Restoring my fathers old hunting Jeep

[JohnL48]

I'm going to attempt to copy and paste my restoration thread from QDMA here, maybe on HT too if I have the energy :-(

Thought some of you would like to see my current project. It's my fathers old 67 CJ5

What it looks like now. After sandblasting and painting EVERY part, The chassis is going back together

I rebuilt the transmission, transfer case and PTO for the front winch. Pretty simple to work on.

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Todays progress, finished the pto

Installed the master cylinder and brake/clutch pedals. Next week, all the brake lines and front driveshaft U joints

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The original tub was shot. I was able to buy this donor jeep without an engine for $400.00 I parted most of it out and made a small profit and kept the tub. It's rough but I'm going to spend the winter working on it. Going to replace pretty much everything from the firewall back except the sides.

My redneck rotisserie I made to paint the frame

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[JohnL48]

How an Italian bleeds brakes

Got all the brake lines in today and the brakes bled. This is almost exact as to how the factory ran the lines on top of the frame due to the exhaust pipe running up to the engine right there

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Here's a tip for removing rust. I used to sand blast everything, too messy. Don't buy that $30.00 a gallon rust remover. Go to lowes and by toilet bowl cleaner called "the works" $1.00 a Qt. Soak your rusted parts in it full strength or cut in 1/2 with water depending on how long you have to wait. Do it outside cuz it stinks.

Here's my rusty PTO shaft before soaking

I got a pc of pvc pipe and capped one end. Put the shaft in and filled 1/2 with toilet bowl cleaner and 1/2 with water and let sit over night

The shaft after, totally rust free

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[JohnL48]

Quick update:
I got the bell housing cleaned up today and placed it on

Also got the front shaft on

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Everything gets painted

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Jeep back in the day

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Just had to set it on there for some motivation

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[JohnL48]

So the next question is do I try to save these fenders with my novice sheet metal and welding skills? This is the best of the 2 and $1000.00 for aftermarket is divorce court for me

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I decided to go for it. Man there are a lot of spot welds

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This is why you don't take shortcuts. Look at the rust that was under this little panel, and this is the better fender. This would have bubbled the new paint within a yr. 39 spot welds for this panel

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Getting back at it after the holidays. Still not sure about saving the fenders so I disassembled the v6 and I'm dropping the block off at the machine shop, then attempting my first engine rebuild to factory specs...oh boy

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Well it's after the holidays so I got all the engine parts organized and ready to drop off at the machine shop. So this is my first engine rebuild. My plan if all the parts check out ok is to do a piston re ring kit, gasket kit, new cam and rod bearings, and a new cam and lifters. this will be interesting. Maybe a new career in the making lol

I removed the old Dauntless decal with a heat gun to try to get to some fresh paint so I can get an exact match

Found some factory markings on the intake manifold under the grease. I'm going to put them back on after paint....told you I was anal...

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[JohnL48]

Cleaning pistons today (therapy)

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I got the machined engine parts back from machine shop, once i get time I'll show you guys the rebuild steps. Could get interesting

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Back at it again after a very busy winter, starting engine rebuild. Put in new main bearings and installed crankshaft this weekend

http://s1071.photobucket.com/user/Tuckerspop/media/Jeep/V6 engine/2015-02-08143809.jpg.html

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[JohnL48]

1. 
   
   
   
   
   
   
   
   
   
   
   I used the green gauge, removed one bearing cap, placed it on the top of the journal then torqued the cap back down.
   
   
   
   
   
   after removing cap
   
   
   
   
   
   Right on the money. all the others checked out good
   
   
2. Put in new rope seals, what a pain in the butt to cut, even with a brand new razor. Will I have issues due to the frayed edges ? I can order a new kit. Not in a hurry to get it done.
   
   
   
   
   
   Assembly lube all the bearings and put heavy weight oil on rope seal
   
   
   
   
   
   Crank is in. All the caps torqued to 95lbs. Directions on the seals with the pins said to insert both pins in the groove on each side (4 pins total) is this correct ? I've seen it with one pin on each side ?
   
   
   
   
   
   
   Checked the end play next. right on the money
   
   
   
   
   
   
   
   
   
   
3. Cleaned up the pistons too
   
   
   
   
   
   Fun fun
   
   
   
   
   
   
   
   
   

 

[JohnL48]

Ring clearance was good

so was the bearing clearance

I've learned to use the right tools

First piston going in

Clearance between piston rods good

Torqued to 35lbs

Pistons are in

Final job for the day, lubed up the cam and it slid right in

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[JohnL48]

Got the timing chain and gears on today. Need to clean some parts now.
#1 piston at top dead center

Went on pretty easy. getting new chain dampers at Napa tomorrow.

Soaking the oil pan in " the works" toilet bowl cleaner to remove the rust

Blasted some parts today.

Spent today glass beading all the bolts for the motor. Just needed some cleaning up

Got the heads on today, Brake cleaned all the sufaces first,

High temp sealer on the bolt threads

Just making sure I get it right. Torqued three times at 35/ 55 / 75lbs

1. Decided to follow directions and advice and not soak the lifters. Applied assembly grease and slipped them in after cleaning intake area with brake clean.
   
   
   
   
   
   Was going to use the old push rods but found damage on one
   
   
   
   
   
   
   
   And of course after a closer look one bad rocker
   
   
   
   
   So i took apart the rockers and checked everything, the shafts were worn. So i ordered new rods, shafts and a new rocker.
   
   
   
   
   
   
   
   
   

 

[JohnL48]

1. Decided to follow directions and advice and not soak the lifters. Applied assembly grease and slipped them in after cleaning intake area with brake clean.
   
   
   
   
   
   Was going to use the old push rods but found damage on one
   
   
   
   
   
   
   
   And of course after a closer look one bad rocker
   
   
   
   
   So i took apart the rockers and checked everything, the shafts were worn. So i ordered new rods, shafts and a new rocker.
   
   
   
   
   
   
   
   
   
2. 
   
3. 
   
   
4. 
   
   
   
   
   
   Everything on motor without texture gets treated with metal prep which neutralizes rust and etch's the metal
   
   
   
   
   
   
   
   
   
   
   
   
   
   
   
   Also cleaned the timing chain cover real good and put in a new rope seal
   
   
   
   
   
   
   
   
   
   
   
5. 
   Then realized Buick Farm sent me a RH rocker instead of a LH which I ordered and says so on the receipt grrrrrrrr back to a stand still. I haven't been able to find a LH anywhere else
   
   New one on right
   
   
   
   
   
   

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[JohnL48]

1. Well I got one rocker arm back together with the new shaft.
   
   
   
   
   
   Then realized Buick Farm sent me a RH rocker instead of a LH which I ordered and says so on the receipt grrrrrrrr back to a stand still. I haven't been able to find a LH anywhere else
   
   New one on right
   
   
   
2. 
   

• 1. So I am unable to find the right side so I bought a complete set of used rocker assemblies on ebay to get the one rocker. I got the one side together while I wait.
     
     
     
     
     New push rods in
     
     
     
     
     Assembly lube on everything then rocker assembly on torqued to 35lbs
     
     
     
     Got the oil pump together. Decided to stay stock, no high pressure or high volume. Started by block sanding the mating surface's.
     
     
     
     
     
     Middle spring is original, I used one on the left, 40 psi and new pressure valve.
     
     
     
     
     
     Brushed some assembly lube in shaft housing
     
     
     
     
     
     Filled the housing with petroleum jelly so it will prime at start up
     
     
     
     
     New gears inserted
     
     
     
     
     Then just scraped off excess with a straight edge.
     
     
     
     
     
     Yes, I'm a gasket shellac compound guy
     
     
     
     
     
     All buttoned up. Now waiting for more parts
     
     
     
     
     

 

[JohnL48]

Today I got the new timing chain dampers on. For the spring I just used a small socket to pop it on. Pc of cake.

Put the intake manifold on next. Easy to place the gasket by putting the 4 bolts in loose then sliding the gasket in.

Torqued to 50lbs

I'm almost done but still need a fuel pump eccentric which is not looking good right now

 

[JohnL48]

Well well look what came today after 5 weeks

Not sure how much the original faded but looks too dark and too green. I'm going to use it at this point but still waiting for fuel pump eccentric

Spraying it definitely changed the color a bit. With all the different shades these dauntless engines came in I'm happy with it. I'm sure the original color on my water pump is not exact due to age anyway

Since you all know by now I have a condition called rustophobia so any metal that would be hidden from paint after the motor was assembled I went ahead and sprayed a coat of enamel on them, I will just scuff before the final painting

 

[JohnL48]

Carb is apart, cleaned and media blasted, ready for rebuild

Some progress to report, I rebuilt the carb. It was pretty easy to do and saved me $ 300.00 to send it out

Finally located a cam eccentric from a member here, thank god for this forum.

Cam eccentric, distributer gear and cam button

I used permatex 2 on both sides of the timing chain cover gasket

Put some chassis grease on the eccentric for start up

 

[JohnL48]

When putting the water pump on a bolt snapped when I torqued it to spec, so much for the torque wrench being accurate.

Oil screen and pan next

Hope it runs as good as it looks

Its all in the details

 

[JohnL48]

Started putting on the fun stuff today

 

[JohnL48]

I never found manifold paint that lasted so I'm trying this Calyx manifold dressing this time. Nice stuff

Just work it in with your finger

Done for the day

 

[JohnL48]

Got some fun stuff today, if my wifes a secret member here I'm doomed

Today's achievements, new points, rotor (cap was wrong. Had to return) spark plugs, wires, fuel pump, coil and vacuum port

Waited 3 yrs to put the dauntless decals on and the wires hide them, :-0

Plasti dip on the wire holders

Apparently a new oil pressure sensor for the 225 isn't made in the proper size so you have to use a bushing

 

[JohnL48]

Bead blasted and painted cast iron grey

 

[JohnL48]

Got her out of seclusion today and washed her

Got to clean up some rusted parts from storage and shes ready for her new heart

New clutch fork and throw out bearing

 

[JohnL48]

New motor mounts painted and put on

Getting closer

Flywheel machined, ready to go on

I learned the hard way to get it to bare metal at all the ground points

I decided wisely to call it a day and get some help for tomorrow