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The Good, The Bad And The Ugly: Project CJ6

Discussion in 'Builds and Fabricators Forum' started by Calvin Evans, Jun 22, 2017.

  1. Jun 25, 2017
    Calvin Evans

    Calvin Evans New Member

    Marysville, WA
    Joined:
    Jun 13, 2017
    Messages:
    16
    Ok, I have been doing a lot of reading on here and other forums. Unless I am mistaken, one of the previous owners of this Jeep moved the front suspension to the front of the axle. I guess this was done to make room for the V8. I do not know if the axle(s) was changed at that time as well, but I suspect not. I have been reading mixed reviews regarding the Dana 25 front axle in my Jeep. Is there a better front axle that has the same gearing as the current rear axle that I could use, or should I try to source a matched set of axles from a later model cj5 or something else? I know that a lot depends on the specific Jeep that is being modified and what the goal is for it, but I am really early in this build and just looking for best practices or places to get started. In the mean time I will keep trying to drink in information from a fire hose...
     
  2. Jun 25, 2017
    masscj2a

    masscj2a Member 2023 Sponsor

    Ware, Mass
    Joined:
    Dec 27, 2013
    Messages:
    743
    Calvin, its funny you mention Vortec V-6's. That's what I just put in my 47 CJ2a. It was a 2000 Olds 4.3. I bought a harness to convert it to a 3 wire hook up (BS) Its never a three wire hook up, but you are led to believe it is. then I had the computer reflashed to eliminate a lot of un-needed items, like the automatic tranny items, security etc. I got to tell you, its one of the best engine swaps I ever did. I know your cj6 is a little heavier, but unless your a speed freak, the 4.3 is a great choice. I also updated the fuel injection with newer MPFI and Sanderson headers. that little thing hauls pretty well. I like it a lot if you can't tell. It will idle up a hill (30 degrees) with no throttle input, in low range, 1st gear with no hesitation at all. I do have a Terra Low kit, with 427 gears and a T-15 tranny. I went with a flanged / offset 44 rear and 30 front with disc's. That's a pretty good combo for most early CJ's. If your going to go hard on it in the rocks, maybe something a little heavier might be best. I think a really good choice is 44's front and rear, but we know how that goes. Just food for thought, like you needed more...............o_O
     
  3. Jun 26, 2017
    Calvin Evans

    Calvin Evans New Member

    Marysville, WA
    Joined:
    Jun 13, 2017
    Messages:
    16
    Oh, I did need more. That is great information. I am probably going to get myself a 4.3 when the time comes. I would love to find a set of those axles in my area...seems like all the u pull it yards in the area have not got any jeep wranglers, cjs, or wagoneers at all and a cursory search of craigslist found only one set of axles (dana 30 and 44 with 3.73 gears) and they are kinda far. Good news is that I have a lot of time to locate a set so I will just have to keep my eyes peeled and jump on them when I find them...unless axles from a cherokee will work, because there are a ton of those in the area, but I hear that the 44 rears are tough to find in the cherokees.
     
  4. Jun 26, 2017
    Calvin Evans

    Calvin Evans New Member

    Marysville, WA
    Joined:
    Jun 13, 2017
    Messages:
    16
    Well...I do not really want to mess with changing out more parts than I need to in order to have my Jeep doing what I want my jeep to do which I am thinking more of a weekend runabout, occasional mild trail use, and as a hunting rig. Perhaps the dana 25 front / 44 rear that it has right now is sufficient with it being geared as low as it is. I dont really want to run more than 31" tires or have a giant lift on it. The army gifted me with a seriously bad back and I dont much enjoy climbing up into a huge rig. I actually like the way it sits right now as far as stance.
     
  5. Jun 28, 2017
    Calvin Evans

    Calvin Evans New Member

    Marysville, WA
    Joined:
    Jun 13, 2017
    Messages:
    16
    No pictures to update with, but I did finish getting the dash out and getting all of the stuff off of the firewall. I am guessing that I am about ready to separate the tub from the chassis. Mostly, though I have been working on my plans for what I want the Jeep to be when it is back together and driving again. I spoke with Daryl on the phone the other day, and he was quite helpful and gave me some excellent advise.

    I am going to keep the 265 in the Jeep, it runs well, and I dont see the need to change it at this time.
    I am going to get rid of the T-90 and D-18 that are in it in exchange for a SM465 and NP205(or maybe a 208 if I cannot find a 205 to fit my tranny). This will allow me to change my rear axle to a centered axle and give me more options for a more agreeable gear ratio to make the Jeep more streetable.

    So, my first order of business is to get the tub off to be media blasted, and then get all of the rusty bits repaired and back to a functional form. I am going to clean up the chassis myself and treat it with some POR15 while waiting for the body to be ready to be mated up to the chassis again. I am going to build in the brackets and holes necessary to mount a hydraulic clutch pedal assembly as well as the hanging brake pedal (because the brake was kinda jury rigged in there, and it has a mechanical clutch currently). I am also guessing that this is the best time to install a saginaw steering system to replace what came from the factory and will be needed since my end goal is a comfortable to drive Jeep that I can use for normal things and probably not for a lot of rock crawling and such. I will have to start haunting the u-pull it yards for stuff to make a workable saginaw conversion for my jeep.

    That is all for now. Have a great day!
     
  6. Jul 4, 2017
    Calvin Evans

    Calvin Evans New Member

    Marysville, WA
    Joined:
    Jun 13, 2017
    Messages:
    16
    I only have the clutch pedal and body mounts left and then off to the media blaster. More pics to come soon.
     
  7. Jul 6, 2017
    mayday

    mayday Sponsor

    Joined:
    Apr 20, 2013
    Messages:
    222
    Have you tryed Olympic 4x4 for looking for parts?
     
  8. Jul 6, 2017
    Calvin Evans

    Calvin Evans New Member

    Marysville, WA
    Joined:
    Jun 13, 2017
    Messages:
    16
    Nope, I will look at them though. I am going to need 2 of every part they used to originally build this Jeep plus 4 each of a bunch of parts I haven't identified yet.
    I am just super focused on getting this thing apart and cleaned up so I can see what I am looking at. Thanks for the tip, I will look into them.
     
  9. Jul 18, 2017
    Calvin Evans

    Calvin Evans New Member

    Marysville, WA
    Joined:
    Jun 13, 2017
    Messages:
    16
    You are probably thinking that I gave up or fell off of the planet, but neither would be the truth...I am just busy and forget to update my build thread...so, where am I at now

    I have removed the body from the frame, there is good and bad to this...the frame is in great shape, and just needs to be cleaned up and POR15 coated to ensure I get another 60 years out of it.

    The axles are good and the transmission, x-fer case, and Studebaker OD all appear to be in good shape, greasy, but not bad

    The engine is good, but has the worst hackjob exhaust ever on it.

    The wiring is all shot, dry rotted, wet rotted, regular rotted, exposed wiring in places, wires that run to nowhere, you get the idea...it all gets to go and be replaced.

    The body is...was...made of rust. I had it media blasted and now have 50% Jeep and 50% ventilation holes. Good thing is that I was looking for some welding practice and now I am getting it. I have started cutting back the badly rotted metal to get to the good metal and welding in patches. I am going to source patch panels for the parts that I can and fabricate the rest. I know that I could buy a new tub, but I don't want to do that, I want to build this thing myself.

    I have sourced a SM465 4 speed tranny (for $70) in great shape and got the NP208 that was attached to it for another $50(also in great shape). I know that the 208 is not as strong as a 205, but for my application it should work just fine. And for the price I couldn't beat it.

    At this point I am going to be making patch panels and welding new metal onto the Jeep body for some time before it is ready for any other steps. I am doing non-structural metal right now to try to get it as solid as I can, and then I am going to put it back onto the chassis and get it square so that I can remove most of the floor and replace it without risking putting an unsightly twist into the body.

    At the slow as hell pace that I am keeping on this it is going to take me a while, but I am just trying to enjoy it, learn as I go, and make sure that I am doing the best work that I can (YouTube vids are helping a ton). I also only have a POS Harbor Freight welder, so I am doing what I can until I have to borrow my brother's big welder.

    Once I am done with the patching and welding I am going to need to source some replacement axles for the stock axles that I have. The offset rear will not work too well with the setup I am going to because the rear drive shaft is going to be only around 18" long based off of some rough measurements. This means that in the near future I will need to be selling on both my axles, t90 trans with SBC adapter and bell housing, D18 transfer case and Studebaker overdrive(the one that mounts to the rear output shaft of the transfer case) so that I can gather the cash to get some replacement axles and maybe some other parts like driveshafts and a non-crappy exhaust.

    I also have a list of junkyard parts that I will need to source the next time the local pull-a-part has a 1/2 off sale. Things like swinging pedals from an XJ, hydraulic clutch setup, master and slave cylinders, saginaw steering box, tilt steering column, and probably other stuff I am not remembering...gunna be fun!

    Thanks for reading the wall of text.

    [​IMG]

    [​IMG]
     
  10. Jul 19, 2017
    timgr

    timgr We stand on the shoulders of giants. 2022 Sponsor

    Medford Mass USA
    Joined:
    Aug 10, 2003
    Messages:
    23,596
    You serious about using a 208 in this? It's the wrong offset for your existing rear axle, and it may be too wide for the CJ frame rails. It's fine as a transfer case, but it's more pickup-truck-sized. And it won't work with your Borg-Warner overdrive. A passenger drop 208 (NP208C?) should be of interest to Wagoneer owners, as a replacement for the BW13xx Quadratrac.
     
  11. Jul 20, 2017
    Calvin Evans

    Calvin Evans New Member

    Marysville, WA
    Joined:
    Jun 13, 2017
    Messages:
    16
    I am aware of the offset issue. I am planning to put intermediate axles into my CJ. When I took measurements it seemed like the 208c would fit in there, but I suppose I might be wrong. I was more concerned with length. I am not going to be keeping the overdrive. I guess worst case, I mock it up in the chassis and it doesn't fit so I have to sell it and find something else that mates to a 32 spline sm465 and will fit.
    Thanks for the advice. I will do a mock-up in the next few weeks (hopefully) and see how it goes.
     
  12. Oct 30, 2017
    Calvin Evans

    Calvin Evans New Member

    Marysville, WA
    Joined:
    Jun 13, 2017
    Messages:
    16
    Oh no, it has been a long time since I posted anything on here.
    Like I said previously, the body of my CJ was mainly made of rust and bailing wire, but with all of my 0 years of fabrication experience I am slowly putting it back together. I am having to learn as I go by watching videos and asking people I know who weld and fabricate professionally, but I am making progress.
    Right now I have the driver side floor fixed, and I am working on the passenger side. I cut out, reinforced, and fabricated new skin for the rocker panels. The bed and rear fenders are going to be completely removed and I have to fab up some new.
    I recently got my hands on a pair of axles from a newer CJ that had been built with lockers and one piece axles and disc brakes, so that will be fun for later.
    I go out and get hands on my Jeep at least once a day even if I cannot do much more than look at it. Big project, and I am just taking my time and learning as I go.
     
    jeepermc and tarry99 like this.
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