJ5 Into A CJ6/II

Discussion in 'Builds and Fabricators Forum' started by tarry99, Jan 20, 2014.

  1. Jun 9, 2016
    rejeep

    rejeep Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Rochester, NY
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    unreal work..
     
  2. Jun 9, 2016
    tymbom

    tymbom Member

    Siskiyou Co.
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    Sweet... (y)(y)
     
  3. Jun 10, 2016
    Posimoto

    Posimoto Hopeless JEEP Addict

    Minden, Nevada
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    Great to see you making progress, Terry.
     
  4. Jun 10, 2016
    Rozcoking23

    Rozcoking23 RUN & GET BIT! 2024 Sponsor

    Stockton, CA
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    I'm glad to see you got the front end finally figured out.
     
  5. Jun 21, 2016
    tarry99

    tarry99 Member

    Northern California
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    Time to weld the front end on...........Well really weld and then grind a portion of the weld off so that a gusset can be added later that covers the joints............that's where grinding a V between the parts become's important to get weld penetration.........kinda of a pain being's I'm using .188 wall on the main frame rails and .125 on the front and rear sections.

    From this:
    [​IMG]
    And this:
    [​IMG]
    To This:
    [​IMG]
    [​IMG]
    I'll leave the top flange on the tube un-welded for now and tie that weld into the gussets that goes on the sides
    [​IMG]
    Gusset pattern .............this is out of .060 sheet metal..........I'll use some .134 CR 1018 to build the final parts.
    [​IMG]
    The part will look like this when formed up.............the same pattern will work on all four locations inside and out at the joint by just flipping the part.
    [​IMG]
    Kinda like this:
    [​IMG]
     
  6. Jun 21, 2016
    Focker

    Focker That's a terrible idea...What time? Staff Member

    WA
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    You're amazing.
     
  7. Jun 22, 2016
    tymbom

    tymbom Member

    Siskiyou Co.
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    So meticulous....
     
  8. Jul 21, 2016
    Broylz

    Broylz Member

    Gallatin, TN
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    Oct 9, 2012
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    I just read through all 23 pages when i saw the title and had a similar thought about my 5 lately.

    All i can say is you do some amazing work. There is no way i could hope to come close to that. I do look forward to seeing the progression from here.

    Thanks for the great write up and pics this far.
     
    tarry99 likes this.
  9. Jul 21, 2016
    tarry99

    tarry99 Member

    Northern California
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    Oct 29, 2012
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    Hey Thanks............been working on it but making individual parts can be slow without much visual reward, should have some more to share here soon.
     
  10. Aug 4, 2016
    tarry99

    tarry99 Member

    Northern California
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    Oct 29, 2012
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    Bought this new in 1986..............Miller DialArc 250 HF Transformer type TIG High Frequency welder.......been working fine for the last 30 years........a few months back It started acting up....just little things at first that I thought were just me , or the filler rod , maybe dirty material or a bad ground and even questioned the Argon gas quality........I would post a question on the Miller Welding board and wait for a response , then order a part and nothing changed...........after several weeks of messing around and changing or adjusting things yesterday it seemed like it was it's old self once again............went back out to the shop last evening and fired it up and the middle range tap 40 -190 Amps was dead............WOW! WTF..... clicked it to the high range and it welded fine............called all my new found friends in welding maintenance this morning and they were all stumped by what had just happened............at there suggestion I took apart a few things today , cleaned some contacts re-assembled and while the mid range was still dead the High Range now started to go into a slow death spiral and now it is also dead...........It's going into the shop tomorrow , $135.00 bucks for a Load test...........and he's backed up 3 weeks before he can get to it...........If it's too expensive to fix...........I may just buy a new Miller Dynasty machine............not what I was looking forward to.

    [​IMG]
     
    Last edited: Aug 7, 2016
  11. Aug 4, 2016
    jeepermc

    jeepermc Active Member

    Western WA
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    Oh that sucks!
     
  12. Aug 4, 2016
    Posimoto

    Posimoto Hopeless JEEP Addict

    Minden, Nevada
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    Ouch! Sorry to hear about that. Hope it's repairable.
     
  13. Aug 7, 2016
    piffey263

    piffey263 Active Member

    Medford, OR
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    Oct 16, 2008
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    Picture makes it look like it's not even a year old..

    Hard to believe it's from 1986. Hopefully they can fix for a realistic price.
     
  14. Aug 7, 2016
    tarry99

    tarry99 Member

    Northern California
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    Oct 29, 2012
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    Yep, I get pretty anal about taking care of my machines and tools............The good folks and techs at the Miller Welding forums are pretty sure it is a part called a Contactor which costs about $250 that has failed. That part is basically a high amperage relay with a coil that takes 60-70 amps of 230 volts input and distributes it throughout the machine when the on-off switch is turned on...............

    The shop I took it to hopefully will look at it next week or week after , and will probably let that process run it's course just in case they find something different or in addition to the part mentioned above , based on the load testing report.

    In the interim I'm looking at newer machines .................
     
    Last edited: Aug 7, 2016
    piffey263 likes this.
  15. Aug 7, 2016
    rejeep

    rejeep Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Rochester, NY
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    You start figuring $/yr. and I think keep the old one humming...

    They don't make them like they use to
     
    Posimoto likes this.
  16. Aug 25, 2016
    tarry99

    tarry99 Member

    Northern California
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    Picked up my old Miller Dialarc tig machine.........needs a few parts but this guys cost for labor and parts was pretty expensive so I brought it home and decided to buy a new machine.
    In the mean time the good fellows over at Miller welding forums gave me a few tips on how to fix it.............problem is Branded Miller parts are pretty rich and some are hard to find , but I have time.

    [​IMG]
    So what I have to do next is cross reference the old electrical parts over to more common parts..........kinda hard but I'm learning the lingo as I go and have a few distributors working on the replacements which in reality are basically the same in load capacity short of perhaps the original physical size and mounting pattern...........My son-in-law is buying the old machine for his shop ....so as soon as its back together it's going for a ride.

    Been 30 years with the old machine so it's time for a new Miller Dynasty 280 DX Inverter type machine...........much smaller in size but more powerful..........with programmable wave shapes and hertz which should be interesting learning some new tricks!
    [​IMG]
    Looks about half the size of it's older brother and has a remote Pedal.........So no more dragging the pedal and lines across the floor.
    [​IMG]
    Put it together tonight and thought I would try it out on some 1/4" aluminum plate..............Not bad!
    [​IMG]
     
    rejeep and Posimoto like this.
  17. Aug 25, 2016
    PieLut

    PieLut Member

    Glendale, Arizona
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    Jul 20, 2010
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    You're going to love that machine. Bit of a learning curve, but that's part of the fun. A friend who works in aerospace passed along a some info on welding clean aluminum, so I thought you could use it.
    Balance...80-82%

    Frequency...225-250

    Use 3/32 tungsten and make the tip sharp

    Use the soft square wave setting
     
    tarry99 likes this.
  18. Aug 25, 2016
    montanacj

    montanacj Member

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    Jul 11, 2012
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    Nice looking build. I only read the last few pages. When time permits I will have a look at the whole thread.
     
  19. Oct 2, 2016
    tymbom

    tymbom Member

    Siskiyou Co.
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    :whistle::whistle::susp::rolleyes::D:rofl::lol:. We need one that's tapping his foot patiently waiting...
     
    rejeep and tarry99 like this.
  20. Dec 13, 2016
    jeepermc

    jeepermc Active Member

    Western WA
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    Updates?? :)
     
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