CJ7 Tub Swap for my Brother

[W_A_Watson_II]

Well, I've completed two days of work on the Tub Swap on the CJ7 for my brother. Progress seems to be moving along OK, I'm sure hiccups are coming, and waiting on parts and part runs. There always seems to be one fastener that doesn't want to cooperate, but I manage to get it and move on.

You can see more pictures and comments at: http://jeep.wawii.com/83CJ7_NewTubSwap.htm

I'll take constructive criticism, but that doesn't mean I'll follow it. Learning about Jeeps now, after working on the Power Wagon's and M37, it's not too much different, just a lot of torx and screws.
.

[TSEJEEPERS]

Looks good Will.
So is the plan to use the original CJ hood, grill and fenders?

[W_A_Watson_II]

Thanks. Will use the Original CJ's Hood and Grill, but picked up some BTF Tube Fenders. Will need to trim the YJ tub's rear wheel opening to clear the 35's.

[TSEJEEPERS]

You do realize the tub will snubb the hood, grill and fenders.
That is like putting a Mercedes body on with a Ford Escort hood, grill and fenders.

[W_A_Watson_II]

As long as the Hood and Grill don't drive off and leave the tub behind I'm good. The Tub will have enough CJ content that I may have to give it anti-rejection drugs to keep it calm.

[W_A_Watson_II]

Completed two more days worth of work. I've finished the cutting and filling of holes in the firewall, and have cleaned and painted the firewall items. I also cleaned out the heater unit and tested the blower. In addition I've removed the fuel tank, and patched the rear frame tub mounts (as well as moving them outboard for the YJ tub). I've also got the wiring harness cleaned up and in pretty good shape. More details and pictures on My Jeep WEB site: http://jeep.wawii.com/83CJ7_NewTubSwap.htm.

[vlucdog]

Will, search Jeep forums for the blazer blower motor upgrade. I think its a seimens #102.

[W_A_Watson_II]

Thanks Bill, you are correct, PM102

[vlucdog]

I did not use the heatsink on the new motor. Hang on to something when you use it.

Bill

[W_A_Watson_II]

With the Power Fluctuations I didn't do any Power Tool work today, but did get a few things done today. I assembled the inner and outer firewall items (Heater, Accelerator Pedal, Brake/Clutch Pedals, column pass-through, Battery Tray, Brake booster and Master Cylinder, and the inner wiring harness and fuse block/connector. His Farm Service Use Winch and Receiver Cradle came in, and I assembled them as well. I'll fabricate a front receiver hitch so he can use it on the Jeep as well as his Farm Service Truck. Then came the disassembly of the dash, and last today, I stripped most of the dash paint.

[W_A_Watson_II]

Just over 50 hours of work into the Tub Swap now. Waiting on some parts, but progress continues. Found a local guy to open up the ID on some large 1/8" washers on a lathe so I can repair the tub mounts on the frame. Hope to have them back late Sunday. I've stripped the paint off the dash, and now have it in primer, as well as the 1st coat of paint on the glove box door inside surface. The frame has been cleaned and a coat of paint, and I've also got the fuel tank re-installed turned 180 degrees. Also got started on the bake lines.

[TSEJEEPERS]

Looking good!
Why did you install the fuel tank 180 degrees?
What kind of shocks are those?
What rear end?

[wdln]

Why did you install the fuel tank 180 degrees?

Isn't the fuel filler on the opposite side for a YJ vs. a CJ?

[TSEJEEPERS]

Why did you install the fuel tank 180 degrees?

Isn't the fuel filler on the opposite side for a YJ vs. a CJ?

Yes it is. I guess that answers that question.

[W_A_Watson_II]

I'll have to take a look and see what shocks they are, they were on it when we bought it. The axles are out of a 1975 CJ5 and are Dana 30/44 Axles. I rotated the fuel tank to I would not have to cut and then fill the fuel filler holes on the YJ tub, as they are already on the correct side. I have new CJ hoses coming, and between the new ones, and part of the old., I should be able to make it work.

I know the automotive Engineers design to put the fuel filler on the opposite side of the exhaust, but in this country we drive on the right side of the road, and thus pull to the right side of the fuel pumps. The Fuel filler needs to be on the left/drivers side.

[vlucdog]

Will, I found this on the YJ section at jeepforum, looks like a good idea to me.


http://www.jeepforum.com/forum/f12/diy- ... n-1163278/

On the washers for the body mount repair. I used 1.250" x .125 thick washers from fastenal.

Looking good, Bill

[W_A_Watson_II]

Hey Thanks, and Bill I like that idea for my YJ! I picked up the 7/8 & 2" x 1/8" washers at Rural King, and it cost me $10 to get the ID opened up to the 1.320".

[W_A_Watson_II]

I've finished the front brake lines.  You know, there are two brake lines I hate, 3/8" & 3/16".  Bending the 3/8" is just never pretty or easy, and I have the most difficulty getting a good double flair on a 3/16" line.  Why can't everything use 1/4" lines?  I also ran the 3/8" supply, and 1/4" return lines for the fuel system as well.
I picked up the washers from a local friend of a friend who opened up the ID on a lathe to 1.032"  Thanks Richard M. for the fine work.  I reinstalled the brake lines after having given them a coat of paint last night, then I gave the dash it's first coat of paint.
Pulled the rear differential cover and drained the ugly smelly fluid. Cleaned the surfaces and installed new gasket and fluid. I welded the tub mount washers to the frame. Finished all but three brake lines, one to the MC, and the two to the tub Brake Shut-Off Valve. Installed the fuel lines to the engine, and figured out how I'll mount the fuel pump. I gave the rear of the frame it's final paint. I pulled the windshields wiper motors and started the swap process. I fabricated the rear bumper fastener plates for inside the rear frame cross member. And last but not least, I had aggravation with the grab handle. Apparently between the 1st (old style) can of paint I used for the first coat, and the second (newer style, but exact same brand/kind) can of paint something changed. The second coat caused bubbling and it lifted the 1st coat and primer! I had to re-strip and clean it, and start the painting over.

[Fraser]

Did you know the locker was in there or is that a bonus?

[W_A_Watson_II]

We knew it was there when we bought it, but I'd forgot until I pulled the cover. Man was the oil nasty looking and stinky!

[W_A_Watson_II]

I mounted the fuel Pump and connected the final lines. I also re-wired the pump and ran the line to the front harness. Fabricated the rear bumper mounting pads. Wet sanded the dash and glove box in preparation for the next coat of paint, had to remove a few imperfections (don't know why). Discovered in addition to the center three mounting points I had to address, I also had to address the upper two on each side. The outer upper corner required that I adjust the hole in the dash. the next hole in I had to drill and will use a nut on the back side. I fabricated some fillers for part of the YJ defroster duct area, and installed threaded connectors for the dash and welded it to the Tub. Since I had the duct, and a little space I fitted the CJ's defroster to what was left of the YJ's opening. It won't work well, especially with a YJ windshield, but it's there. Last but not least, I re-painted the dash and glove box.

[W_A_Watson_II]

Good Progress today. Fabricated a new tunnel shifter cover. Will still need to cut the shifter holes, but will do that later when I know the correct locations. Well, with the aid of a 2nd Engine Hoist (Thanks LaVelle H.) I lifted and set the YJ tub on the CJ this morning by myself. It went on easy and with no issues (hopefully that's a good sign). I pulled the rear wheels off so the hoist would slide in, and because I need to measure, mark, and cut the wheel well openings to clear the 35's. Pieced together a new fuel filler and vent hoses for the YJ filler opening to fill the CJ's 180 degree rotated fuel tank. Should work out well. Installed the fuel tank and axle vent lines onto the new tub. I also removed and transferred the CJ's rear wiring harness to the YJ tub. I then welded up two cuts and three cracks in the TJ tub I started the installation of the CJ's Tail Gate onto the YJ tub. I've marked the holes, and fabricated the backing plates needed to mount the hinges. Still need to fabricate the strap brackets though

[W_A_Watson_II]

Well, 92 hours into the job and I think I see a light, hope it's not a freight train. I removed the old tailgate latches from the CJ tub, and welded them into the YJ tub. Finished welding the extra plate to the front 2" reviver hitch. The winch looks kind of weird setting up and out like that, but should work well.

[vlucdog]

That picture makes the winch look huge. It does llook good on the front of the WWII VFD Pumper though. Bill

[Jon Martin]

Looks like you will be ready to hit the trails pretty soon. Hmmm????? I wonder what the FSF stands for on the shackle reversal mounts for the spring???? I know what Frank and I would say it stands for!!!! On a serious note, what does the receiver mount look like from the top and how thick is the receiver tube on the winch mount? Unless it was a straight line pull, I would be concerned with something bending...... or to quote Pirate 4x4.... It needs more triangulation. Oh Will, when you are done with the tub swap project, Jill needs a new tub and a new frame.