Tim E's 68 Cj5 Build

I have pretty much been flying solo on my Jeep project up until this point, but decided to share some about my build. Found this forum recently and have really enjoyed seeing others' progress, experiences, etc. Maybe you find something interesting in my build, maybe I just get some help remembering where my "yard sale" of parts belong.

About my build:
I purchased a fairly original 1968 CJ5 about 5 years ago with 50k on the clock. Overall it was in pretty good condition for being nearly 50 years old. Problem being that most of the seals...also 50 yrs old. So, like many other adventures here, it started with "fixing a few leaks." Once I had the transmission and transfer case out, well...you know the rest of the story. Thing is, of all the vehicles I have owned, this is by far my favorite to drive, so it is worth doing and worth doing right. That being said, "right" for me is making it drive-able and reliable. So, I will stick with as original as possible, but if there is a modern upgrade to make it more durable or simply work better, I am probably gonna do it. I firmly believe the best Jeep accessory is gasoline.

I know, "pictures please". I also know that after all this, it is still likely to leak somewhere...

As purchased

Disassembly

This is where I am currently at, turning the corner from tear-down to re-build. Actually just sandblasted the frame and coated it with 2 coats of KBS Urethane (will post pics soon). Engine is currently at the machine shop, so I will be tackling the axles next to get back to a rolling chassis. More to come...

 

Thank you sir. Had some serious deja-vu looking through your build...like welding up all the holes around the tub. That was just like fun, only different.

The PO installed disc brakes already, but I did read through the disc brake compilation thread you put together...great info. The MC was full of gunk, new one on the way and I will be sure to address the check valve, residual pressure valve and correct line routing. Brakes were just okay before, should be much better addressing the items mentioned.

Thought I was doing so good with my pictures/post, but I believe when I uploaded them, they somehow were private and only you and I could see them? For the rest who have been so patiently waiting.

 

Found the "Change Permissions" setting for my album...sorry bout that. Great video/info. As they say, "Sometimes the littlest things make the biggest difference." Here are some better pics of my discs. PO was a fairly knowledgeable Jeep guy and said they were from a Ford F150 and bolted right up with very minor grinding for clearance. No idea what year of F150, but it all looks pretty legit...very heavy duty caliper mounting plates as you can see. Discs are 1 1/8" thick.

**EDIT: Upon further research and confirmation from jeepermc in a subsequent post, they are in fact NOT Ford backing plates/calipers. They are the more common Chevy backing plates/calipers and later CJ rotors. **

Picture angle makes it look like the caliper is touching the knuckle, but there is actually at least 1/8" or so clearance

 

Had this beat-up original bumper with tow mounts added, 2 dozen holes drilled, winch plate and braces welded to the frame, etc.

After much cutting, grinding, drilling rivets (fun)...the tumor was removed. (free, you pick up)

Ordered a reproduction bumper (heavier gauge than the original it seems). Will be cutting it down 2" on each side as it looks quite wide with my narrow track and 33x10.50 tires.

 

Current state of affairs is frame sandblasted and sealed with 2 coats of KBS Rustseal. Tried sandblasting myself with a HF pressure tank, but quickly realized I would need about $80 worth of media alone. Called a local guy who did it for me right away (dropped it off on Saturday evening, picked it up Sunday morning) for $100. Couldn't get the money out of my wallet quick enough, $$ well spent. Cleaned up great and had about a 100 grit sandpaper finish to the metal. Perfect for the urethane to adhere according to the KBS instructions. Quart of KBS Rustseal (they have a multitude of colors) was $40. Goes a long way as I still have 1/3 of a quart left and could easily do axles, transmission and transfer case with that much. Also ordered their "Motor Coater" (enamel) in Buick Green, so we will see how that does soon. Anyway, here are before and after pics of the frame...

 

Great looking Jeep even before you started. Looking forward to seeing this one get a new lease on life!

Looks like you've got a really nice workspace there too!

I'm still waiting for warmer weather to get back to work on mine.

 

Thanks, it really was in pretty nice shape for its age. Most of the mechanical things are fairly minor and age related. There is some rust in the usual places, but nowhere near what I have seen on here for you guys in the North and coastal areas. I feel for ya...heck, your username is GraySkies and Focker's quote is "Rust Never Sleeps"!

Seriously though, I am very fortunate. First, I found the "mythical unicorn" of a wife who does not question my "investments"...hence the nice shop full of tools. I live in a fairly moderate climate, have my health, good friends...and a rebuilt Jeep baby on the way. Life is good. I almost titled this thread "My Thankful Build" truth be told. I don't take any of it for granted. Still fresh in my mind is replacing a broken CV joint out in the cold (-40 F cold) in a car I paid $1 for just so I could get to a job that paid $5 an hour. I have another Jeep related story that really put life into perspective for me too, perhaps another day...

Put that thing on a trailer and motor on down, we'll make room (and progress) until Spring. There's a mythical beer fridge in the shop too, just sayin...

 

welcome to the forum . if you didn't do a introduction
looks like a good start
nice garage/shop

 

Looks like you have a great jeep there, I'm looking forward to following along with your build. Welcome to the forum!

 

Not exactly earth-shattering, but I did clean up my leaf springs and started gutting the axles (key components to get me back to a rolling chassis). Axle rebuild parts are on order. I will likely have the axle housings sandblasted then wait for a little warmer weather to paint them prior to re-assembly. Couple of things I wanted to mention...

I found some youtube videos by a guy who goes by MetalShaper. Really great info, says he has rebuilt over 500 CJ axles and it seems right from his knowledge level. I believe he does restorations and even builds entire tubs from scratch! He also mentions having worked with a lubricant company to formulate some of the correct lubes for steering boxes, steering knuckles, etc. I plan to email him and see about trying some.

Also wanted to share one of my most handy shop items as it relates to the axles and leaf springs...my shop sink. They were remodeling a local hospital and I picked up a stainless steel surgical scrub sink for $50. I plumbed one side straight hot water and the other with a regular hot/cold faucet. You can fit some big items in there. So, watch CL for these gems or keep a close eye on your local hospitals, etc.

*edit* Oh, and the towel bar is the (non-correct) grab bar re-purposed from my CJ!

 

:Adam Carolla: Every sink is a urinal :Adam Carolla:

 

Hmmm...never thought of that, but now that you mention...


"Its all just pipes Jerry!" - George Costanza

 

Progress update...

Rebuilt my original steering wheel using KBS Coatings Numetal epoxy putty to fill in the cracks/gaps. Thought about a replacement wheel, but wondered if those might shrink/crack over time too...plus, have heard of some fitment issues. Anyway, I basically followed the instructional videos on KBS's website for steering wheel repair using their NuMetal product, lots of filing and sanding, but it went well. Sorry I didn't take more pics of the process and my "before" photo isn't very good, but I am sure you are all familiar with how the old wheels look.

Before...

After...

Also, some various parts sandblasted and ready for urethane coating...

 

Good stuff. I'm genuinely slightly jealous of your nice clean work space...

I also have the unicorn wife that lets me spend money on my project, until she brought her 68 Bronco home... Beware of that trap...