October 26, 2009 - Another long delay between posts ... I just started the process of painting the CJ, which is chronicled here.

March 14, 2005 - I can't believe I have not updated this site in two years!  Since the last update, I have not done a lot of work on the CJ, although I did flop it over again.  Today's news is that I'm in the process of building a workshop for the Jeeps (and other assorted junk).  Check here for a write up and progress on the shop.

March 25, 2003 - I FINALLY got the trailer registered yesterday … what an ordeal! Click here for the complete saga ... it's good for a laugh or two! I will NEVER build or buy an untitled trailer again - it's just too much of a hassle!

March 18, 2003 - I bought a trailer last weekend and rebuilt it. The deck was rotted out, most of the paint was gone, and the wiring was shot, but the tires are new, axles are straight and hubs/bearings are in good shape. It took 14 pressure-treated 2x6's, eight rattle-cans of RustStop, a roll of wire, solder, heat-shrink tubing, screws and lots of sweat to work over. Now I have to jump through the obligatory hoops to get it titled and registered (it's never been titled in Texas). Another week of paperwork and I won't have to worry about renting a trailer to haul the CJ anymore!

February 1, 2003 - The CJ is back together, although it still needs paint. I found new reproduction hood, fender & windshield frame on eBay, got urethane motor mounts and windshield gaskets from Quadratec, and bought used windshield glass locally. The top is out being sewn back up and should be ready next week. It should be ready for the trail next weekend!!

December 16, 2002 - I flopped the CJ over on its side in Clayton this weekend (taking a stupid line on an obstacle). Broke a motor mount and crushed the hood, windshield frame, and left fender. More on the repairs later ...

October 20, 2002 - After less than a year, the rear BDS springs have sagged severely ... I guess the cage and trail box were too much weight. Thanks to BDS's 'no fine print' warranty and Bob Supplee (of Supplee Four Wheel Drive), I have new rear springs plus a set of helper springs.

September 23, 2002 - Lots going on, but no time to report:

• Replaced the clutch (the clutch chattered bad when cold and throw-out bearing was squealing).  A previous owner apparently had this done before, but must have hired Bubba to do the work - three bolts were missing off the bell housing, they didn't resurface the flywheel, and they didn't replace the pilot bushing (the pilot bushing was so worn it was reamed out 1/8 inch).  I also had to replace the throw-out arm boot, which was a PITA to find at the last moment - thanks Collins Brothers!).  Wow, no more bucking bronco or squealing pig!
   

• Clocked the transfer case up flat using a clocking ring I bought off eBay.  It took a few shots to get it stabbed becasue we had to grind a little off a nub on the transfer case to get it to fit into the T5 transmission when rotated.  We had to use a torch to bend the Currie Twin Sticks to get them vertical again; the rotation caused the whole shifter to be shifted up and over, necessitating modifications (trimming) of the tub.  I need to find a bigger boot to cover the holes.  Took the opportunity to change the lube in both the transmission & transfer case and replace the transmission mounts with polyurethane mounts.   Now I need to get or fabricate a flat skid plate.  It also looks like a I may need a longer CV-Joint front driveshaft - the angle at the transfer case is a bit steeper.
   

• Got a used QuickAir 2 compressor, but have not yet installed it - I'm planning a tank / manifold setup.
   

• Installed a Dynatrac U-Bolt flip kit.  Had to weld new shock mounts on the rear axle, but gained lots of clearance.  Well worth the money.  




• Installed a Tachometer.

May 22, 2002 - I finally got a winch for the CJ: a Warn XD9000i.  I mounted it last week and got it cabled up on Monday.  I used marine terminals on the battery and replaced the battery cables (to ground and starter solenoid) with plain lug-to-lug cables ... much cleaner.  I'll probably get to test it out at Yanush this weekend.  (Note: the winch got a real good workout at Yanush in July - worked great)

I had to move the spotlights to make room for the winch plate and so had to rewire them. I took the opportunity to use heavier gauge wire and to solder and heat-shrink all of the connections.

Other upgrades this week include:

• Installed an external speaker for the CB radio (now I can hear it on the highway) (Note: the speaker died the next weekend - pitched it)

• Installed taillight guards (saw too many broken tail lights last weekend)

• Installed grab handles ('oh hell handles') on the cage

• Installed shift knobs from an AA Atlas II transfer case (they have the shift pattern on the knobs)

April 9, 2002 - It appears that the Jeep fever is contagious - my brother Don just bought a new TJ.  My wife called his wife and welcomed her to the Jeep Widow's club.  Don's already planning all the mandatory modifications: lift, tires & wheels, etc.   Here's a link to his new Jeep web page.

I picked up a Chevy heater blower motor from Ed Westerbeck (Rock Taxi) ... sometime before next winter I'll find the time to install it - it should keep us nice and toasty!

April 5, 2002 - I finally installed the Currie Twin Stick shifter for the Dana 300 (it's been sitting in the box for 4 months).  Install was easy, but the Currie shift boot is a joke - it doesn't cover the hole in the floor.  I ended up cutting the stock boot and slipping it over the Currie boot.  I guess I'll look into other boot options.  I'm also considering removing the interlock pills to allow me to shift into low front wheel drive.

Feb 25, 2002 - I installed a new Uniden Pro520-XL CB radio and F-40 fiberglass antenna ... now I can get rid of the cheesy had-held CB.  I also remounted the RoughNeck trail box that came with the CJ and replaced the lock cylinders in the console & trail box to match.  I got a cylinder for the glovebox, but need to modify the existing latch to work with it.
 

Feb 21, 2002 - I finished up the Herculiner, repainted the cage and got the Corbeau seats installed last Friday.  I also got some cheapo lap belts from the local auto parts store, which are installed as well.
 

Don & I started the Howell injection install last Saturday, but ran into a few snags, the biggest of which was that Howell sent me the California harness with a 49-state kit.  The harness had a connection for a 4-wire heated oxygen sensor, but the sensor they supplied was only a single wire unit.  I got a new oxygen sensor from Howell on Tuesday and got it installed last night.  Finding a circuit to power the computer was also a challenge (needs power with ignition switch in both on and start positions) ... I remembered reading on one of the forums that the oil pressure gauge had such a wire, which saved me a lot of hassles.  I finished up the install today - WOW, it cranks right up, purrs like a kitten, and runs like a bat out of hell!

Since I had the glove box out, I decided to replace the heater control cables and dash indicator lights. I have had the parts for months, but never took the time to install ... it was a lot less work than I had anticipated.  I also took the opportunity to fix the cigarette lighter and the messy wad of cables from the stereo.

Feb 13, 2002 - Lots going on, but no time to report it ... I ordered the Corbeau Baja SS seats and associated hardware from Brett at AFM - still waiting on delivery.  I also ordered the Howell TBI injection kit; Don and I plan to install it this weekend.

What started out as a simple project (re-rattlecan the roll cage) has turned into the typical Jeep project from hell.  Once I lifted out the cage, I saw the tub was rusted out and falling apart under the original roll bar mounts (behind the front seats).  After a weekend of wire-brushing, sanding, sealing, cutting, fitting and riveting patches, filling & priming, it is ready for a top coat.  While I was at it, I realized the neat-o Astroturf was holding water and so had to go.  So now I am prepping the tub for Herculiner - scrubbing with Goo-Gone to remove the adhesive left by the @#$% carpet tape, scrubbing away years of grease & grime with TSP, sealing & priming the rust spots, etc.  I hope to finish the prep tonight and start the Herculiner install tomorrow ... more later (and pictures too) ...
 

Jan 21, 2002 - Last weekend's Clayton, OK Freiling run shook out some more problems with the CJ.  It looks like I need new seats - the driver's seat frame broke (rusted out) before we ever got on the trail - nothing a block of wood and a ratchet strap wouldn't fix!  As usual the @#$% Carter BBD carb sporadically gave me fits.  It also looks like I need a new thermostat - it takes forever to warm up.

On a positive note, the hand throttle worked like a charm, the rocker sliders did their job nicely and the footman loops kept everything in its intended place!  I disconnected the swaybar for this run - looks like it's not going back on.
 

I finally got footman loops installed in the rear of the tub on Monday, so I can anchor down my cargo (tired of getting whacked in the back of the head, Don?) 

I installed a hand throttle ... I had no idea how tough it was to find a bike shop who carried plain old generic bike shifters, but finally found one.  Took all of an hour to fabricate a mount and get it installed. 

Lastly, I got a set of slightly used rocker sliders and got them installed today.  Murphy was with me - one of the bottom mounts hit the frame tie-in for the roll cage ... I got Russ to move the tabs.

Jan 4th, 2002 - After taking the CJ-7 on it's shake-down cruise at Muenster, I drained & refilled the differentials.  Look at what I found in the rear axle:

These appear to be pieces of a thrust washer from the Detroit No-Spin locker.  Drivetrain Direct is replacing the Detroit under warranty, but I'll still have to pay for return shipping and installation labor. 

I drove it 45 miles from North Dallas to Pilot Point, then my brother, Don, & I trailered it to Muenster.  The drive was rather scary - the caster is off a bit, so it likes to wander on the freeway.   I drove it back from Pilot Point that night, which was equally as scary.  I guess I need to get some caster angle shims ...

I installed the Garvin bumpers and spare carrier and rewired the off-road lights while Russ was working on the cage.  After I got it home I started installing Astroturf in lieu of carpet ... I mis-measured a tad, so I'll have to get more Astroturf to complete the front.

I also bought some new seat sliders, but found that the seats frames were so rusted I could not remove the old sliders ... oh well ... I guess I need to find some seats ...
 

Send comments or questions to Joe Church (jchurch@lex-con.com)