My Project "Goldie" (lots of pics)

[Charlie_B]

I guess making a "build thread" is the thing to do these days. So here I go. This summer is the summer to get my rig up to par. Its always needed some lovin in almost every place. And I feel like Ive just been polishing the turd for the last few years. The 1 yr old flexplate and starter gave up on me last fall. And instead of pulling off the slush box just to put it back on, the project list began. Things are getting slighty more serious with the g/f and I imagine that my ability to pull off a major project like this wont be around too much longer.

The list

Done:
-rebuild qtrac (OEM)
-rebuild tranny

In Progress:
prepping/painting backside of front clip and hood.

To Do:
-fix floor pans
-fix quarter panels
-fix flares
-strip/undercoat
-body rust repair/new sealer
-paint

The realistic wishes:
-4" lift (which I could higher, but trying to stay road legal)
-33x12.5 M/T? A/T? (see above)
-rebuild front end (tie rods, steering box, etc)
-u-joints
-rebuild at least top end of the motor (8600, Edel, T/A, Bulltear, fresh heads)

The pics (in order of appearance)
spare tranny/t-case
http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1647.jpg
http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1646.jpg

My SWEET (haha) work bench I built to practice some more welding
http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1648.jpg

Some of the goodies
http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1645.jpg

t-case damage (from other thread)
http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1665.jpg
http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1666.jpg

rust reconnaissance:eek:
http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1667.jpg
http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1668.jpg
http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1669.jpg
http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1670.jpg

Last night I pulled the rear seat and cargo carpet out. I was pleasantly surprised at the lack of rust on the rest of the truck compared to the passenger side. The inside of the body panels around the flares and rear quarters arent pretty. But I think I can clean it up and convert it well enough to stop the spread of rust. The fellow member (supercheif79) that I bought the spare tranny/t-case from stopped by last night with another t-case and tranny along with an old starter (ill use as a spare). :thumbsup: So now I can pull apart spare t-case #2 and see what Ive got.

The plan is to pull out the drive train (minus motor, I dont have a hoist). And then get at the floor pans, and repaint the entire interior. Im still not anywhere near certain on paint. Part of me wants to keep the Golden Eagle stuff and do a nice spray job. I have no spray stuff or a good place to spray. The other part says screw it, rub it up against a tree and smile because I have less than $100 in paint. Either rattle can or roll on. I really dig the 2 tone Cherokees Ive seen.

So Ill try to keep this update as a help to get me motivated.

Thanks for looking.

Until next time, keep on :fsj:

[krek]

Subscribed! :thumbsup:

[bg2pres]

whatever you do, don't get rid of those seats! If you do, call me first. I am needed the buttons and good front seat frames...

I have a brown Golden Eagle and I have rebuilt it. Very important is to reset your front and rear diffs. This is what causes most of the "clunk" in your transfer case. I have rebuild from radiator to rear bumper. Finishing up body now.

I put the new 40 gallon tank underneath from aerotanks and it was a perfect fit and I can do long runs now.

The only thing I have to complete on the engine is the cruise control and I can't figure out what I am missing.

[bigun]

Well like brother krek Subscribed!

[Charlie_B]

Finally made some progress. I wound up using the case, diff and yokes from t-case #2 and the low range and input gear from #1. The needle bearing being trashed was likely related to the side gear in the diff being crooked nad wearing into the pin. So I bagged the complete diff, even though it was nicer looking.
http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1680.jpg

http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1681.jpg

I tore into the transmission this morning. With GSmikie right by my side! :thumbsup: Got it mostly cleaned up and had to order some new parts. The low roller clutch and the 2-3? accumilator piston. But they are on the way, along with a deep sump aluminum pan :cool: .

Got a question about something. When gsmike talks about steel seals being better than the teflon, is he talking about the 6 needed (2 for pump, or something like that)? I cant seem to find anything online for steel and my rebuild kit has neither.

http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1685.jpg

thanks for looking :drivin:

[Carleysjeep]

Dude you need some Evaporust!! Only joking , I just finished reading that thread. Seriously nice project, sounds like fun. Good luck. :)

[newtojeeps]

Are we having fun yet? Looks great so far. Keep up the good work:thumbsup:

[COLOFIREMAN]

Well good luck but your bench won't stay that nice for long. :rolleyes: ;)


:eek: Man thats alot of RTV on that TH400 pan!!!!:eek: :D

[Charlie_B]

Definitely having fun..or at least trying to. My wallet isnt though.

The bench has at least fulfilled its expectations to this point. It hasnt fallen over and has given me a place to put a vise. The plywood was originally intended to be temporary until I could find a suitable work bench counter top.

All that rtv And it had a cork gasket. Came off in one big peice. Ive never been inside an auto tranny before, but Im pretty surprised at how nice the inside of this one looked. $20 in unexpected broken parts aint too bad in my book.

Opportunities to work on it have been few and far between. but hopefully after this next week I can put more time into it and get it on the road soon.

bg2pres: send me a pic of what your stuff under the hood looks like. I stupidly pulled my functioning cuise control apart a couple years ago and still have some pics from back then.

[jaber]

Well like brother krek Subscribed!

X3 on the subscription, your doing a fine job and hope to do the same on a trans and t-case soon. I even have the vid from Mike and the Napa kits he suggests in the vid. I just dont have a shop big enough or the is clean enough to do it in yet. Dirt free is the word...

I have a brown Golden Eagle and I have rebuilt it. Very important is to reset your front and rear diffs. This is what causes most of the "clunk" in your transfer case. I have rebuild from radiator to rear bumper. Finishing up body now.

I put the new 40 gallon tank underneath from aerotanks and it was a perfect fit and I can do long runs now.

The only thing I have to complete on the engine is the cruise control and I can't figure out what I am missing.

Cant wait to see your pics also. Sounds like a nice ride.

[Carleysjeep]

send me a pic of what your stuff under the hood looks like. I stupidly pulled my functioning cuise control apart a couple years ago and still have some pics from back then.

I know that feeling! Yesterday I changed the a/c compressor on the waggy. I was putting it back together and couldn't get the alternator bracket to fit on for squat! There are 4 wagoneer in town including mine. My buddy has his torn apart with an engine swap under way. So I grab my digital camera, go knock on a door of this guy I don't know. I explain what I am doing and ask to take pictures of the brackets. So with pics in hand, head to the house and finish the install. Today I have cold a/c and life is good! :thumbsup:

[elij10travis]

hey i gopt some mint flares for the fender if u need any jsut give me a call u got a cell ill send the pictures to it if you want. im looking to buy som new fenders anyways. 207 3192214

[fulsizjeep]

http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1680.jpg

mighty fine! :thumbsup:

[Charlie_B]

never would have dug into my first QT without you Flint. Thanks. :thumbsup: This is my second, and I feel like I can do them in my sleep now. Although, this was the first time I tore open a diff and R&R'd the shifting mechanism. And Im glad I did with how bad the diff pin looked in case #1. But those cones and brakes sure were purdy.

Case #2 had the rubber seal around the whole thing (as seen in the pic). My last one didnt. What is your preference? With or without the rubber seal? BTW, my last one is leaking, but most likely due to excessive sealant. I really tried to be practical with the sealant this time.

thanks for looking
-Charlie

[fulsizjeep]

I prefer the case halves with the rubber seal and usually junk the one's we get with no rubber seal groove. With the rubber seal you can go real light on the sealant. Glad the site has been helpful! :cool:

[Charlie_B]

No new pics, but made a little more progress this past weekend. Im waiting on more parts for the tranny rebuild. So I started take care of "free" stuff I can do. She's in the garage now, so my motivation just grew. The tranny is almost ready to pull out, t-case is out. Pass door, pass fender, hood, and grille is off. Ive got to finish pulling the tranny, drop the gas tank, pull driver's fender and door, and finish taking apart the front clip. Then Im going to wire wheel the h&^* out of everything. And get it cleaned up for some POR action. I want to coat the inside of all panels, top/bottom of floor pans, and frame. I'll tackle the engine bay when the time comes. But with everything apart, Im starting to think I dont want to mount this nice tranny/t-case to this old and tired motor, so who knows what will happen.

Im hoping things will pick up speed with warm weather finally here. I just need to make a few purchases to keep things rolling.

[OBX-AUTOMOTIVE]

JUST GUESSING,FROM YOUR PIC, YOU COULD USE A REAR SECTION,AND YOU MAY NEED THE RIGHT AND LEFT REAR FLOOR CORNERS ALSO!

I'LL BRAKE A SECTION AND SEND IT WITH THE RIGHT FLOOR,YOU CAN ADD IT ON, IF YOU NEED TO,BUT YOU'LL HAVE TO WING IT AT THE TRANS HUMP.

:) :drivin:

[Charlie_B]

What section are you referring to sending? The rear? Or peice in between front and rear? Thanks alot!

The driver's side is fine. The first floor pan pic shows it. Unless Im not seeing something??? The portion under the seat belt is carpet. I still need to get that huge torx bit for the seat belts.

[OBX-AUTOMOTIVE]

What section are you referring to sending? The rear? Or peice in between front and rear? Thanks alot!

The driver's side is fine. The first floor pan pic shows it. Unless Im not seeing something??? The portion under the seat belt is carpet. I still need to get that huge torx bit for the seat belts. IT'S AN ADD ON TO THE REAR OF THE FRONT FLOOR PAN I'M SENDING,IF YOU NEED TO USE IT.

I'M SHIPPING YOUR FLOOR PARTS TODAY..

I WOULD STAY AND TALK,BUTS I GOTS TO GO!>>>>>> :thumbsup: :)

[OBX-AUTOMOTIVE]

IF I REMEMBER RIGHT :rolleyes: THIS IS A PIC OF BAYBILLYS CHEROKEE!

I ALSO SENT HIM A EXTRA SECTION, TO ADD TO THE SPACE,AT THE REAR PART OF THE FRONT FLOOR AND THE FRONT SECTION OF THE REAR FLOOR PAN.

AS YOU SEE HE ONLY CUT OUT HALF, OF THE CENTER OF THE FLOOR!:rolleyes: :D :thumbsup:

http://i3.photobucket.com/albums/y96/GEMOBX/MY%20FSJ%20TANGIBLE%20PRODUCTS/flpa.jpg

[Charlie_B]

Looks like a lot of fun...

It seems the Jeep curse is still alive and well. Just got the "how come my motor is making this clank clank clank noise?" phone call from the woman. I swear every single time I get into a position to at least see the light at the end of this tunnel, something comes up. sucks big time :(

[littlebuck23]

Way to jump in head first!! Looks like a great project.

I will definatly be watching this one.

[HeavyIron]

Looks like a lot of fun...

It seems the Jeep curse is still alive and well. Just got the "how come my motor is making this clank clank clank noise?" phone call from the woman. I swear every single time I get into a position to at least see the light at the end of this tunnel, something comes up. sucks big time :(

Sorry to hear about that Charlie_B :(

Nice work so far though :thumbsup:

[Charlie_B]

Im 90% sure her problem is a water pump. After getting it hot, it starts screeching from the front of the motor. Add that to the normal noisy 4.0 and it can sound nasty. Especially over the phone... About $50 and a few hours this weekend will fix it. Could be a WHOLE lot worse. I immediately thought it was lifter or valve related.

Pulled some more trim off the cherokee last night. Tonight I should be able to get pretty close to having her stripped down (except for the underside). Right now it is able to roll. Once I support the motor it wont. So Im waiting until I get the tranny built until I am 100% committed to having the truck in my tiny garage until she's done. Should have parts today or tomorrow to finish it up.

[Charlie_B]

A few pics to show some progress. I busted both pump bushings I had :o so finally got a new one and had it put in. Tomorrow I plan to finish up the trans. And Im hoping to get some POR on the truck. Ive got the weekend to myself (g/f at a wilderness first aid camp) so I should be able to stay motivated and concentrated.

Trans parts ready to go back together

http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1694.jpg


My tiny workspace/garage

http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1688.jpg


As clean as it will probably ever be

http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1695.jpg

Ive got to take a BUNCH of photos before the stickers come off. I read where someone said something about not ever seeing good shots of the GE hood
http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1686.jpg


My neighbors LOVE me :D

http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1691.jpg

http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1692.jpg

http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1689.jpg

http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1693.jpg


The badly rusted flare. Im getting a fiberglass replacement and a new lower quarter panel. This what a qaurter panel full of towels to supress the jack/lug wrench noise looks like.

http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1690.jpg

About 3 years ago in the springtime things started to warm up and I started noticing a foul smell. So I did some investigating thinking I had just left too much smelly/wet ski equipment back there. Popped open the access panel, saw a bunch of towels. So I started pulling them out wondering why there were towels stuffed in there. After about a minute or so of digging and pilling the towels in front of me, I noticed the pile was moving on it own. I dry-heaved for about 30 min. Finally got some gloves and a big trash bag and a water hose and flushed it. Im still wary of sticking my hand down in there. :o

Ive got the front floor pan and a peice for in between the front and rear and the rear and corner peice is on its way (thanks Gary :thumbsup: ) Once that shows up, Im going to tackle the undercariage and POR the top/bottom of the pans. Then I figure its going to take a lot of elbow grease for the rest of the body.

Open to any suggestions on the various tasks I have at hand.

Thanks for looking
-Charlie

[8Dayes]

Charlie,

awesome thread... thanks for all the pics as you progress. looking good.

quick question: what kind of grill/brush guard is that in your avatar? where did you get it? i likey... and am doing some research for one for my 87 GW.

peace.

[Charlie_B]

Its the stock pignose and I beleive the brush gaurd was a factory option. A while back I scrapped it like an idiot. There's so many things I just gave away or tossed that I wish I had now (a/c compressor, working cruise control, brush guard) :(

[Charlie_B]

Finished the trans up last night.

One last look inside

http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1723.jpg


Valve body mod to prevent unwanted up shift. Also plugged the hole.

http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1725.jpg


BOOYYAAHH! It looks so dirty now.

http://i641.photobucket.com/albums/uu139/sti__this/Cherokee/2009%20Build/DSCN1726.jpg


There was definitely a few things that I screwed up on and wont do again. And a doubt or 2 rests in my mind. I was following the dvd and forgot about the exra TCI parts in the kit. And I tried to install the pump spring after I had already installed it into the case. First I dropped one of the valves inside the case. After some lucky shaking of the heavy ** case and some probbing with my fingers, I got it out. Then when trying to put the snap ring in, it went into the case, and got lodged back by the center clutch pack. Pump came back off, ring was retreived, and much easier to install on the bench. Then I only saw 2 of the valve body gaskets, so I tossed them on. Well, there are 3 in the TCI kit (1 you choose between your year). I used the wrong combination and left out the 1 I was definitely supposed to use, regardless. And of course none of this realized until after I had the valve body, filter, pan (no gasket yet) on. And as I was putting the valve body on the first time, I misread the torque specs as ft/lbs, instead of in/lbs and slighty overtightened the valve body. I thought it didnt seem right, and went on very cautiously stepping the pressure up; then finally reread everything, and stopped. Needless to say, on the second go-around they went to spec. But that doesnt make me feel any better about it.

Well, Its all back together and it was definitely a learning experience. I hope it moves. :o

The sad part is, Im already thinking about the next one, possibly using a new tailshaft and t-case as an excuse. :D

I picked up some POR yesterday and am going to start cleaning up some of the rust and treating.

[Charlie_B]

Its been a while since the last update. Ive made some progress, but it doesnt seem like much. Right now Im fighting with limited working space and only being able to work on a few things at a time. Once I get the stuff put back on the truck, I think the process will start going much quicker. Im hoping to get the inside of the doors, tailgate, and fenders completed (minus final wetsanding and polishing) this weekend. Then Im going to start stripping the bottomside of the truck for POR. Next up will be replacing the pass. side floor pans, rear flare/quarter panel repair, then interior POR and paint.

This is the first time Ive attempted most of this. My only "body work" experience was with my g/f's xj last december replacing rocker panels and quarter panels. I dont expect it to be perfect. I just want it protected and solid. A 5' paint job will be awesome.

Ive decided to go ahead and replace all the weatherstripping. Some of it got torn up during removal. Most was junk.

Again, thanks for looking.
-CB

[aallison]

Dude, you got way more balls that I do to tear into a transfer case and an auto. To me those are magical devices that somehow work. Way cool thread.

[fulsizjeep]

I wish I could make that kind of body work progress on a couple around here. Keep it up! :thumbsup: Is that Petty Blue?

[Charlie_B]

Its Rusto Gloss Royal Blue ;)

[Desert Rat]

Awesome DIY project! I wish I had the space and time....I'm having enough troubles keeping everything in my fleet running and trail worthy...no way I could take on a resto project.

Looks like the truck sat for years with either bad weather seals, or the windows open....wierd that all the floor rust is on the passenger side.

[Charlie_B]

Im pretty sure its a bad windshield gasket and I can see a slightly rusted corner section of it. Its definitely had water sit in it, just not 100% sure where it came from.

The frame, floor pan minus pass. side, and most of the body is in good shape. Ive got the front fenders ready for bondo (thats PC-7 epoxy paste in the pic). And have a glass replacement (that needs some work) rear flare and a replacement quarter. And Ive got a whole set of pass. pans from Gary.

[YellowJeep]

Its Rusto Gloss Royal Blue ;)

Are you keeping the golden eagle decals and bird? My wife REALLY wants me to ditch mine when I paint the rig, but I keep telling her there is no way!

[Charlie_B]

Unfortunately not. They arent in terrible shape. But with the amount of body repair and repaint needed, I cant save them. And Im not spending the money on a decent paintjob or the stickers to just run it up against a tree. It wont be a hardcore wheeler, but I dont want to cringe everytime a branch runs down the side of it. So far I have about 60 in paint and supplies. And will need to spend about nother 50 or so to finish. Alot of my supplies, paint, and time have been used to learn from my mistakes.


I was REALLY close to buying a gallon and a half of olympic white car paint though. All I was after was a pint of hardener to mix in the rustoleum, and the guy almost had me talked into it.

[COLOFIREMAN]

Looking good, love the progress pictures.:thumbsup:

[Carleysjeep]

Man, buff that hood and keep the eagle!

[Charlie_B]

Man, buff that hood and keep the eagle!

I wish I could. But the whole truck needs paint in a serious way. And I cant imagine trying to retain the stickers during a paint job. Not to mention some minor rust is coming through the stickers on the side.

I got her in the air and pulled the tranny this morning. While turning the motor over by hand to get to the flexplate-tq convertor bolts, I slipped and put a nice hole in my BJs aluminum radiator. :banghead: Shouldve pulled it in the first place. If Im not breaking stuff, Im not working on it. For some reason, not wanting to remove the radiator was the only thing holding me back from taking the entire front clip off. Well, its out now. So the clip is coming off and at this point the only thing Im not planning to tackle is the firewall. Ive got a lead on a motor, but wont have the funds for a while. So it may have to wait until next year. At that point, Ill strip the firewall and rust proof it.

Im thinking of trying to remove the gas tank this afternoon. Everything except for the lines (brake, fuel, etc) will be removed from the bottom side of the truck. And Ill go ahead and start stripping it for POR and replacing the rotten floor pans.

[wickedwagon767]

After about a minute or so of digging and pilling the towels in front of me, I noticed the pile was moving on it own. I dry-heaved for about 30 min. Finally got some gloves and a big trash bag and a water hose and flushed it. Im still wary of sticking my hand down in there. :o



So you never did say what was down in there? :D

Nice,real-world build

subscribed:thumbsup:

[Charlie_B]

It was little slimy wiggly maggots! UUUGGGHHH :o

I got the rest of the front clip off yesterday. Now the only thing left to remove are the side windows, front window, dash, gas tank, and brake/gas lines.

I hooked my car battery up to it to see if my fuel level guessing gauge would tell me how much gas is in the tank. But it didnt move. Im pretty sure we didnt run it out of gas. But I cant hear it sloshing when shaking the truck around. So Im gonna cautiously try to drain it and see what happens.

The list keeps on growing. And the budget keeps on going over. Im already thinking of how its going to be with snow tires on my car after its been lowered. And not looking forward to it. But Id really rather just do this thing right the first time and not mess with it anymore.

[bg2pres]

How is it coming?