CJ5: Lachlan's build-up

[Lachlan]

Hey guys,

After 2 years of use as a paddock basher, I've decided to start seriously rebuilding my CJ5. It was an interesting case when we bought it: 4 different sized tyres, 3 shock absorbers, the engine didn't work, and it's still running a Datsun clutch and pedal box. But it has its perks, including a full floating Dana 44 rear axle, 170ci 6 cylinder engine, and strengthened frame rails and axle tubing on the front and rear axles.

It's going to be a bit of a learning curve for me, being my first "ground-up" project, and attention will be shared between it and university. But eventually I plan to put it through 2 stages of restoration, first to get it running and registered, and a second lot to improve efficiency and capability - both on and off road. My aim is that the final result will look like a stock CJ5, but there will be vast improvments to the drivetrain and suspension system. Repairs necessary at this stage:

• Top end engine rebuild; lifters, electronic ignition
• Full transmission and transfer case rebuild
• Brake system overhaul, including fitment of a brake booster
• Steering box and front knuckles will need rebuilding
• New tub, gauges, electrical system
• New shock absorbers
• 4 point roll cage

Planned upgrades at this stage:

• 2" lifted Skyjacker springs, 1" lifted heavy duty greasable shackles
• OME heavy duty shock absorbers
• 31" tyres
• Bucket seats, seat belts, a radio and some bloody sound deadener!!
• Far into the future I intend to completely rebuild the engine; including an aluminium cylinder head from Classic Inlines, 2 barrel carby, full sports exhaust system, HEI ignition, etc etc.

The CJ5 is far from perfect at the moment, and this will take a while; but hopefully you'll all enjoy watching, and I'll see ya at a Jamboree some time!

[Lachlan]

I've finished rebuilding the rear hubs - I stripped it all down to the spindle, replaced all the backing plate bolts with new high tensile ones, replaced the rear bearing cups/cones, and repacked it all with fresh grease. I'm yet to check the bearing preload, but it's a helluva lot better than it was. No more creaking, no overheating that I can see, and the rear wheels spin very freely.

I'm gonna repack the front hubs and replace all the hub bolts over the next week or so; I'll add pics as I go.

[JAG811]

Looks good mate ... I'll be watching the progress !!

[cj4a nz]

lachlan will be watching as well
if money goes far enought and going to use off road go for a 6 point cage safer if it does have a lie down
still got the cj3?

[JAG811]

Anything new ?

[Lachlan]

Hey guys, sorry I took so long! Nothing much to report yet as I'm just in the final throes of Semester 1 exams... The jeep has developed a crack in the exhaust header, so I've moved the header and ignition to the top of the to-do list. I'm looking at getting a two piece header and HEI distributor freighted in from the States: see distributor and header details.

I've also decided to get the header ceramic coated, for two reasons. The first is a much higher fatigue resistance, reduced cyclic thermal stresses, etc etc, for longevity - I don't want the crack to repeat itself. The blurb on the site says the header will last up to 10 times longer than the mild steel variant, and the JetHot site confirms this. The second reason is a large reduction in underhood temp (around 30 degrees C cooler!); I've had troubles with the clutch fluid actually leaking through the cap, and I believe this is because it's heating up way too much. The header looks to be of a much higher quality than the one I've got, so I'm assuming the welds won't crack this time, and the header should be up to the task of mild off-roading. I'm planning to run dual outlet exhausts, but I haven't done any planning to that end just yet. The removable secondaries mean I can re-route the exhaust straight from the header, without affecting the ceramic coating at all.

The distributor and header should combine to an increase of at least 20hp, as well as all the benefits of electronic ignition. I've still got a bit to save for them, so it's postponed pending funds... But I'll update when something happens.

[Lachlan]

I did check and adjust the preload on the hubs, and I haven't had any troubles with them so far. I've attached a pic of my old header - you can see the crack on the left primary in the picture (4th cylinder). The weld has acted as a stress concentrator, but the fact that the headers are pitted pretty badly doesn't help. The pitting, and cyclic thermal stresses (adding to surface wear), is what I intend to avoid by opting for a ceramic coating.

@cj4a_nz I might consider a 6-point actually, depending on how far I go towards an off-roader. It's definitely safer, that's for sure... That'll be further along the track though. Do you have one on your lil number? I haven't got a CJ3, but I do have the other green jeep pictured in my garage! She's in pieces though, I need a new floor for that one...