AND SO IT BEGINS: 1956 CJ5 total basketcase rebuild...

rocket

Well Oiled
Sep 3, 2015
1,835
Sierra Mtns
First Name
Rodney
Willys Model
  1. Wagon
Willys Year:
  1. 1963
Man did I miss something? When did you decide to go full crawler Rodney? Like Jose said, you make more progress with a torn tendon than I do with my full body motion. Jeez!
Not really Full Crawler. Just a coil spring disc brake trail rig.
 

rocket

Well Oiled
Sep 3, 2015
1,835
Sierra Mtns
First Name
Rodney
Willys Model
  1. Wagon
Willys Year:
  1. 1963
I hobbled back up to the shop today, and cut out the cross member over the differential, and I boxed the frame at that point and built a cross member from 4" square tubbing with a mounting flange for the new 15 gallon fuel tank.

CJ5 tank mount 2.jpgCJ5 tank mount 4.jpgCJ5 tank mount 3.jpgCJ5 tank mount 5.jpg
Next I need to make some straps to hold the tank up in place. The Intermediate CJ's used the skid plate. And I've heard it is a major PITA to drop and change the tank. I think I'll try and come up with something easier. I think I would rather have tank straps and a separate skid plate.

My 4 1/2" Ryobi grinder died today. I guess you can't expect them to last forever. Especially when I've been using 5" cut off wheels and 7" lap sanding disc in it. I did find a Porter Cable grinder with the paddle switch on sale at Amazon for $39.00 with free 2 day shipping.
 
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rocket

Well Oiled
Sep 3, 2015
1,835
Sierra Mtns
First Name
Rodney
Willys Model
  1. Wagon
Willys Year:
  1. 1963
My son has the new 72up CJ5-6-7 Hood in the back of his Suburban. He picked it up in Grassy Valley after work last week. I found it on Facebook Marketplace for $40.00 (stole it). trailhead Joe picked up a 72 up Grille from a ECJ5 Forum member for me in Napa and he will bring it with him this weekend to the BBQ in the Foothills. Once I get both these parts, I can figure where the front cross member and grille/core support goes.. I've been told the hood is 3" longer than the early one which will give me enough room for a real cooling fan on the engine and an adequate radiator for the V8.
 

Stakebed

Well Oiled
All-Star
Mar 4, 2020
4,348
Northern California
First Name
Joe
Willys Model
  1. Pickup
Willys Year:
  1. 1957
My son has the new 72up CJ5-6-7 Hood in the back of his Suburban. He picked it up in Grassy Valley after work last week. I found it on Facebook Marketplace for $40.00 (stole it). trailhead Joe picked up a 72 up Grille from a ECJ5 Forum member for me in Napa and he will bring it with him this weekend to the BBQ in the Foothills. Once I get both these parts, I can figure where the front cross member and grille/core support goes.. I've been told the hood is 3" longer than the early one which will give me enough room for a real cooling fan on the engine and an adequate radiator for the V8.
Stakebed Joe.20210404_110909.jpg
 

rocket

Well Oiled
Sep 3, 2015
1,835
Sierra Mtns
First Name
Rodney
Willys Model
  1. Wagon
Willys Year:
  1. 1963
Well the hood turned out to be a 55-71 just like I already have. But I found E-bay has new repop for $185.00 with free shipping.

Still have the cast, but managed to cut the Bubba Angle Iron bumper off behind the spring mounts .
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I made new frame extensions out of 3" square stock and added a 3" square tube cross member 3" further forward for engine/fan/ radiator clearance and to mount the new grille and longer hood..
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I have a 3" square tube front bumper made up to match the rear, and I will add heavier stock between bumper and cross member to mount the power steering gear box.
 

rocket

Well Oiled
Sep 3, 2015
1,835
Sierra Mtns
First Name
Rodney
Willys Model
  1. Wagon
Willys Year:
  1. 1963
I got the cast off a week ago Monday. I'm hoppling around in really stiff Logging Boots. But at least I'm walking. I put the Crutches and wheel chairs away , and did a little Fab work on the CJ5 frame today.
I finished capping the 3" tube bumper ends and welded it in place. then cut a 1" by 2 1/2" channel and slotted it for the front grille mount and welded that in place. Without the body on the frame and the hood in place I could only measure and get a semi accurate position for the grille so I exaggerated the slot. It will probably work with the early hood, or the intermediate long hood.

20210423_141505.jpg20210423_141445.jpgThe front of the frame should be stiff enough, to handle the power steering gearbox ,along with the coil spring mounts and drag link and mount.20210423_141439.jpg
 

rocket

Well Oiled
Sep 3, 2015
1,835
Sierra Mtns
First Name
Rodney
Willys Model
  1. Wagon
Willys Year:
  1. 1963
I got back to the shop and killed two birds with one cut off wheel. I started with a 1/2" plate of steel 6" square .First I drilled two 7/8" holes in the plate, and then I cut out two shackle mounts that will double as tow bar mounts, the angle pieces left over will make nice corner gusset plates, but I don't want to weld them in till I get the power steering gearbox located.
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I cleaned up the shackle brackets and welded them in place. Shackle bolts fit nice and tight. Hopefully they won't rattle too bad.

20210425_145459.jpg

Not bad looking welds for an Old Def Dumb and Blind Guy!
20210425_145343.jpg
 

rocket

Well Oiled
Sep 3, 2015
1,835
Sierra Mtns
First Name
Rodney
Willys Model
  1. Wagon
Willys Year:
  1. 1963
I started welding today and ran out of welding wire almost instantly. Harbor Freight now gets 29.99 for China wire, Amazon gets 38.00 I went back in my E-Bay records and ordered two more 10LBS rolls of Kiswel Made In USA .035 solid wire for $35.00 with free shipping. I had bought this same wire before I started on the CJ5 project and didn't expect to burn through 20 LBS of wire this quick. I was happy with the wire, it burns clean and well. I think I'll go to Auburn Iron Works this week and exchange my spare Oxygen and Argon/CO2 bottles just to be ready for the frame modification "Push"
Kiswel Inc | eBay Stores
 
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rocket

Well Oiled
Sep 3, 2015
1,835
Sierra Mtns
First Name
Rodney
Willys Model
  1. Wagon
Willys Year:
  1. 1963
Thatsa lotta welding!
The last thing I was doing before running out of wire was moving the fuel filler door. I got the original cut out. Cleaned up the remaining metal and cut a patch panel. I actually got a couple of spot welds on before running out of wire.
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I'll move the filler to the back right corner to match the new 15 Gallon rear gas tank. I cut the filler neck out of the rusted out under seat tank and cleaned it up, cut in half and soldered it to the new tank. The filler will go back in the corner and a short piece of 2.5" hose should connect the two.
 
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