I took a some pictures of that and the interior so you could see the shifter arrangement. . .I'm gonna heat the shift lever with the torch tomorrow and bend it so that I can get rid of the interference. . .I have to download the pictures to the computer still so I'll post them tomorrow.
The steering arm and other stuff should show up on Wednesday. . .so I should be really close by the end of the week.
I think I'm gonna cut and weld the old driveshaft myself. . .if for nothing else than to work temporarily so that I can move this thing around under it's own power on the property.
Here's some quick pic's with the excess rectangular tubing cut-off so you can see how much I'm extending the driver's side frame rail to mount the PS box
The whole thing is finished now. . .I even capped off the front so that it would look a little cleaner. . .so here it is finished. I do want to grind the welds on the cap down flush. . .I did a stitch weld since the metal was pretty thin that I used to cap the front so it doesn't look as nice as my welds usually do, otherwise I would have left the welds as is.
I'm gonna drill the threads out of the PS box today so that I can nut and bolt it in place instead of threading bolts into it. . .I didn't have the box mounted to the frame rail when I was welding (couldn't get to the areas that needed welded with it mounted) so it shifted just enough on me that I think it's gonna be better to just nut & bolt it. . .I've got to cut some spacers to space it properly off of the frame rail also.
Here are two pic's of the tranny & transfer case shifters mounted up inside the cab. . .you can see the holes in the floor board that need patched still.
I fixed the one small wiring SNAFU that I had from the wiring that I have finished. . .the gauge lights were on all the time, key on or not. . .turns out I had grabbed the wrong brown wire and hooked the gauge lights up to the cigarette lighter lead. . .those little wires are hard to read while you're under the dash. . .anyway I got that fixed.
I also got the bumper mocked into place. . .I just need to finish drilling the mounting holes in the frame rail and get some longer bolts for the PS box. Turns out I'm mounting the driver's side bumper mounting through the frame extension I made for the PS box. . .a PITA, but as it turns out a good idea. . .this way the bumper mount will act as a sort of steering brace and help act as a crossbrace to help spread the load to the passenger side frame rail when the steering box is pushing/pulling on the driver's side frame rail.
I also measured the old driveshaft and it's about 8" too long so I may be able to shorten it and use it. . .save me about $200 on a new rear driveshaft, but I'm definitely going to need a new front driveshaft.
I'm back from a week of snowboarding at Whistler in B.C., what a great week!!!
I've pretty much got all the parts now. . .here's what was waiting when I got home:
-front brake rotors
-front brake pads
-inner & outer front wheel bearings & oil seals
-exhaust U-bend (makes 2 90* bends)
-2 bullet mufflers
-4' of 1 1/2" poly rod for body mounts and a center square to mark the center to drill the rod for bolt holes
-steering shaft firewall support bearing
-steering column support
-steering shaft-to-steering box 36 spline coupler
-rest of the AN6 fuel fittings
-transmission cooler line adapter fittings
-transmission cooler line
-transmission cooler line fittings
-Edelbrock auto tranny kickdown cable bracket
-A&A Mfg. battery box kit (gonna end up using a Ballistic Fabrication battery box instead)
-drag link hardware (3/4" rod ends, 3/4" threaded tubing adapters, jam nuts, drag link mounting bracket, high misalignment spacers0
-steering stabilizer-t0-tie rod mounting bracket
-engine-to-frame ground strap
-frame-to-body ground strap
-power steering pump bracket
-extra long front wheel studs (for aluminum wheels)
-extra fat front wheel lug nuts (for aluminum wheels)
-new U-joints for rear driveshaft
-LED tail lights
I think that's about everything in the pictures. . .not much left but to button everything up and test it out now. . .hoping to have it done by the end of the month (I keep on saying that, but I'm still only at about 9 months for a complete vehicle build from top to bottom!).
Grrr!!! there are always gremlins to set you back!!!
I thought I was all ready to start up the engine on Sunday and when I started to fill the coolant system I found a small, previously un-noticed crack in the lower coolant hose. I replaced that and once again started to fill the coolant system and this time I found a freeze plug that was leaking. . .I will remember to check that ahead of time from now on, and of course it's the freeze plug behind the motor mount so it's not gonna be super easy to remove and replace.
I go the replacement freeze plug today and I've got a temporary lower coolant hose (good only for initial test fire. . .it doesn't fit properly so it's got a bit of a kink in the hose and I wouldn't dream of running the current hose set-up!!!).
Anyway. . .I'm still plugging along and making minor progress. . .work plus a full school load are really slowing my progress even though I have more money to spend now.
I'm still hoping to have this thing started, moving, and steering on it's own in the next two weeks though.
That's funny because I was actually thinking of getting that!!!
I'm in the middle of building my own 6.8 SPC AR15 as well so I'm on the GG&G website quite a bit checking out the goodies for my new hunting rifle there!!!
Still plugging away. . .work has really slowed progress, but now I'm pretty much down to waiting for my rod ends and tube adapters for the drag link and buying a rear driveshaft and it should be moving under it's own power and driveable. . .not complete but driveable.
Got the steering linkage and colum all done this weekend. . .pic's to follow.
Next is the exhaust. . .and I'm ordering the driveshaft stuff tomorrow, I have to replace the coolant temp gauge and work on some wiring and it should be running. . .once it's running the front fenders and hood go on and I will start work on modifying the rear fenders to accomodate the much larger tires.
Still not done yet, but I've made a TON of progress!!! Seems like everytime I think that I'm almost done a bunch of little things slow me down. . .but that's the way of it.
Here's the progress I've made:
-new Tom Wood's rear driveshaft installed
-more of the wiring completed. . .all that's left now are the gauges, the speedometer cable (not really wiring, but close enough), and the front parking lights
-made new grille, cab, and bed mounts from 1.5" delrin
-all the steering is pretty much done now (steering column, steering shafts, tie rod, and drag link). . .I do still have to fab some better steering box-to-frame spacers and get PS hoses and mount the PS pump to the block. . .for some reason I'm having more trouble getting the PS pump mounted than anything else!!!
-the exhaust is all done (at least for now. . .not the final exhaust system. . .right now it's just some turn downs right after the 2 1/2" bullet mufflers). . .have a feeling that's gonna be loud, but that's what she wants
-buttoned up the coolant system. . .no more leaks
-buttoned up the fuel system. . .no more leaks
So here's what's left. . .that I can think of anyway
-mount PS pump to block
-get PS hoses
-attach speedometer cable
-fill & bleed the brake system
-wire up radiator fans
and finally fire the beast up!!!
Once I make sure the engine is running and the thing is moving under it's own power I will mount the front fenders and hood. . .she'll probably run wihtout rear fenders for a little bit while stretch them to accomodate the 40" tires!!!
Almost done. . .in class tonight but all I have left to do is to finish wiring up the radiator fans (one ground and two power wires) and finish bleeding the brakes and it should be ready to run. . .not finished, but running and I would say 95% complete. . .
. . .the only other stuff not done are just cosmetic stuff.
Sorry, no progress over the winter. . .between moving, my Dad passing away, helping my Mom move and sell my Dad's business I have been swamped. . .
. . .I'm getting 220 power installed in my new garage and I finished machining new, heavy duty power steering box mount to keep from bending the Grade 8 hardware. . .so I should have some pic's for you in about 2 weeks (going on a well-deserved and long overdue vacation for a week and a half starting next Saturday).
The sun is back out finally and motivated to get back to work and finish this thing up. . .for a little while anyway. . .I wanna ditch the leafs for a four link out back and a three link up front in the future. . .and I can't forget the plans for an NP-203/205 doubler either. . .
So I figured out why I haven't had any motivation to work on the Willy's for so long. . .it's because I had that stupid tarp over it!!! I took the tarp off today and just set the hood in place to get it out of the garage, then I stood back and looked at it and I thought. . .
. . .DAMN, that thing is gonna be AWESOME!!!!. . .
. . .you should never cover any of your projects so that you can't see how awesome it's gonna be. . .
. . .still no 220 in the garage yet, but I did reconnect the single 110V/20A circuit that was already run out to it so I could turn the lights on and see in the garage. . .which means I am now cleaning out the garage right so that I can pull the Wrangler into it and walk around and find everything and get this thing going!
One minor hickup, I was gonna mount the steering box and reconnect all the steering linkages today, but I drilled one of the bolt holes in the wrong location on the frame reinforcement plate that I made, so I will have to wait until Monday to fix that. . .so hopefully Monday the steering will be hooked back up and I will have the new brake master cylinder installed and bleed the brake system. . .that will leave only getting the engine timing right to get this thing going!
I'm hoping to have some significant progress for you guys before next weekend. . .
I've been back to work on the Willy's again the past few days and I've decided to move backwards and correct some stuff that has been bothering me. . .here's the short list. . .
-I'm replacing the hard brake lines I made (37* AN fittings) and I'm gonna use some pre-made 45* double flare lines. My lines had some leaks in them and were keeping me from being able to properly bleed my brake system. . .I need some better tools (and more attention to detail) before I flare my own lines and they work properly.
-I'm working on a better steering box mounting situation. . .the previous was structurally sound, but it was a cosmetic eye-sore. . .hopefully I can come up with a better plan soon.
Once I get these two things, the only thing left to do in order for this thing to be running is getting the engine timing right. Once that's done I will get back to work puttin the front and rear fenders on and working on the interior and cosmetic issuess.
I made some slow & tedious, but significant progress today. . .
. . .re-did the PS box mount to get the box into place. . .I have to machine some spacers to space the cylindrical part of the PS box body off of the plate and cut some gussets (3"x3" triangles) to reinforce the plate (3/16" mild steel)
The only thing that I don't like right now is that the box sticks out past the end of the frame, but once I get the bumper mounts figured out and the bumper on it will be protected and it looks a LOT cleaner and better now than it did when I had this abortion welded onto the front of the frame!!!
I also ordered all new hard brake lines and fittings so I can replace my leaky, home-made hard lines. . .using 3/8"-24 TPI 45* double flare line instead of -3 AN lines this time (because that's what's available factory flared for hardline). . .hopefully I will have that stuff installed before next weekend.
I will be bench bleeding my new MC this weekend as well. . .once all that stuff is done all I should have to do is to machine some spacers to mount the PS pump on the cylinder head and get the timing on the engine right and it should be moving under it's own power!!!
I also got the front drive plates installed as well. . .I had to dig them up because I couldn't remember where I put them. . .now I just need to get a front driveshaft ordered and I'll four wheel drive. . .tempted to wait until I do the 203/205 doubler, but who knows how long that it will be down the road and driveshafts aren't very expensive (at least compared to the adapter kit for the 203/205 doubler!!!).
I'll post a pic of the truck up with the hood on it tomorrow (camera battery is charging right now).
OK. . .here's a pic of what the truck looks like with the hood on. . .
Finally starting to look like a real truck again!!!
Just a little bigger than our YJ Wrangler. . .
GRRRRR!!!! I'm going to eat you!!!
The only bad thing about having a big truck with 1-ton, 8-lug running gear is that it takes FOREVER to take all those wheel lug nuts off, the wheels & tires weigh a TON, and it takes another FOREVER to get all those wheel lug nuts back on!!!