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Rebuild For "miles"

Discussion in 'Builds and Fabricators Forum' started by Jw60, Nov 24, 2009.

  1. Dec 16, 2022
    timsresort

    timsresort Active Member 2023 Sponsor 2022 Sponsor

    South Lake Tahoe CA
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    Nice, what gauge?
     
  2. Dec 16, 2022
    Jw60

    Jw60 Sitting up n buckled down. 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sedalia MO.
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    18ga aka .048"
    The top edge is hemmed and the two material thicknesses are broke instead of having a separate backing strip. It's a lot easier that way using pressbrakes and gets rid of the sharp edge on the inside.
     
    Last edited: Dec 16, 2022
  3. Dec 16, 2022
    Jw60

    Jw60 Sitting up n buckled down. 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sedalia MO.
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    No actual work on the jeep today since I was out in the factory.
    I'll update this post to be a more complete to-do list but for a start I'll do the big projects on this thread and any others like the brake master cylinder swap I've got going. This is roughly sorted by priority, ability to get done, and some things are dependent on others to be done first.

    1. Dual reservoir master cylinder (stepped bore) with added proportioning valve,
    1a.mechanical stoplight switch.
    1b. clutch pedal shaft rebuild.
    1c. Trailer brake controller pigtail. Reverse light switch, 20a Circuit breakers for trailer brakes, 30a breaker for trailer 12v aux.
    1d. Flat tow harness

    2. Saginaw steering. This project is why I've pulled the jeep off the road but slowest going due to cost.
    2a. Front suspension bushings
    2b. Hydraulic lift for snowplow

    3. Body repairs, general bent fenders and corners.
    3a. Corner guards with bow sockets
    3b. New Body mounts (I ain't got none)
    3c. Fix floorboard level / new driver and passenger floor. currently floor is 1.75" above bottom of body with sign posts for channels. Sign posts.are rusted out and the road sign floor is heavy. Fuel Tank is really tight to the seat.

    4. general weather proofing of equipment and security of components.
    4a. Remote vents for everything (note to self: distributor vent)
    4b. Snorkel capability, I want to run a trail with deep (37" possible) water crossings. Snorkel itself will be a sewer hose and tail pipe extension.
    4c. Waterproof pcm enclosure with glove box

    5. 36" stretch (cj6 style for now, m170 alteration later)
    5a. Body
    5b. Frame
    5c. Electrical, brake line, driveshaft
    5d. Sliders, skidplates
    5e. Soft top
    5f. Hard top
    5g. Seats
    5h. Rear heat

    6. Sm465 (I've had the transmission kicking around for 15years)

    7. Dana 30 (d25 ain't broke yet)
    7a. Front locker

    8. Rear fuel tank (auxiliary)

    This is a heck of a list but if I can get to 5c I'll run the bikini on some top bows for most of the summer. The full soft top and sliders will need to happen for a Colorado appearance.
     
    Last edited: Dec 17, 2022
    timsresort, blalp!, 73 cj5 and 2 others like this.
  4. Dec 17, 2022
    timsresort

    timsresort Active Member 2023 Sponsor 2022 Sponsor

    South Lake Tahoe CA
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    Now that is a list. I made a list for my 3B the other day, it came nowhere near yours and still made me nervous.
     
  5. Dec 17, 2022
    Jw60

    Jw60 Sitting up n buckled down. 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sedalia MO.
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    Luckily it's just a CJ and the powertrain is good enough. I've got about 45min a day I can work on this for welding, grinding, and other loud noises. Half of my 30' by 30' basement has become my workshop. So on warmer nights I'll work on electrical and quiet on jeep stuff, Lunch is power hour, and on the colder days I can work on subassemblies downstairs.
    The biggest constraint is cost so that's why a lot of stuff is clean up and things I've already got supplies for. The power steering, dana 30, is all from scratch. The sm465 I have and was in good rebuilt shape but needs the adapters.
     
    timsresort likes this.
  6. Dec 17, 2022
    Jw60

    Jw60 Sitting up n buckled down. 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sedalia MO.
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    Remote oil filter is removed to provide a place for a power steering pump, and the exhaust can now go where the oil lines were making room for the steering shaft.
    I had to pull my starter off to pull the bellhousing cover to pull the block adapter off. I could modify the cover but it's not an issue anymore.
    Front brake lines are in place but might come back off so I can drill and tap for remote reservoirs but on the ends of the master cylinder instead of the side... where the brake arm goes.
    The now front residual pressure valve was used for all 4 wheels with the single reservoir master cylinder. I found the rubber duck bill valve inside is cracked making it a 0psi RPV. It is now in a fairly easy place to work with so I'll go with it as it is for now. The rear line is next and it already has the RPV valve on the adjustable proportioning valve. I'll snake that up to the master cylinder and bend the bends in place. The clutch pedal pivot on the frame is removed so I can clean it up and make something different...

    [​IMG]20221217_150157 by Joe with a jeep, on Flickr

    [​IMG]20221217_162005 by Joe with a jeep, on Flickr

    [​IMG]20221217_163636 by Joe with a jeep, on Flickr
     
  7. Jan 10, 2023
    Jw60

    Jw60 Sitting up n buckled down. 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sedalia MO.
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    I haven't updated this recently, not as much time as i'ld like but I'm not very fast at dishes, laundry, or cooking...
    I got a tie rod for a 75 cj so it needs 5" removed, it looks like I can get a right hand tap reasonably so I have identified the correct right side and will trim that up.
    A manual steering box is on it's way, power steering would be nice but I'm afraid the complexity isn't justified.

    Now I'm looking for a manual Saginaw Pitman arm for a jeep... not really confident in what I found. Rock auto doesn't have any listed for jeeps and Amazon is worthless.
    I plan to rework my motor mounts to clear the shaft and my exhaust manifold will need adjusted to clear.
    Manual Saginaw to 1"DD shaft.
    3/4" DD shaft telescopes inside 1" shaft
    3/4" DD shaft to 7/8 smooth bore column (this likely needs to be a double)
    Cut column and I just need the bushing
    I have a postal jeep frame with the Saginaw holes in both frame horns so that horn will be copied. (No postal column with it)

    The dual master cylinder swap should wrap up soon. There is a lake of oil and brake fluid under this thing. I'll replace the front bushings next.
     
    Ol Fogie, blalp! and Fireball like this.
  8. Jan 11, 2023
    jeep peep69

    jeep peep69 Member

    redding ca.
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    The postal frame steering box bolt hole don't match a 4 hole Saginaw box you need to use a commando mount or make your own
     
    blalp! and Jw60 like this.
  9. Jan 14, 2023
    Jw60

    Jw60 Sitting up n buckled down. 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sedalia MO.
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    This post is brought to us by @3b a runnin whom I owe a case of brew or something.

    This arrived yesterday:
    36 spline on both ends. 6.5 turns stop to stop
    [​IMG]
    [​IMG]
    [​IMG]

    I'm planning to mock it up with some 12ga as a bracket and a stout 12ga Pitman arm. Then I'll get a real bracket made from 1/2" plate and a proper Pitman arm with the drop needed. I know I need a double U-joint at the column but I'm not sure if I can run a straight 3/4 dd shaft or if I should use a 3/4 DD and 1" DD shaft for adjustability. Seems like an added expense...
     
  10. Jan 17, 2023
    73 cj5

    73 cj5 Not ready for the junkyard yet

    Clinton, Mississippi
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    I am fairly certain I have a few manual Saginaw boxes with the stock pitman arms still attached. May have a few other steering baubles too. Drop me a line if you want.

    This go around I couldn't run the steering shaft straight to the box so I cut it in half and added another joint in the middle with a heim joint for support. At the time I ordered the additional joint and heim, it was cheaper than a double ujoint at the steering column. Just an example.

    [​IMG]
    [​IMG]
     
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  11. Jan 17, 2023
    Jw60

    Jw60 Sitting up n buckled down. 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sedalia MO.
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    I've got the shaft, u-joints, and an omix-ada 18006.04 manual arm for a wrangler on the way.
    I'm copying a jeep I know, I’ve just got a 4.3 and snow plow parts to avoid.
    Ordered the new junk on Amazon :D
    Pitman arm number was pulled from other sites to verify manual Saginaw.
    [​IMG]Screenshot_20230117-064212_Samsung Internet by Joe with a jeep, on Flickr

    Here's what I'm shooting for, mine sits higher so I'm starting with the drop arm.
    [​IMG]20220910_155729 by Joe with a jeep, on Flickr
    [​IMG]20220910_155818 by Joe with a jeep, on Flickr
     
    Last edited: Jan 17, 2023
    timsresort likes this.
  12. Jan 17, 2023
    Jw60

    Jw60 Sitting up n buckled down. 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sedalia MO.
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    New energy suspension front bushings are in place. They don't have an outer shell and slide in place, way easier on the frame side of the shackles.
    With that done It looks like I need longer shocks and limit straps... that's just gonna get added to the list for later. I'll do my mock up with the shocks disconnected anyway to verify clearance.

    I should take this opportunity to remove a leaf or three...

    [​IMG]20230117_125254 by Joe with a jeep, on Flickr
     
    dozerjim, timsresort and 3b a runnin like this.
  13. Jan 18, 2023
    Jw60

    Jw60 Sitting up n buckled down. 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sedalia MO.
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    The omix-ada 18006.04 Pitman arm measures 5.5" hole to hole horizontally and the drop looks like it will work.
    I'm a bit concerned that the arm isn't long enough especially being 6 turns lock to lock and
    It looks like the knuckle is 6.25" to the tie rod.
    [​IMG]
    [​IMG]
    Gonna tack some stuff together and see.

    I'm waiting for the u-joints but it looks like I'll be cutting an inch out of the bottom of the radiator support.
     
    Last edited: Jan 18, 2023
  14. Jan 20, 2023
    Jw60

    Jw60 Sitting up n buckled down. 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sedalia MO.
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    I've got a plan.
    So... there is a fine line between frugal and cheap...
    A frugal person might buy some items that are on sale, mix and match some parts, use a lathe
    Buy a steel collar use a lathe again and off the shelf bronze bushing instead of the way not cheap AA bushing and shipping.

    So I got a single u-joint and a double u-joint 3/4" 36spline to 3/4DD and 3/4"DD to 3/4"DD the steering column... is that right?!?! Sure. https://www.amazon.com/dp/B0B74F7B45?ref_=cm_sw_r_mwn_dp_3F8FPXYKKG1YRXWRQGQR

    Yeah looks like this:
    [​IMG]20230119_185136 by Joe with a jeep, on Flickr

    That's not quite right is it... I know.
    So the double and single are in the wrong location...
    No problem:
    [​IMG]20230120_125127 by Joe with a jeep, on Flickr

    Now the single u-joint is 36spline to 3/4DD and the double u-joint is 3/4DD to 3/4DD... Not quite...

    [​IMG]20230120_200753 by Joe with a jeep, on Flickr

    So the plan here is to take the column to the lathe and turn it to .875 od.
    Then take the 3/4DD and turn it to .875 ID
    Then take the 7/8 collar and turn it to 1" ID and 1.43" OD with a 1.5" lip.

    That's the plan for now. We will see.
     
  15. Jan 20, 2023
    Fireball

    Fireball Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Pullman, WA
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    Are you planning on a plunge section in the shaft so the steering column doesn't impale you in a wreck?
     
  16. Jan 20, 2023
    Jw60

    Jw60 Sitting up n buckled down. 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sedalia MO.
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    I understand the double u-joint at the base of the column allows for angular collapsibility:
    https://www.borgeson.com/steering-system-design-and-tech
     
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  17. Jan 21, 2023
    Fireball

    Fireball Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Pullman, WA
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    Interesting. It seems like most production vehicles with front steering boxes utilize both angular and telescoping collapsibility.
     
  18. Jan 21, 2023
    Jw60

    Jw60 Sitting up n buckled down. 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sedalia MO.
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    Telescoping does make installation easier, allows for future changes and accommodates tolerance buildup. I just feel like it will rust up or get loaded with mud in this application. Either way future state is worlds better than the column being bolted to the frame.
     
  19. Jan 21, 2023
    Jw60

    Jw60 Sitting up n buckled down. 2024 Sponsor 2023 Sponsor 2022 Sponsor

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  20. Jan 21, 2023
    homersdog

    homersdog Tulsa, Ok 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Tulsa, OK
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    I did mine with the advance adapters kit. I used the original column. I did it per their instructions and have not had any problems. But that being said mine is a power steering box so there normally isn't as much torque going through the steering column as would be on a manual box. I have driven it without the power steering pump running and still no problems.

    [​IMG]
     
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