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66 CJ5 Rebuild

Discussion in 'Builds and Fabricators Forum' started by PieLut, Jul 25, 2010.

  1. Aug 26, 2014
    PieLut

    PieLut Member

    Glendale, Arizona
    Joined:
    Jul 20, 2010
    Messages:
    464
    Two more items knocked off the list. First is a quick release fire extinguisher mount. I modeled this after a design already sold online.
    Much easier and faster to just buy one, but I enjoy the challenge. After designing on the computer I sent it off to the water jet guy and he cut these from 1/8" steel.
    Overall it turned out well and it functions as it should. The location in front of the seat gives me quick access.

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    The second item was mounting the used 8724 Warn winch. I started by making a 3/8" thick mounting plate. Mounting holes and cable slot machined on mill then tacked in place for test fitting. The upper holes are self explanatory, but the lower holes are more complicated. The lower holes pass through the bumper and are sleeved with 3/4" OD tubing for additional strength and support. Fits well and looks good, now I need to wire it up and she is good to go.

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    Bonus Pic from the first trip out this April

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    Last edited: Jan 6, 2018
  2. Aug 26, 2014
    uncamonkey

    uncamonkey Member

    Greeley CO
    Joined:
    Jun 2, 2009
    Messages:
    2,104
    You do some very nice work. My only comment is that where your fire extinguisher is would never work in my CJ3B. It's mounted where my legs usually are. If it works or you then I'll keep quiet.
     
  3. Jan 25, 2017
    PieLut

    PieLut Member

    Glendale, Arizona
    Joined:
    Jul 20, 2010
    Messages:
    464
    A few updates to report.

    First project was to build a CB radio mount. There are many options for mounting a small radio and I decided to mount it flush with the dash to allow easy access. It was important to have it in a place that would make it easy to hear as well. 4 foot FireStik and UnidenPro 510XL radio.

    Simple steel bracket under the dash

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    Then I made an antenna bracket on the tire carrier

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    Came together quite nicely


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    Next up was to update the original headlamps with new Hella H4 units. I bought the Hella Vison Plus 7” lamps. Part 002395301. About $36 a piece with bulbs from Amazon.

    Part of upgrading the headlamps was to add some relays to improve performance of the lights. I purchased a headlight relay kit from Speedway Motors. Part 910-342630. $40.

    This was a great purchase and made install very easy and clean. The kit basically makes it a plug and play setup. Overall a great upgrade and relatively inexpensive at about $110 for everything.

    I first removed the headlights and disconnected the wires. Then I removed the original rubber grommet but was careful to save them to reuse with the new wires.


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    Then I disconnected the driver side headlight wiring harness from the terminal block.

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    I did the same procedure for removing the passenger side grommet. You keep the original headlight plug for the passenger side. The original plug will attach to the new wire kit. This is what makes it a plug and play type setup. The kit comes with new headlight plugs and these will have to be installed into the headlight "buckets."

    I made a simple bracket to attach the relays to the passenger side fender.

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    Two wires attach to the positive side of the battery.


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    This picture shows the kit tapping into the old headlight plug on the passenger side.

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    The entire kit is plenty long for our Jeeps and the wires are covered in a nice black cover. I simply routed my wires, secured with zip ties and installed the new lights.
    The headlights are not as convex as the original style. They still look good and they are definitely brighter!

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    Last edited: Jan 6, 2018
  4. Jan 25, 2017
    tarry99

    tarry99 Member

    Northern California
    Joined:
    Oct 29, 2012
    Messages:
    3,784
    Looking good as always...........I hope that radio has an auxiliary speaker plug in ...........................tough to hear with that little bottom mounted speaker facing down. A speaker up near your ear on the roll cage works pretty good or behind you.
    The old Highway patrol Motorola speakers did a good job and are tough..............something like this: HSN4032B External 13 Watt Speaker (HSN4032)
     
    Last edited: Jan 26, 2017
    jpflat2a likes this.
  5. Jan 26, 2017
    PieLut

    PieLut Member

    Glendale, Arizona
    Joined:
    Jul 20, 2010
    Messages:
    464
    Hi Terry,
    It has worked good so far. I have made a couple trips with it in place and no issues hearing it. The radio is loud with the volume up.
     
  6. Jan 26, 2017
    tarry99

    tarry99 Member

    Northern California
    Joined:
    Oct 29, 2012
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    Great...............Your ears must be better than mine.
     
  7. Jan 26, 2017
    Focker

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

    WA
    Joined:
    Aug 18, 2014
    Messages:
    7,540
    I'm really glad you posted an update. I haven't seen this thread before... Great work!

    I want to drive my CJ more this year and I just might do the headlight upgrade after seeing your post.
     
  8. Feb 1, 2017
    sgogpn

    sgogpn From the top of Lions Back... 2022 Sponsor

    Glendale, AZ.
    Joined:
    Nov 20, 2002
    Messages:
    349
    Dude you make the sexiest looking welds ever :D
    Stop out and see me next time you're out running around.

    Mike
     
  9. Feb 10, 2017
    Posimoto

    Posimoto Hopeless JEEP Addict

    Minden, Nevada
    Joined:
    Aug 7, 2003
    Messages:
    4,538
    Hey Jonah, I am waiting for the Hella setup to arrive so I can do the same headlight conversion. My question is why did you use two relays for the conversion. Does each headlight have it's own relay?
     
  10. Feb 10, 2017
    PieLut

    PieLut Member

    Glendale, Arizona
    Joined:
    Jul 20, 2010
    Messages:
    464
    Hi John, yes each headlight has its own relay. Not my design since I purchased the relay wiring kit. But I believe two relays are common.
     
  11. Feb 11, 2017
    Posimoto

    Posimoto Hopeless JEEP Addict

    Minden, Nevada
    Joined:
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    Thanks Jonah. I think it's going to be nice ditching the sealed beams. BTW, I found the same relay kit at Summit Racing.
    United Pacific Headlight Relay Harness Kits 34263
    Essentially the same price as Speedway but I can drive over to Summit and pick it up.
     
    Last edited: Feb 11, 2017
  12. Mar 15, 2017
    Focker

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

    WA
    Joined:
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    This doesn't sound right?

    I did a DIY relay upgrade yesterday (write up to follow) and I did one relay for low beams and one for high beams. Originally you have power going through the switch where it's split for one low and one high beam output.
     
  13. Mar 15, 2017
    piffey263

    piffey263 Active Member

    Medford, OR
    Joined:
    Oct 16, 2008
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    1,214
    It depends on how you wire it, I did what you did Focker. My k5 has a diy harness one relay for low, and one relay for high.

    Example of why its better,
    I accidently knocked my dimmer switch wires with my foot. I Lost the low beam circuit, but still had both high beam headlights. I will keep this method.
     
  14. Mar 15, 2017
    Posimoto

    Posimoto Hopeless JEEP Addict

    Minden, Nevada
    Joined:
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    I think he actually meant that the high beam and low beam circuits each have their own relay. That's how mine is setup also. The hardest part of the conversion for me was figuring out how to get the spade terminals to unlock from the plugs so I could fish the wires through the hole in the buckets. Great upgrade.
     
  15. Mar 15, 2017
    Focker

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

    WA
    Joined:
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    I just looked at Speedway's PDF and the diagram shows a Hi and Low relay. Whew...I was going a little nuts trying to draw up one relay per light. :confused:
     
  16. Mar 15, 2017
    PieLut

    PieLut Member

    Glendale, Arizona
    Joined:
    Jul 20, 2010
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    You are correct, one for high and one for low. Sorry about the confusion.
     
    Focker likes this.
  17. Nov 14, 2018
    PieLut

    PieLut Member

    Glendale, Arizona
    Joined:
    Jul 20, 2010
    Messages:
    464
    Small update to add...I made a bracket to hold a used bottle jack. Some scrap metal in the garage and a can of "hide the rust". It's an old USA made bottle jack, so it should last a few weeks. Two bolts keep the bracket from rolling in to my feet.
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    Valentino84 and Hellion like this.
  18. Nov 14, 2018
    tarry99

    tarry99 Member

    Northern California
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    Well here's hoping you never need it!
     
  19. Nov 15, 2018
    Muzikp

    Muzikp Active Member

    Sacramento Ca.
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    Sep 27, 2016
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    Glad this thread got updated, hadn't seen it before, great build.
     
  20. Jan 2, 2019
    mike starck

    mike starck Member

    salem,oregon
    Joined:
    Jun 22, 2006
    Messages:
    762
    What are you guys using for the dimmer switch? Still on floor or other. When I wired my '69 I used the two relays and a ON-ON toggle switch on dash next to light switch for dimmer. Up for high and down for low beam .
     
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