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Building a Scrambler from left overs

designerRob

CJ-8 Member
Silver Member
City
Allen Park
State
MI
Bought this upholstery kit for some YJ seats I picked up at a swap meet years ago. A place in CT made these. The bottom of the back rests needed a little more vinyl to cover the foam, but overall a nice kit. I've got the carpet and the seats now. Need to get that 304 put together.
Those look very nice. Do you have a link to the upholsterer?
 

Kim Dawson

CJ-8 Member
Member
City
Molalla
State
Or
Got some work done on the engine today. Pistons in and the heads on and some parts on the front. 110 lbs of torque on the head bolts gave my arms a work out. Waiting on new valve lifters. I didn't keep the old ones in order so I can't re-use them or the cam will go flat. Those cam bearings were a problem. My mechanic friend installed them with his cam tool but distorted one so when the cam went in it wouldn't turn. So he ordered another set and did it again and that time it came out nice. Probably lost a month because of that. I feel better about it now.
 

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Kim Dawson

CJ-8 Member
Member
City
Molalla
State
Or
Got the Engine mounted in the chassis and put the flywheel and clutch stuff on. Then I noticed that the bell housing had two sets of trans mounting holes but none fit the borg warner 4 speed. So off with the bell housing. There were four more holes that were smaller and shallow that did match so I drilled them out and tapped them. Hopefully everything will fit now. A little more done.
 

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certifiablejeep

Definitley Certifiable
Lifetime Member
City
Bedford
State
NH
Got the Engine mounted in the chassis and put the flywheel and clutch stuff on. Then I noticed that the bell housing had two sets of trans mounting holes but none fit the borg warner 4 speed. So off with the bell housing. There were four more holes that were smaller and shallow that did match so I drilled them out and tapped them. Hopefully everything will fit now. A little more done.
I am not sure what bell housing that is for from the pictures, but just make sure that the input shaft of the trans is at the face of the bellhousing and you have good connection with the pilot bushing and you don't have any distance issues... or engagement issues.

cb
 

Kim Dawson

CJ-8 Member
Member
City
Molalla
State
Or
I am not sure what bell housing that is for from the pictures, but just make sure that the input shaft of the trans is at the face of the bellhousing and you have good connection with the pilot bushing and you don't have any distance issues... or engagement issues.

cb
Thanks. I'll check that out. This bell housing looks like the right depth. I have another one that is about 2" taller. I was wondering why the trans wouldn't go that last almost 3 inches . . . . wrong clutch plate. Needs the 1 1/8" dia opening and only has about a 1" opening. Just ordered the larger clutch/pressure plate. Sometimes left overs work, sometimes they don't.
 
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Kim Dawson

CJ-8 Member
Member
City
Molalla
State
Or
New clutch and pressure plate came so I could do the bell housing and trans so I could figure the right holes to use for the trans mount and the mounting plate. Had to jack the frame apart a little and elongate one hole to get the plate to fit. Made my own torque bolt/mount. Put the transfer case on and now can look for a rear driveshaft to fit. I'll do a want ad. Cleaned up an Offenhouser intake I pulled from a parts Jeep I bought recently. Not bolted on yet but the gaskets for it came today. After rebuilding the engine, it just didn't seem right to put the 2 bbl intake and carb on it. Got some alternator brackets from the parts car but water pumps were different castings. Had to make some spacers to get the brackets to work on this pump. Had to buy a heli-coil tool to fix threaded holes on the front of the head that I needed to use. Every time I discover something I need I order it and hurry up and wait.
 

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Kim Dawson

CJ-8 Member
Member
City
Molalla
State
Or
Today I put on the offy intake and the rebuilt Holly. Got the fuel filter and fuel and return lines all hooked up. Valve covers on. Finally got the right size belts for the front of the engine and all brackets on. Amazing the alternator took 4 brackets and 4 spacers. Kind of neat the way the bracket that bolts to the back of the alt swings with it as you rotate the alt to tighten it. That alt is definitely secure. Time to contact Filler Neck Supply Co again (thank you Randy) and order the lengths to reach my center mounted tank. Got the exhaust parts on the way so I can get that figured out. My new yoke came today for the back of the TC and got that on. The old one had the threads drilled out and no flat surface for nuts. Hooked up the power steering lines yesterday. Fitted the air cleaner (thanks Certifiable) and put the mounting stud in the carb. Certifiable has a driveshaft on the way so things are coming together.
 

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Kim Dawson

CJ-8 Member
Member
City
Molalla
State
Or
Just a little more done. Got the U-joints in the driveshaft I got from Craig and installed it. Thank you Craig. Put the fluid in the trans and TC. Still waiting for my friend to weld up the exhaust for me.
 

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Kim Dawson

CJ-8 Member
Member
City
Molalla
State
Or
Had my neighbor weld in the patch pieces I made to fix this windshield. Water got behind the rubber and rusted out these two places with a vengeance. This was left over after I replaced it with a nice no-rust CA desert frame. My neighbor is finishing up welding the exhaust and I should have the chassis back this weekend.
 

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Kim Dawson

CJ-8 Member
Member
City
Molalla
State
Or
Exhaust is all done. My friend brought the chassis back this evening. Backed it under the body. Will straighten it out in the daylight. I like centering the tank and running the dual exhaust alongside the tank and out the back. Finally some more progress.
 

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Kim Dawson

CJ-8 Member
Member
City
Molalla
State
Or
Today I got the body mounts in place and the body bolted down. Not as easy as it sounds on this one. A previous owner had replaced and added sheetmetal to the floor areas which changed the height of the floor in some places. I set it on the body mounts front and rear and measured the in-between-mounts and cut the rubber, sleeves, and bolts to fit. A little more time on that than I expected but it all fits nice and the body is same distance out from the frame both front and rear. The heat shield plate on the firewall was interfering with the engine and pushing the body back a little. I cut the top brace, overlapped it, and pop riveted it which gave it a half inch or more room so it clears now. Always good when the body meets the frame.
 

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Kim Dawson

CJ-8 Member
Member
City
Molalla
State
Or
Went through my tub of tail lights. Did some swapping around of innards and plugs to make a decent pair. Pulled the tail light wiring harness from my rusty postal tub, cleaned it up, installed it and connected up to the under-dash harness. Also put the tail gate brackets and cables and carrier parts on. Now I need to modify my tonneau cover to fit around the carrier brackets. Found a hump cover that was close and moved the TC shifter hole down 2 inches. Nice finally having this project inside.
 

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Kim Dawson

CJ-8 Member
Member
City
Molalla
State
Or
Today I fitted the carpet and got the shifter boots installed. Then I scrounged up some seat adjusters and got them and the seat brackets together and installed the seats. Nice to have them off of my bench. The trans shifter boot was only 7.99 delivered. I don't know how they can make anything on that. Had to drill more holes in the seat brackets to fit these later seats on the CJ brackets. Assembly always seems to eat up more time than expected.
 

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Kim Dawson

CJ-8 Member
Member
City
Molalla
State
Or
Got the fuel filler lines fitted and installed. Not as easy as it looks. Those lines are stiff. Took a few different tries to get the right combination. After cutting to the right lengths, install on filler neck, feed through frame opening, secure filler neck, and muscle them onto the tank. My tank is centered for dual exhaust. Those nice pre-formed filler hoses would have been nice if they were long enough. Made this bracket out of SS for the DeLorean roll-over valve. Now I need a T and some 1/4" hose to get that finished.
 

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Kim Dawson

CJ-8 Member
Member
City
Molalla
State
Or
Got to fit the front fenders and grill. Then removed the driver fender until I get steering, clutch linkage, and brake lines in place. Holidays and whacking my back slowed me down on this. Back to slow progress.
 

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