Custom 1959 CJ5 - Jeep Wrangler Forum
Jeep Wrangler Forum

Go Back   Jeep Wrangler Forum > General Tech Forums > Builders Corner

Join Wrangler Forum Today


Reply
 
Thread Tools

Please support our sponsors and let them know you heard about them on WranglerForum.com
Old 02-04-2013, 09:23 AM   #1
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Custom 1959 CJ5

The purpose of this thread is to show where this project started and where we hope to take it. It is my long time roommate and very good friends Jeep that I have helped him build it every step of the way.

Click image for larger version

Name:	IMAG0071.jpg
Views:	220
Size:	224.5 KB
ID:	205538

Here are some pictures of what the Jeep looked like the day we brought her home.

Click image for larger version

Name:	IMAG0072.jpg
Views:	205
Size:	226.1 KB
ID:	205539

It didnt stay that way for long

Click image for larger version

Name:	IMAG0080.jpg
Views:	190
Size:	228.4 KB
ID:	205540

Click image for larger version

Name:	IMAG0081.jpg
Views:	180
Size:	225.6 KB
ID:	205541

Click image for larger version

Name:	IMAG0082.jpg
Views:	173
Size:	225.5 KB
ID:	205542

We used the trusty engine crain to lift the body off with some tow straps.

ken78744 is offline   Quote Quick Reply
Old 02-04-2013, 09:39 AM   #2
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Once we got the body off it was time to start working on the body it had some issues to say the least...

Click image for larger version

Name:	IMAG0093.jpg
Views:	147
Size:	155.7 KB
ID:	205549

The body was literally broken right here...

Click image for larger version

Name:	IMAG0089.jpg
Views:	147
Size:	166.8 KB
ID:	205550

Here is some usual rust

Click image for larger version

Name:	IMAG0088.jpg
Views:	154
Size:	201.6 KB
ID:	205551

More usual rust

Click image for larger version

Name:	IMAG0090.jpg
Views:	146
Size:	143.5 KB
ID:	205552


Click image for larger version

Name:	IMAG0091.jpg
Views:	156
Size:	199.9 KB
ID:	205553

And someone else tried to patch the floor

ken78744 is offline   Quote Quick Reply
Old 02-04-2013, 09:53 AM   #3
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Click image for larger version

Name:	IMAG0152.jpg
Views:	147
Size:	123.6 KB
ID:	205557

Click image for larger version

Name:	IMAG0263.jpg
Views:	153
Size:	199.9 KB
ID:	205558

Click image for larger version

Name:	IMAG0265.jpg
Views:	153
Size:	147.6 KB
ID:	205559

Click image for larger version

Name:	IMAG0269.jpg
Views:	149
Size:	129.0 KB
ID:	205560

Click image for larger version

Name:	IMAG0270.jpg
Views:	154
Size:	164.2 KB
ID:	205561We ordered some new floor boards for the front from JCwhitney I think and a new rear floor section from them as well we welded up the giant crack on the drivers side cut out the front floor boards and welded in the new floor boards. We start the work required to get in the new rear section it was a PITA to say the least, but like everything else we got it done.

Click image for larger version

Name:	IMAG0152.jpg
Views:	147
Size:	123.6 KB
ID:	205557

Click image for larger version

Name:	IMAG0263.jpg
Views:	153
Size:	199.9 KB
ID:	205558

Click image for larger version

Name:	IMAG0265.jpg
Views:	153
Size:	147.6 KB
ID:	205559

Click image for larger version

Name:	IMAG0269.jpg
Views:	149
Size:	129.0 KB
ID:	205560

Here we just used some plate from HomeDepot and welded it in place.
ken78744 is offline   Quote Quick Reply
Old 02-04-2013, 09:55 AM   #4
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Dont know why it double posted the pictures???
ken78744 is offline   Quote Quick Reply
Old 02-04-2013, 10:41 AM   #5
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Here are some pictures of us cutting out and welding in sections of the rear floor.

Click image for larger version

Name:	ForumRunner_20130204_103832.jpg
Views:	137
Size:	64.1 KB
ID:	205572



Click image for larger version

Name:	ForumRunner_20130204_103922.jpg
Views:	121
Size:	66.4 KB
ID:	205573

This is before we got the plasma cutter I don't miss cutting everything with a grinder!!!!
ken78744 is offline   Quote Quick Reply
Old 02-04-2013, 11:00 AM   #6
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Can't upload anymore pictures on the phone app just keeps crashing...
ken78744 is offline   Quote Quick Reply
Old 02-04-2013, 03:26 PM   #7
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Here are more pictures of cutting and welding


Click image for larger version

Name:	ForumRunner_20130204_152524.jpg
Views:	168
Size:	74.5 KB
ID:	205676



Click image for larger version

Name:	ForumRunner_20130204_152524.jpg
Views:	168
Size:	74.5 KB
ID:	205676
Attached Thumbnails
Click image for larger version

Name:	ForumRunner_20130204_152444.jpg
Views:	67
Size:	65.6 KB
ID:	205675  
ken78744 is offline   Quote Quick Reply
Old 02-04-2013, 03:29 PM   #8
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Some welding, we had to weld strips of metal on the inner fender wells at the bottom to attach the new floor pan...

Click image for larger version

Name:	ForumRunner_20130204_152737.jpg
Views:	147
Size:	77.8 KB
ID:	205678



Click image for larger version

Name:	ForumRunner_20130204_152818.jpg
Views:	136
Size:	60.7 KB
ID:	205679

The back lip was completely gone because of rust, but was able to use some 1/2" angle and it worked perfect as you can see in the picture...
ken78744 is offline   Quote Quick Reply
Old 02-04-2013, 03:36 PM   #9
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
It is time to move... We needed a bigger garage so we moved to a house with a two car garage

Click image for larger version

Name:	ForumRunner_20130204_153245.jpg
Views:	99
Size:	116.0 KB
ID:	205682

FLYING JEEP!!!!!


Click image for larger version

Name:	ForumRunner_20130204_153340.jpg
Views:	136
Size:	101.1 KB
ID:	205683



Click image for larger version

Name:	ForumRunner_20130204_153419.jpg
Views:	147
Size:	113.0 KB
ID:	205684

In this picture we still have the original motor and transmission in the Jeep that will soon change...
ken78744 is offline   Quote Quick Reply
Old 02-04-2013, 03:48 PM   #10
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
We have decided to go with stronger axles instead of the Dana25 front and Dana44 offset rear...



Click image for larger version

Name:	ForumRunner_20130204_154314.jpg
Views:	127
Size:	91.0 KB
ID:	205685



Click image for larger version

Name:	ForumRunner_20130204_154414.jpg
Views:	107
Size:	96.9 KB
ID:	205686



Click image for larger version

Name:	ForumRunner_20130204_154511.jpg
Views:	115
Size:	82.6 KB
ID:	205687



Click image for larger version

Name:	ForumRunner_20130204_154620.jpg
Views:	128
Size:	101.5 KB
ID:	205688

Here in this last picture you see one of the inner Cs that we cut off the narrow the front axle. Well part of the axle tube has to come out so you can reuse the inner C it did come out after lots of talking to it nicely...

We have now gone with a Dana44 front and a 8.8 the 44 came out off a 77 Dodge truck and the 8.8 came out of a Ford 96 Explorer
ken78744 is offline   Quote Quick Reply
Old 02-04-2013, 03:53 PM   #11
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Here are so pictures of use welding the inner Cs back on with about 7degress rise on the diff...


Click image for larger version

Name:	ForumRunner_20130204_155151.jpg
Views:	102
Size:	105.9 KB
ID:	205689



Click image for larger version

Name:	ForumRunner_20130204_155218.jpg
Views:	106
Size:	90.9 KB
ID:	205690



Click image for larger version

Name:	ForumRunner_20130204_155251.jpg
Views:	104
Size:	103.5 KB
ID:	205691



Click image for larger version

Name:	ForumRunner_20130204_155322.jpg
Views:	103
Size:	100.9 KB
ID:	205692
ken78744 is offline   Quote Quick Reply
Old 02-04-2013, 03:57 PM   #12
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Here is a trus and other parts we ordered to make the axle stronger...


Click image for larger version

Name:	ForumRunner_20130204_155510.jpg
Views:	105
Size:	91.9 KB
ID:	205693



Click image for larger version

Name:	ForumRunner_20130204_155534.jpg
Views:	112
Size:	87.6 KB
ID:	205694

The diff cover is a 1/2" thick!!!!

Click image for larger version

Name:	ForumRunner_20130204_155608.jpg
Views:	106
Size:	92.5 KB
ID:	205696



Click image for larger version

Name:	ForumRunner_20130204_155644.jpg
Views:	109
Size:	91.2 KB
ID:	205697
ken78744 is offline   Quote Quick Reply
Old 02-04-2013, 03:57 PM   #13
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
And lots more to come!!!!
ken78744 is offline   Quote Quick Reply
Old 02-06-2013, 01:28 PM   #14
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Ok back at it here are some more pictures of the trus in place and finished

Click image for larger version

Name:	ForumRunner_20130206_132212.jpg
Views:	96
Size:	86.9 KB
ID:	206489



Click image for larger version

Name:	ForumRunner_20130206_132248.jpg
Views:	82
Size:	105.8 KB
ID:	206490

Here is the Ford 8.8 in these pictures we are shaving the bottom 1" off of it so it doest hang up on stuff...

Click image for larger version

Name:	ForumRunner_20130206_132328.jpg
Views:	95
Size:	94.7 KB
ID:	206491



Click image for larger version

Name:	ForumRunner_20130206_132401.jpg
Views:	90
Size:	84.5 KB
ID:	206492

In these pictures I welded a plate on the bottom because it was a little thin after we shaved the bottom, we didn't cut all the way through it but close and thia plate will help protect it...

Click image for larger version

Name:	ForumRunner_20130206_132445.jpg
Views:	85
Size:	123.7 KB
ID:	206494



Click image for larger version

Name:	ForumRunner_20130206_132518.jpg
Views:	79
Size:	90.0 KB
ID:	206495

We also got a trus for the rear axle as well don't want it to get jealous of the front axle....
ken78744 is offline   Quote Quick Reply
Old 02-06-2013, 02:52 PM   #15
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Time to make a up are minds about the power plant for this beast...

Sold the old flat 4 for $800(still have the trans and t-case) and bought the new motor for $200...

Click image for larger version

Name:	ForumRunner_20130206_144742.jpg
Views:	82
Size:	121.8 KB
ID:	206509

Here we are pulling the old motor out...

Click image for larger version

Name:	ForumRunner_20130206_144903.jpg
Views:	81
Size:	109.7 KB
ID:	206510



Click image for larger version

Name:	ForumRunner_20130206_145020.jpg
Views:	85
Size:	143.5 KB
ID:	206511

Here is the new motor a Benz 300d OM617 5cyl Turbo diesel!!!!! It is coming out of a 1980 300D by way of plasma cutter and engine crain!!!!
ken78744 is offline   Quote Quick Reply
Old 02-06-2013, 03:28 PM   #16
Supporting Member

WF Supporting Member
 
daddyjeep's Avatar
 
Join Date: Apr 2005
Location: Smethport, PA
Posts: 2,355
Now that is a cool powerplant. That is going to be a very cool Jeep.
__________________
87 YJ, 5.2/46RH/NP231, Custom 4 link/ Radius Arms, Ballistic Nitrogen Shocks, 35" Cooper STT DaddyJeep build Thread:http://www.wranglerforum.com/f8/dadd...ld-122601.html
daddyjeep is offline   Quote Quick Reply
Old 02-06-2013, 09:08 PM   #17
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Quote:
Originally Posted by daddyjeep View Post
Now that is a cool powerplant. That is going to be a very cool Jeep.
Thx I get a lot of people asking who makes the motor mounts for that set up in a jeep... I have to tell the no one they have to be custom made...

Click image for larger version

Name:	ForumRunner_20130206_210751.jpg
Views:	97
Size:	74.1 KB
ID:	206719

Here is one we already made, but that is just one still have to make the passanger side...

We cut two plates with the plasma cutter one to go on the motor the other goes aginst the 70s Chevy v8 motor mount so the motor doesn't rattle your teeth out....
ken78744 is offline   Quote Quick Reply
Old 02-06-2013, 09:32 PM   #18
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Well the time has come to address suspension on this beast at first we thought about leaving it with the old leaf springs and what not, but why would we do that after all the work to the axles and what not...

So we have gone with a fully custom 3-link front and rear with custom made shock towers to... all the tabs, brackets, and tubing has come from ballistic fabrication out of Arizona they only sell top notch stuff!!!!

The control arms have 4140 chromemoly hemi joints on all ends...

The shocks we decided to go with are also from ballistic fabrication and they are 16" travel 2 1/2 od air shocks set to hold 1500lbs each

We setup the suspension at about 6" up travel and 10" down travel so it can hit trails with a little speed if wanted with out having to worry about bottoming out a $300 shock...

Here are some pictures and more to come when I get home to the computer...
ken78744 is offline   Quote Quick Reply
Old 02-06-2013, 09:43 PM   #19
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Click image for larger version

Name:	ForumRunner_20130206_213638.jpg
Views:	86
Size:	70.5 KB
ID:	206736



Click image for larger version

Name:	ForumRunner_20130206_213745.jpg
Views:	87
Size:	79.0 KB
ID:	206737



Click image for larger version

Name:	ForumRunner_20130206_213820.jpg
Views:	82
Size:	71.8 KB
ID:	206738



Click image for larger version

Name:	ForumRunner_20130206_214036.png
Views:	93
Size:	218.4 KB
ID:	206740



Click image for larger version

Name:	ForumRunner_20130206_214036.png
Views:	93
Size:	218.4 KB
ID:	206740

In this picture we are testing flex it does great and this was with no front track bar "(for some reason the treads got crossed on one of the hemi joints on it so had to make another track bar)" so the front isn't exactly center, but new track bar has been made and that corrected...
Attached Thumbnails
Click image for larger version

Name:	ForumRunner_20130206_213923.jpg
Views:	62
Size:	84.8 KB
ID:	206739  
ken78744 is offline   Quote Quick Reply
Old 02-06-2013, 09:50 PM   #20
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Wish I had more on the phone but all on the computer at home...

Click image for larger version

Name:	ForumRunner_20130206_214858.jpg
Views:	88
Size:	78.9 KB
ID:	206747



Click image for larger version

Name:	ForumRunner_20130206_214953.jpg
Views:	91
Size:	73.2 KB
ID:	206749

I think I have more pictures of the control arms to... Here are some of the front but not the greatest angles...
ken78744 is offline   Quote Quick Reply
Old 02-06-2013, 10:57 PM   #21
Jeeper
 
CMA_Rider's Avatar
 
Join Date: Feb 2010
Location: Hixson, TN
Posts: 3,167
Send a message via Yahoo to CMA_Rider
Sub'd
__________________
2003 White TJ Sport 4.0 5 speed D44 w/ Aussie Locker 3.73 tow pkg 3"BDS, 4"N20 Shocks 1.25bl 1.25mml Swaybarless-F&R 33x12.50r15
2001 customized Suzuki Intruder 1500 100hp Harley Killer
70 CJ5 Build
CMA_Rider is offline   Quote Quick Reply
Old 02-07-2013, 11:06 AM   #22
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Well we have decided on 46" military michelin tires with 20" hummer beadlock rims.

To do this with the suspension we moved the rear axle back 8" and the front forward 5" making the wheel base 105" total...

To make the 46s fit the rear we moved the rear fender well back 7" here are some pictures of are handie work...
Attached Thumbnails
Click image for larger version

Name:	ForumRunner_20130207_110350.jpg
Views:	52
Size:	98.0 KB
ID:	206906   Click image for larger version

Name:	ForumRunner_20130207_110441.jpg
Views:	51
Size:	91.8 KB
ID:	206907  

Click image for larger version

Name:	ForumRunner_20130207_110521.jpg
Views:	45
Size:	101.3 KB
ID:	206908   Click image for larger version

Name:	ForumRunner_20130207_110556.jpg
Views:	47
Size:	96.6 KB
ID:	206909  

ken78744 is offline   Quote Quick Reply
Old 02-07-2013, 11:17 AM   #23
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Dang phone app keeps crashing on me more when I get home this afternoon
ken78744 is offline   Quote Quick Reply
Old 02-07-2013, 11:18 AM   #24
Jeeper
 
deucestudios's Avatar
 
Join Date: Dec 2011
Location: Malvern, PA
Posts: 227
Quote:
Originally Posted by ken78744 View Post
Well we have decided on 46" military michelin tires with 20" hummer beadlock rims.


Cool thread.
That's a lot of rubber!
__________________
My '98 Wrangler - Pond Scum

Jeep Fiend Club
deucestudios is offline   Quote Quick Reply
Old 02-07-2013, 01:48 PM   #25
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Quote:
Originally Posted by deucestudios View Post



Cool thread.
That's a lot of rubber!
We are going with 4.1 low gear in the transfercase and 5.13 gears in the axles...

More pictures
Attached Thumbnails
Click image for larger version

Name:	ForumRunner_20130207_134601.jpg
Views:	37
Size:	91.9 KB
ID:	206949   Click image for larger version

Name:	ForumRunner_20130207_134700.jpg
Views:	44
Size:	99.4 KB
ID:	206950  

ken78744 is offline   Quote Quick Reply
Old 02-07-2013, 01:57 PM   #26
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Here are some pictures of the custom shock towers that we made for the front...

Click image for larger version

Name:	ForumRunner_20130207_135648.jpg
Views:	57
Size:	130.8 KB
ID:	206951



Click image for larger version

Name:	ForumRunner_20130207_135719.jpg
Views:	51
Size:	86.3 KB
ID:	206952
ken78744 is offline   Quote Quick Reply
Old 02-07-2013, 02:06 PM   #27
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Click image for larger version

Name:	ForumRunner_20130207_140148.jpg
Views:	62
Size:	120.0 KB
ID:	206953

Here is the Benz motor MOSTLY clean and getting ready to start building those custom motor mounts that I showed you guys one of already

Click image for larger version

Name:	ForumRunner_20130207_140238.jpg
Views:	58
Size:	99.3 KB
ID:	206954



Click image for larger version

Name:	ForumRunner_20130207_140332.jpg
Views:	55
Size:	95.5 KB
ID:	206955

Here is the body with the rear fender wells almost completely finished...

The tire in the picture is my spare 32" off of my LJ just imagine 46" tires it is going to be a beast!!!!
ken78744 is offline   Quote Quick Reply
Old 02-07-2013, 02:15 PM   #28
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
Here are some pictures of the dana300 transfercase that we are going to use... We are putting in a LOWMAX 4.1 low gear set for it and advanced adapters twin sticks for multiple transfrcase options...

Click image for larger version

Name:	ForumRunner_20130207_141226.jpg
Views:	57
Size:	79.4 KB
ID:	206956



Click image for larger version

Name:	ForumRunner_20130207_141310.jpg
Views:	54
Size:	78.5 KB
ID:	206957



Click image for larger version

Name:	ForumRunner_20130207_141354.jpg
Views:	57
Size:	65.3 KB
ID:	206958

In this last picture I am taking apart the t-case for larger gears...
ken78744 is offline   Quote Quick Reply
Old 02-07-2013, 02:28 PM   #29
Jeeper

WF Supporting Member
 
ken78744's Avatar
 
Join Date: Aug 2012
Posts: 689
We are also going to be running a turbo350 trans w/32 spline output shaft...

The adapter plate between the motor and the trans is $1,300+ it comes with a starter and custom flywheel but that is a crazy price for that so we are in the process of a side project at the sametime. We are making are own plasma table...
ken78744 is offline   Quote Quick Reply
Old 02-07-2013, 02:53 PM   #30
Jeeper
 
00tj2's Avatar
 
Join Date: Aug 2011
Location: Westchester, NY
Posts: 1,216
Any reason your picking the turbo 350 over the 700r4??

__________________
I know a lot of things, most of them are only correct in my own head...

Better to be judged by twelve then carried by six. I'm sure this is going to get me in trouble down the line
00tj2 is online now   Quote Quick Reply
Reply

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Jeep Wrangler Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
If you do not want to register, fill this field only and the name will be used as user name for your post.
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:

Log-in

Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off



» Rates
Get low rates on auto insurance in Canada!

» Network Links
»Jeep Parts
» Featured Product

All times are GMT -5. The time now is 07:57 PM.



Jeep®, Wrangler, Liberty, Wagoneer, Cherokee, and Grand Cherokee are copyrighted and trademarked to Chrysler Motors LLC.
Wranglerforum.com is not in any way associated with the Chrysler Motors LLC