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Sunny Delight - now Shelly 2.0

Picked up the rest of the stuff and decided to clean the full top this morning. This sat outside the past couple years on a very rusty Scrambler tub under a tree. Cleaned up some. Really doesn't matter since it will get repainted if I intend on using it.
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As far as an update on Sunny Delight as a whole, I am in the process of tear down but at a snail's pace. I am also going through a decent amount of parts I sold with it to determine what to keep and what to sell. Progress is slow due to some family business being taken care of that takes a lot of my time these days but it's also great therapy to get to work on it and take my mind off things. Here are some pics. No real surprises in the condition since it was in pieces when I picked it up. Thankfully it sat either inside a garage or under an awning since I sold it.
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Why did I wait this long to get one of these?!?! Thanks @rubclt for the suggestion

Edit: I used this to remove the dreaded 16 roll bar bolts. I got each one red hot from the bottom then got the head of each bolt hot (burned the paint off but never got red). 14 bolts came out by hand with a long handled ratchet. The other two sheared off flush at the heads. I’ll take this win any day over my history with these bolts. And the icing on the cake?!? This was done in an hour. This is a China special $150 tool off Amazon. I’ve wasted $150 multiple times over in the past in drill bits, cut off wheels, etc for these bolts.
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Why did I wait this long to get one of these?!?! Thanks @rubclt for the suggestion

Edit: I used this to remove the dreaded 16 roll bar bolts. I got each one red hot from the bottom then got the head of each bolt hot (burned the paint off but never got red). 14 bolts came out by hand with a long handled ratchet. The other two sheared off flush at the heads. I’ll take this win any day over my history with these bolts. And the icing on the cake?!? This was done in an hour. This is a China special $150 tool off Amazon. I’ve wasted $150 multiple times over in the past in drill bits, cut off wheels, etc for these bolts.
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Miniductors are very cool to have. My brother bought one before all the lower priced imports were available. Definitely good to have working on CJ's. Amazing how fast the can get a bolt/nut red hot.
 
Engine is out and is awaiting pickup by new owner. Guy is also buying the T5 I had leftover from another project

Edit: guy backed out on the T5. Sold it two days later to a different guy from the FB Marketplace add I had up.

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Tear down complete. All I need to do is load the tub and other body parts onto a trailer to take to my paint and body guy. He hopes to be ready for me in 1-2 weeks.

Overall there really weren’t too many surprises during tear down.

frame cleanup and mending to take place once I have the body parts gone.
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These snails pace rebuilds are the ones to watch! Tearing it up down there my man! Keep showing that work who's boss.
 
Me and my helper just got the tub off the frame. He’s a little slow and doesn’t say much but he’s a workhorse. Got him cheap years ago at Northern Tool.

Frame repair / stiffening work begins Sunday. Time to get it stripped all the way down
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Frame is all welded up however I still need to clean up a few of the welds. Pics to come afterwards. Also need to clean up the Runk bumpers a little where things were added and removed in the past. With it as cold as it is today that work will have to wait. Don’t want to grind in the garage and get everything filthy and I’m not going to do it outside today. Too cold for that

So I decided to mock up the front end. Runk Bumper plus the Warn 8274 and plate. Not a lot of room left over but it fits.

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Update on the lift kit situation ….

I have always used BDS kits on my personal CJs and have recommended them to others / installed them when I had a shop. Never a complaint from me. I have installed other kits such as Rubicon Express and OME. No questions with their quality - just stuck with what I knew and liked which was BDS.

Plans were to purchase the same 2.5” YJ conversion kit from BDS as always. That’s when things got interesting. Their website has changed dramatically with most of their emphasis on modern vehicles. No worries. I always order through my local dealer. I’ve done that multiple times in the past. Easy peasy. I just like to check out the BDS site to ensure nothing has changed with the kit.

Local dealer said things have gotten “interesting“ with BDS lately and he’s unable to place an order for what I want without calling them directly. Ok, whatever works. He said he’d call me back. While I waited, I decided to call the BDS support line and ask about the kit and if anything had changed since the last kit I purchased. Guy I spoke to, while polite, didn’t seem to care once he heard I was working on an old Jeep. He ended up telling me to “work with your local dealer” to order a kit and told me to have a good day.

Local dealer called me back frustrated. Said he spoke to their vendor contact at BDS and essentially got the same feeling - that they don’t seem to care about older vehicles anymore. Vendor contact told him to “piece the kit together himself and call back with the part numbers.” When my guy shared he couldn’t see them anymore on the BDS site the contact essentially said to keep looking.

Two different BDS representatives gave myself and my local dealer the same feeling / lack of support.

So here we are. I ordered an OME kit put together through Quadratec. Went with Bilstein shocks. One front spring has not arrived yet but it doesn’t matter at the moment. No where near that stage in the build.

That reminds me - I need to post the RE 4.5" kit for sale.

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It’s weird knowing that the body parts are an hour north of me and the frame and bits are 45 mins Northeast of me at powder coat. Monday I drop off the axles for the gear job. After that all I will have in my possession are 5 wheels and tires, a steering column and a small assortment of parts. Lol
 
Here is a pic of the underside of the gas tank crossmember. 3/24/81 would make sense for a build date (at least of this part/frame) but I wonder what the “90 AW” represents ?
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My slow but dependable helper "Red" came to work the past couple days so I was able to get the suspension and axles installed. Will clean up the axles some when it’s not freezing outside. Gas tank, fuel and brake lines, steering and the rolling chassis will be done. Then we wait. I’ll have plenty of time to restore the steering column, polish the rocker moldings, etc. OH! And move everything in June when we depart Mt Holly. Lots of things in the air these days

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Chassis build continues. Aside from all the black being powder coated I am painting all bolts with clear coat as well. Gotta make this thing as protected as possible for our upcoming move to the coast.
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