CJ5 wild stretch and full build (Big Booty Judy)

[chaplinfj60]

Cheap ass evil energy Amazon bands. They were actually really well made. I was surprised.

i found two different ones on amazon and screwed myself by mistake. one style had a lip and the other did not. they do not interchange with each other. fyi. both on amazon both 3 inch but got them at different times. awesome looking so far. exhaust is pain full but rewarding in the end.

good job

 

[1Sinner]

Thanks bud, yeah, I made sure to get them all with the male/female lips and try to buy them in 4 packs to keep them more consistent. I bought another pack last night actually, and made sure they were lipped.

 

[1Sinner]

Not much, but its progress. I got home, did a little trimming on the slider, finish bolted the aluminum armor and completed the layout for the side bolts on the steel armor. I'll drill some pilot holes and then use this as a template to complete the drivers side. Then exhaust mounts, cats and tubing can go in.

 

[1Sinner]

Drivers side wrapped up tonight, and pilot holes drilled on both sides. Tomorrow I'll finish drill and chamfer both sides and get them mounted so I can work on muffler location and running the rest of the exhaust.

 

[1Sinner]

Spent the morning while it was cool finish drilling, chamfering and mounting the sliders. Everything is mounted with flush stainless bolts and an accent for when it's all painted. Now I'm read to bend up a set of steps/slider bars to mount to the lower portion of the sliders and I can finalize and route the rest of the exhaust.

 

[1Sinner]

Bent and added slider bars this morning.

had to add a small filler panel to the back of the slider plates because I goofed on a measurement and forgot to account for the wing that kicks forward onto the front fender section. But I really wanted to show where the exhaust is going to come out of the body. Ther is also going to be a steel flare extension welded on to the back portion of the slider plate and help hide my goof.

Passenger side

then added a center support to both sides. Going to use some 10ga to plate the entire step area, with dimple dies that face up for better traction getting in and out.

 

[1Sinner]

Ticking off some exhaust fitment this evening. I still have to run mounts off the bottom of the sliders with isolator bushings. It's even with the bottom of the frame rails, but hopefully not too vulnerable with the size and how tight it's tucked to the rail. I didn't really have any other option.

passenger side

exhaust exit with stainless tips. Its too late, hole is already cut, but whatcha guys think?

 

[gt1guy]

How tight is the fit where it comes through the side? Being SS it's going to grow more than it would if it was mild steel.

That looks really good though.

 

[1Sinner]

How tight is the fit where it comes through the side? Being SS it's going to grow more than it would if it was mild steel.

That looks really good though.

It has about ¼ inch clearance all around, and the tip will be anchored. There is a second expansion Bellows going in between the tip and the muffler.

 

[csutton7]

Awesome progress going on --way to go.

 

[chaplinfj60]

i dont think i have seen a cooler exhaust exit out the side on a off road rig than this.... well done SIR well done....

 

[1Sinner]

Exhaust work is...... exhausting. Love hacking up brand new parts. Ordered these stainless oval and immediately started cutting them up because I knew nothing commercial would fit. Like every other part on this thing.....

added the expansion bellows, and had to cut a ton off of it as well.

Made brackets and welded them to the tip, centered in the outlet, so the tip can act as its own mount and support a portion of the weight

not a lot of room under here

convoluted connection to the muffler

but its there. Everything is self supporting, but im making some stainless mounts and bushings that will support the muffler and the cat.

3/8 clearanceonce Everything is mounted, it should be fine, otherwise ill be trimming stuff up per usual.

But damn if that dont look good

 

[Firstram]

That is very clean, how loud will it be with the side exit so close to you?

 

[1Sinner]

No idea, can't be worse than the old cj my pops built with the muffler dumps just behind the rear edge of the doors, or the open header sand jeeps I usually hang with at glamis. With the true duals, I'm honestly hoping not terrible. The videos I've watched, those particular mufflers sound pretty mellow compared to other series Flowmasters.

 

[Grnjp92]

No idea, can't be worse than the old cj my pops built with the muffler dumps just behind the rear edge of the doors, or the open header sand jeeps I usually hang with at glamis. With the true duals, I'm honestly hoping not terrible. The videos I've watched, those particular mufflers sound pretty mellow compared to other series Flowmasters.

Read through this whole thread, my admiration has no bounds! After year one I probably would have put it on the back 40 and told myself...I'll get to it soon.lol great work!

 

[1Sinner]

Read through this whole thread, my admiration has no bounds! After year one I probably would have put it on the back 40 and told myself...I'll get to it soon.lol great work!

Thanks bud. Sticking with projects of this scope are the hardest part. I'll have to dig up pics of the samurai I did for my pops, it was like a 3 year labor of love project too.

 

[Grnjp92]

Thanks bud. Sticking with projects of this scope are the hardest part. I'll have to dig up pics of the samurai I did for my pops, it was like a 3 year labor of love project too.

My brain won't keep me on track for a project like that! 😒 I just find reason's not to deal with them lol!

 

[1Sinner]

This one was actually a tin top at the beginning of life. Pops wanted a hard cab pickup samurai. Couldn't convince him to do toyota axles and a frame stretch. He wanted stock wheelbase, stock width, hard cab and a turbo. I sectioned 2 feet out of the tin top, grafted everything back together, cut the bed off a convertible Sammy, grafted that on. Built a removable cage, full aluminum dash, stuffed it with auto meters, he bought a turbo system from some dude in Arizona (it ended up not working out after he spent a few thousand at the tuner) and he went back to a weber, decked head and header. But yeah, this was a three year project. I had that body off so many times. Then I did it to myself again with the jeep. But the Sammy helped me up my skills a lot. He drives it almost every day.

 

[1Sinner]

Time consuming but necessary stuff today. Nobody made a commercial mount I found that fit my constraints, or the space, so I made some. Muffler mounts out of stainless.

Using grommets in the mounts with tubing sections for to allow them to free float in the mounts.

Like so. I may have to use high heat silicone grommets in the future, but I'll try these for now.

ready to weld in.

3/4 of an inch below the slider and the slider acts as a heat shield for the floor.

both sides sit flush with the bottom of the frame rail and should keep it somewhat protected. We'll see. But other than setting up a purge and final welding, exhaust is completely fit and finished.

 

[1Sinner]

Nothing crazy this weekend. Spent too much time working on the beater civic to get a lot done, then hung out with family yesterday, so today I built some fender flare extensions, just to finish off the flares and armor. Little stuff to make it all come together, and these help the rear flares match the front fenders.

 

[gt1guy]

Damn, you nailed those flares.

 

[1Sinner]

Damn, you nailed those flares.

Thanks bud!

 

[1Sinner]

Alright, dumb bullshit. But I wasn't paying 2-300 dollars for a v8 round billet charcoal canister. Took an old vacuum bottle and made a canister to hide in the rear wheel well, and will fill with busted up charcoal briquettes. Same as a canister, and should keep the fuel smells away.

wrapped in lint free cloth, vents, doesn't shed and will help from getting holes/manifold from getting clogged.

same here.

 

[RMO]

Why all the emissions crap, would think your CJ is old enough to be exempt.

 

[1Sinner]

Why all the emissions crap, would think your CJ is old enough to be exempt.

It is definitely exempt. It's more about eliminating fuel smells. I would rather smell exhaust than raw fuel. Also a large part of the reason my mom gave up being around classic cars, a long day on the trails or in the car would make her nauseous and I want to take her for rides, and I also don't want my wife to hate riding in it. She is pretty sensitive to smells as well (though she hasn't complained about fuel). In the end though, if I can improve the emissions, without harming performance, what does it hurt? Just one less thing for the eco nazis to complain about.

 

[gt1guy]

That makes sense.

 

[RMO]

It is definitely exempt. It's more about eliminating fuel smells. I would rather smell exhaust than raw fuel. Also a large part of the reason my mom gave up being around classic cars, a long day on the trails or in the car would make her nauseous and I want to take her for rides, and I also don't want my wife to hate riding in it. She is pretty sensitive to smells as well (though she hasn't complained about fuel). In the end though, if I can improve the emissions, without harming performance, what does it hurt? Just one less thing for the eco nazis to complain about.

Gotcha, makes sense and thanks for explaining.👍

 

[1Sinner]

Filled the canister with actual coal. I had an old coal fired forge and forgot I had this stuff laying around.

but that isn't what this post is really about. I began laying out the side panels for the aluminum top.

got every measured. Set, cut and ready

measurement marker.

and then royally screwed the panel up. Ill have to get pics of the panel. I may have screwed the large frame up as well. Ugh. Got pretty disgusted trying to fold the long seam. So, after another beer, i went and grabbed the steel top and tossed it on. Very tempted at this point to just extend it and build aluminum doors only. A large part of the problem with the aluminum panels, is they are too big to handle well by myself. None of my fabricator buds live in town, so my closest help is 45-1hr away. Still pondering.

 

[gt1guy]

Big parts solo does have it's limitations. Modifying the metal top will allow you to get the rest of the things done you need to get it running. At that point you're enjoying it. Then you can build the alum top slowly as you have extra hands around.

Either way, it's going to look fantastic.

 

[1Sinner]

After putting the top on hold again for now, back to odds and ends. Started inner fenders

Prepped, trimmed and bead rolled

couldn't find my dzus tab locator, so i drilled a flush head bolt and epoxied in a sharpened dowel.

tabbed

turned out decent

boths sides done

geometry off the inner shock hoop gives it decent flow with the rest of the paneling.