Warloch's 63 Cj5 Build

[Warloch]

I'm finally going to get serious on building the '62 CJ5 and thought I would put what's left to do in a thread (well, most of it is left to do).

UPDATE : Checked the Title and I got it wrong - its actually a '63

Plan:
231 EF V6 with EFI from Summit Racing
T18 - Already Built
D18 and might put in an OD - Budget Item
D27 up front and putting Suzuki Disc conversion on it
D44 out back with 11" Drums and there may be a power lock in it
I believe there are 4.88s in it now, will have to verify it
Manual Saginaw - Summit column
Swinging pedals from Wilwood
Replacing Floors - front and back with parts from Classic Enterprises
Custom rear fuel tank for EFI

I'll add notes on the build summary here as it comes together - what parts I decide to keep/put in.
Parts List:
Classic Enterprises for Body Parts - Floor(s), Hat Chanel, Toe Boards, Rear Panel and Mounts.

Her are the pics as it sits in the shop right now:

Drive_Train_Start

• Warloch
• Jun 3, 2019

Tub2_Start

• Warloch
• Jun 3, 2019

Tub1_Start

• Warloch
• Jun 3, 2019

 

[Focker]

This better not take 10 years.

 

[colojeepguy]

You've moved a lot of stuff out of your shop!

 

[FinoCJ]

Sounds pretty much like how I would build one...keep it moving forward.

 

[Warloch]

You've moved a lot of stuff out of your shop!

Built another shed, moved the Red 50 to the garage so I could free up a bay to do this...

This better not take 10 years.

Focker - it "shouldn't" take 10 years, but it might take 1.5 with the way work and health BS has been going The original plan was to have it done this summer, but that got blown out with the surgeries last winter...

I cut the tool box out and put some bracing in the tub. Classic said 'your order has shipped' so we will see what shows up when.

 

[colojeepguy]

I'm very interested in the Wilwood pedal setup...I'm thinking about a hanging pedal conversion on mine.

 

[Chilly]

This better not take 10 years.

That hurt a little.

 

[Warloch]

The wife had me help 'mulch' some of the branches and tree damage we cleaned up and hadn't finish - cut into the jeep time today.

Well - I got the Classic Enterprises Parts - always nice, couple dings from shipping but nothing to worry about.

Classic Ent Parts 1

• Warloch
• Jun 8, 2019

Body Parts from Classic Enterprises - Front Floors and Hat Channels

Classic Ent Parts 2

• Warloch
• Jun 8, 2019

Classic Ent Parts - Toe Boards, Rear Panels and Body Mounts

Classic Ent Parts 3

• Warloch
• Jun 8, 2019

Classic Ent Parts - Rear Floor and Mid Riser

You can see the holes in the floors in this pic from under the tool box.

See Through Floor

• Warloch
• Jun 8, 2019

You can see through the floor where the tool box was

Took less than 1 1/2 hrs to cut the front floors out - I didn't have a plasma the last time I did this type of work... Have I mentioned how nice it is to have a Plasma Cutter for this 'stuff'.

Front Floors Cut Out

• Warloch
• Jun 8, 2019

Front Floors out

Maybe I'll get to cleaning some tomorrow, weather depending, or it will have to wait till next weekend.

 

[sterlclan]

Have I mentioned how nice it is to have a Plasma Cutter for this 'stuff'.

just got one myself....cant believe I waited this long. now im looking for things to cut up.

 

[FinoCJ]

The few times I missed around with a plasma cutter, it made very rough and jagged edged cut....I probably did not know what I was doing but seemed difficult for precise sheet metal work. May have also been the version of the tool that was designed more for thicker pieces of metal.

 

[Steve's 70-5]

Which column are you using from Summit?

 

[Warloch]

Which column are you using from Summit?

I'll have to dig it out as I bought it a few years back, but it should be This One - 30" Floor Shift Tilt - I've also used the 28" but I think they were out at the time. I've used several of these over the years and I really like them for the price.

 

[Warloch]

I finished cleaning out the attachment points for the front on the tub. Getting the back fender tabs off the riser.

Front Floors Cleaned 1

• Warloch
• Jun 15, 2019

Front Floors Cleaned 2

• Warloch
• Jun 15, 2019

There is just the toe boards to pull out now.

Toe Boards Left

• Warloch
• Jun 15, 2019

I found a nice crack in the riser board - I'm glad its being pulled as well now.

Crack In Riser

• Warloch
• Jun 15, 2019

All cleaned out and ready to start welding holes and cracks.

Ready To Start Filling Holes 1

• Warloch
• Jun 15, 2019

Ready To Start Filling Holes 2

• Warloch
• Jun 15, 2019

There are a TON of holes in this tub, its going to take me a while to get them all filled and ground smooth. More details on the plan for body parts later.

One thing to note - I've done several builds like this in the past. The blue '49 I hung from my hoist and worked on as the last one this deep. I will NEVER do that again. The rotisserie I build has already saved me TONS of TIME and TWISTING to get in the positions to do things... not to mention a SIGNIFICANT reduction in the swearing coming out of the shop while doing this. What I posted here, I did in about 3 hours on Friday afternoon - I didn't figure I would be to this point till Sunday. This will make it a MUCH easier process and I'll do all the under dash work before I put the floors back in (structure work and fixes). I can not recommend this enough, and if your on the fence, its worth it far and away.

Saturday I started filling those MANY holes and fixing some of the cracks. I decided to cut and replace the spare tire frame as its just in bad shape and I may as well get it done while I'm here. I also need to order some weld through primer as my Big R has decided they are now catering to the 'fake' ranch folks and don't carry Van Sickle paint any longer - nor do they have fine threaded nuts, they have bolts, just no nutz any longer - on many levels...

 

[Warloch]

Time for my Update... Progress getting the new rear floor and riser put back in.

First some idea of what I'm working with on the rear qtrs and holes for it:

D Rear Holes

• Warloch
• Jun 22, 2019

P Side Holes

• Warloch
• Jun 22, 2019

D Rear Qtr Pre Work

• Warloch
• Jun 22, 2019

D Side Holes Top

• Warloch
• Jun 22, 2019

Cleaning all the rust out - straightening the sheet metal.

Rear Ready

• Warloch
• Jun 22, 2019

PSide Ready

• Warloch
• Jun 22, 2019

Then I coat with some Weld Through Primer to get it ready for assembly

Back Weld Through Primer

• Warloch
• Jun 22, 2019

P Side Weld Through Primer

• Warloch
• Jun 22, 2019

Getting it all test fit and clamped in - Needed just a touch of fitting on the rear floor as they didn't cut the gap for the riser - not a big deal.

Riser Clamped For Install

• Warloch
• Jun 22, 2019

R Floor Clamped For Install

• Warloch
• Jun 22, 2019

All fit and welded in place. Getting some structure back in it and feeling like I'm making some progress a couple hours at a time.

R Floor Installed Top

• Warloch
• Jun 22, 2019

R Floor Installed Bot

• Warloch
• Jun 22, 2019

Some items on the Body and what I'm doing - planning with it. I'm not a big 'make the body perfect' person. I want to remove all the wood, clean the rust, fill holes, beat the rear corners and other places 'close'. Make the metal tub solid and strong. I don't plan on putting any filler on it as my experience is unless its really thin, it cracks and causes issues if you wheel a rig. I have seen some JB weld used successfully in some key areas to help with thinning metal and I might try it - have not finalized it yet.

 

[Steve's 70-5]

I sprayed this in my hat channels. It is like water, runs every where. If you use it, wear safety glasses, gloves, old clothes. Cover your garage floor if you want to keep it clean. If you get it, purchase some extra straws.

Eastwood Internal Frame Anti-Rust Coating, 14 oz. Spray

 

[sterlclan]

The hat channel is a spot that fluid film works well.

 

[Warloch]

I've used the old trick of drilling small holes in the channels and spraying expanding foam in them - seems to work well too. Still debating about how I want to do these.

I am going to use a Seam Sealer that I've been pulling out that the former owner used to clean up and seal the seams - its good stuff and seems to fit the bill well and hold up. The newer version of it is Dynatron 550 Auto Seam Sealer Caulk and there is a brush-able a buddy recommended called Evercoat 365 I'll be checking out.

I started working on the rear corners and cutting the back panels out - we will see how far I get this week as I've got to leave town for a couple days for work. Some serious bugger welds and mess back there to finish up before moving to the front half.

 

[Warloch]

Time for today's update - Getting the rear body work done first...
I got the rear Panels out - they fought hard and were a HUGE PITA to get out, especially with the rear gate surround still in place.

D Rear Panel Out 1

• Warloch
• Jun 30, 2019

D Rear Panel Out 2

• Warloch
• Jun 30, 2019

After pulling the panels, I had a spot on the back D side Fender that had been pushed down. The PO had used the seam sealer to fill it in from the top, but I figured I would fix it as much as possible since I have the supports and panel out on both back fenders.
Started with this

D Rear Fender Fold Pre

• Warloch
• Jun 30, 2019

And then got it put back 'mostly' in shape

D Rear Fender Fold Post

• Warloch
• Jun 30, 2019

After cleaning up the panel areas I put some weld through primer on them and punched through the spot weld holes. Used all my clamps on each, but I got them in place right enough.

Both Rear Panels Replaced

• Warloch
• Jun 30, 2019

Next question to ponder is do I take the filler neck out and put a panel on it since I'm putting a rear tank on this build.

D Filler 1

• Warloch
• Jun 30, 2019

I figure I have an afternoon to finish pounding on the rear corners to get them 'good enough'. She has some scars, but I think it will look fine for a trail rig when I'm done.

Then I'll move on to filling all the 'holes' in the back half before putting the new spare tire bracket back in. So I hope the weather and time will hold this week so I can call the back half done by the end of next weekend.

 

[Boyink]

Repurpose the filler neck - on board water tank, 110V outlet, onboard air outlet...something.

 

[FinoCJ]

Looks good...keep making progress. Let me know if you need an extra set of hands...Guessing you don't need any help though. I'd love to see you do your steering set up. Cheers