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CJ5 wild stretch and full build (Big Booty Judy)

Parts on the way! Ordered the rest of the stuff for the drivetrain. Billet double disc converter, engine seal kit, head studs, trans seal kit, 62 lb/hr injectors, timing chain, melling HV oil pump, cam tensioner, oil cooler for the trans, and the condenser and fittings to finish plumbing AC. Going to try to push through, finalize everything in the next month or two, and tear down for bodywork by December.
 
Regulator came in today! Portable camping fire pit is done!
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It'll burn low
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and It'll also throw a shitload of heat! I never made it even close to 30psi. I think this was reading 2psi.
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working on finishing the fuel system braided stainless with teflon/E-85 compatible liner. After the lines were made, i fire sleeved Everything with fiberglass/nomex braidand used stainless safety wire to hold it on.
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safety wire detail
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found a place on the frame rail for my regulator and routed the inlet to the rails as far away from heat as possible. Rails are tied front and rear with braided hoses, so it's 360* fuel feed.
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hidden and protected
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stainless hard line for fuel supply and braided stainless for return. Still need to make heat Sheila's, but I'm at least 2" from the exhaust. I also put a tee in after the regulator so I can use it as a bleed/drain port if i need it to service the fuel system later.
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Regulator came in today! Portable camping fire pit is done!
20240925_181426.jpg
It'll burn low
20240925_181734.jpg
and It'll also throw a shitload of heat! I never made it even close to 30psi. I think this was reading 2psi.
20240925_181747.jpg
working on finishing the fuel system braided stainless with teflon/E-85 compatible liner. After the lines were made, i fire sleeved Everything with fiberglass/nomex braidand used stainless safety wire to hold it on.
20240925_212436.jpg
safety wire detail
20240925_212439.jpg
found a place on the frame rail for my regulator and routed the inlet to the rails as far away from heat as possible. Rails are tied front and rear with braided hoses, so it's 360* fuel feed.
20240925_212855.jpg
hidden and protected
20240925_212901.jpg
stainless hard line for fuel supply and braided stainless for return. Still need to make heat Sheila's, but I'm at least 2" from the exhaust. I also put a tee in after the regulator so I can use it as a bleed/drain port if i need it to service the fuel system later.
20240925_212912.jpg
The fire pit is pretty cool and a great idea. Wonder how long it'll last before the ammo can "burns out".
 
The fire pit is pretty cool and a great idea. Wonder how long it'll last before the ammo can "burns out".
I dunno, but I'm going to make a bunch for Christmas.
Fire pit is awesome! I've always had that on my "to do list" but never pulled the trigger on it yet.
Do it! It really didn't take long to build.
 
Not much progress this weekend, but some is better than none. Made the upper closure plate for the passenger side.
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made , welded the brackets in and attached the rivnuts for the upper mounts on the grille closure plates both sides. Tryingbto knock out the rest of the minor body work.
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Replacement truck norris cam should be delivered tomorrow. Still waiting on the transmission seal kit. Ordered the bungs I needed to make the coolant overflow and power steering reservoir tanks, plus the power steering cooler. Running out of things to build. :lmao:
 
Managed to get everything mocked up and just about ready to install in the grille shell for the AC condenser, transmission cooler and power steering cooler. Derale supplied the coolers and summit supplied the universal condenser. Going to order up some AC hard line once I have the final mounting in place and I can finish most of the rest of the plumbing.
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Wholly shit that is clean. I have to tip my hat to that solution.:beer:
Thanks bud. It took some time to put it together for sure. Hoping to make the feet and get everything final mounted this weekend. Then start building the power steering and coolant overflow reservoirs.
 
Daniel made good. Shocks have been returned, shortened to 14s, with new reservoirs with compression and rebound damping adjusters, including new reservoirs for the rears.
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With the brackets completed, i made some feet for the bottom of the cooling sysck.
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And everything fits nice and snug
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Had to space the radiator out a quarter inch to clear everything. Modified the shroud for free flow flaps and trimmed the shroud for the fan to within a quarter inch of the fan OD to not lose any flow.
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ready for final plumbing!
 
Front brakes are in! That checks another system off the list! Wilwood 2 piston calipers for the fronts. Obviously my rotors have been sitting way too long....
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wilwood 1" master and proportioning valve, Ford hydroboost setup all copper/nickel brake lines throughout the system.
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Ran factory style expansion loops under the proportioning valve to hopefully keep things happy and never crack.
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might be a little much, but all the hard lines got two layers of self sealing shrink tube anywhere they may vibrate and rub a hole.
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Front axle is plumbed
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ran a 2psi inline valve to ensure the front brakes always have good fluid pressure, ran a hard line down the panhard with flex lines at the top and bottom. All flex lines are 10" stainless braided teflon. It lets me carry several spares in the event of failure, since all flex lines (except to the front calipers) are the same. Here you also get a good look at the speed flaps I added to the fan shroud.
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passenger side view of the panhard, flex and tee I used to tie into the axle side plumbing.
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I would add a couple wraps of F4 tape on the the zip tie tabs. Not sure if it would wear through or not but it’s cheap and peace of mind for me
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You do great work. Can’t wait to see the rig out in the wild :grinpimp:
Thanks man!
Looks great!!! Wanna come to Tennessee and rerun my buggy brake lines??? :lmao:
You buy I'll fly. I'd like to come adventure around Tennessee a bit.
I would add a couple wraps of F4 tape on the the zip tie tabs. Not sure if it would wear through or not but it’s cheap and peace of mind for me
That's where I've double layered the self seal shrink tube. That stuff is pretty tough, but I'll definitely look to add tape or sleeving in a few spots.
 
You're really powering through now. Progress looks great.

Interested to hear how the 2psi residual valves work out. I always thought they were for drum brakes to cancel out the spring pressure.
Have you ran them before?
 
You're really powering through now. Progress looks great.

Interested to hear how the 2psi residual valves work out. I always thought they were for drum brakes to cancel out the spring pressure.
Have you ran them before?
I haven't. The 2psi ones were recommended for discs. There's a 4 psi disc one and a 4 and 6psi one for drums. I've noticed a lot of guys having to pump once or twice to get good pedal pressure. Hopefully this keeps that from happening. I can always remove it later if I don't need it. Or if it causes excessive loading. But 2 psi shouldn't.
 
What's this? There's a pile of stainless stuff on my table? It's time to completely finish the exhaust and build the reservoirs for the cooling and power steering systems. Got the shop cleaned up, did a bunch of setup and dug my purge tee and spare regulator out so I could set up a back purge for the stainless to keep it happy while I was burning full pen welds through the schedule 5 tubing.
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purge setup with some of that fire sleeve to keep the tube from melting and used a vent screen on the end to act as an argon diffuser (not shown). I also like to use a copper cable ground for when im doing stainless or round tubing welds. I get more contact, theres less chance of arc-ing out and it easily fits in the clamp. Made out of spare battery cable and terminal ends.
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Cat/muffler assemblies welded
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head/down pipes from the manifolds are done. 25 welds this afternoon. Not too shabby.
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not the prettiest ive ever cooked into stainless, bit not terrible for freehand and multiple positions. No sugaring on the inside of the pupe and managed full penetration on all the pie cut butt joints.
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Just need to finish the last exhaust sections to the side dump tips and them I can focus on the reservoirs.
 
Looks great and that's a lot of weld in one shot.

I thought you already finished your exhaust a while back. I remember you messing with the exhaust manifolds and seeing pictures of tail pipes sticking out of the tub. Guess I assumed they were connected together.:laughing:
 
Looks great and that's a lot of weld in one shot.

I thought you already finished your exhaust a while back. I remember you messing with the exhaust manifolds and seeing pictures of tail pipes sticking out of the tub. Guess I assumed they were connected together.:laughing:
They were all connected, but just tacked. I didn't want to use clamps on anything so I got everything set and ready for final weld, and moved on to other things in the mean time.
 
Not a monster update, but managed to finish welding all the exhaust today, but I'm definitely excited. Picked up this little Southbend (edited for idiocy, it was advertised as a Logan, the data plate was dirty as hell, apparently it stuck in my brain, even after i cleaned it) today to fill most of the needs of the monarch I had on loan for a while that my buddy ended up selling. So I can start making bushings and things again. Nice little 110v lathe with several chucks one 3 jaw and 2 4 jaws, a turning plate, taper attachment, collects and back stocks. Going back tomorrow to the seller to pick up a planishing hammer, a big shot bag, and a foot operated double shrinker stretcher setup. Need to get a little aloris tool post for it, but will definitely make my life easier.
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