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  #1  
Old 07-22-2008, 08:54 PM
cu4whln's Avatar
cu4whln cu4whln is offline
350 Buick
 
Join Date: May 16, 2008
Location: Canton, Mi USA !
Posts: 1,047
Chero: SO it begins . . .

EDIT : 35 + pages now
"Heavy build" begins on page 13
"Finished" pics start on page 28
New : Magazine cover shot: page 40

Hi Everyone !

I have been "lurking" here for awhile.. reading up on all the great info you guys have written up.Amazing what you can learn by reading - But why ??

After many years of lusting after an SJ . . I finally got one! I have built up a few Jeeps, but this is my first "Full Size". My last build was my beloved CJ about 9 years ago. It's still going strong.

79 Chief arrived yesterday.... I drove it around the block one time.. and started to take it apart. First project is to pull the carpet.. and do some floorpan work. So, out come the seats, sill covers, console, etc.

Yep, there is water under there ! Big surprise, huh ?? So rip out the pass compartment jute and throw away the carpet. Scrub the floor rust with a wire brush... wow.. talk about powered metal ! And in some areas it's like liquid metal.. metal mud. Get it pretty cleaned up, and vacuum the floor.

Now I can start to watch for water leak paths, and get a driver floorpan.

Next: Remove all the door trim panels, rear trim, clean it up... make sure all the drains are clear... and pull the rear cargo area carpet(s).The floor in the back is perfect....just the front floors needs attention.

I have printed all the leak articles / postings... going to follow your leads on fixing the leaks.

So - Hello - and goodbye for now. I will post my slow progress [ job thingy interferes with my hobby ]



Oh, it must be mine now.. cut my hand on the floorpan. [ read my sig ]
__________________
It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness"
1985 CJ : Renegade -locked and loaded
2001 XJ : Driver 1998 XJ 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief


"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280

Last edited by cu4whln : 03-01-2010 at 08:50 PM.
  #2  
Old 07-22-2008, 10:17 PM
Ugly Truck Nut Ugly Truck Nut is offline
Gear Head
 
Join Date: Sep 19, 2007
Location: El Paso, Texas
Posts: 667
Welcome aboard, and may I be the first to say:

.
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George

'74 Cherokee, 401
'76 J-20, 401
M725, future project
  #3  
Old 07-23-2008, 04:10 AM
woodironman's Avatar
woodironman woodironman is offline
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Join Date: Jun 29, 2006
Location: seeleys bay ontario canada
Posts: 173
i added two drains in the corner by the kick panels drivers side and passenger side, water use to lay there before. also got rid of the carpet that seems to be the reason the floors rot. mark
  #4  
Old 07-23-2008, 07:29 AM
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chrisnsarah chrisnsarah is offline
FSJ Maniac
 
Join Date: Sep 24, 2000
Location: Nampa, ID
Posts: 3,282
Attack those fresh air vents first for the water leaks. The air vent door housing is not watertight. I improved mine by running gutter sealant along the seams, putting a dab on top of the pivot, and building a small "dam" on the underside of the factory drain. I then reinstalled them using butyl tape that you can get at an RV store. No more leaks. Clean all the leaves out while they are out too. Also check the radio antenna grommet and the body plugs above the vents. My Cherokee also had a rusted body seam way up on the firewall. I did my best to seal it with gutter sealant and so far, so good.
__________________
'64 J200 thriftside
'67 J2000 townside custom cab
'68 Jeepster Commando
'69 Super Wagoneer
'75 J10
'79 Cherokee S WT
'75 Cherokee
'61 Aristocrat Lil Loafer
  #5  
Old 07-23-2008, 08:11 PM
cu4whln's Avatar
cu4whln cu4whln is offline
350 Buick
 
Join Date: May 16, 2008
Location: Canton, Mi USA !
Posts: 1,047
Quote:
Originally Posted by Ugly Truck Nut
Welcome aboard, and may I be the first to say:

.

Yea , yea... I'm busted !

I will get a few pics of the project as I go along.

I promise.. really !

Thanks for the tips guys !
__________________
It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness"
1985 CJ : Renegade -locked and loaded
2001 XJ : Driver 1998 XJ 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief


"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280
  #6  
Old 07-23-2008, 08:33 PM
AlsChopShop's Avatar
AlsChopShop AlsChopShop is offline
 
Join Date: Sep 20, 2005
Location: Portland, Orygun!
Posts: 5,428
welcome to the madness!

i like your sig, seems i can't get even the smallest project done on any rig until i'm bleeding.

Al
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79 Cherokee Chief "Kronk" - TBI350/SM465/NP205
99 Dodge 2500 4x4 - Cummins 24v
07 Mazdaspeed3 GT - Big turbo, 340whp
  #7  
Old 07-23-2008, 09:07 PM
jeepdad56's Avatar
jeepdad56 jeepdad56 is offline
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Join Date: Aug 19, 2007
Location: Bayville NJ
Posts: 210
........or burned your hands..... good luck with the project
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1977 J10 "OBNOXIOUS"
360 Edelbrock 650 ,Intake and Valve Covers,Hedman Headers,Mallory Ignition,Flexalite Fans,Detroit Tru Trac Locker, Warn Hubs,Dana 44s, T18,Dana 20 Twin Stick,35 TSL SSRs on 15x8 RockCrawlers, 12,000 MileMarker Winch,Custom front Bumper and rear Hitch,Linexed Bed,Tailgate and Rockers.....Thanks to Headhoncho 4 pic
  #8  
Old 07-24-2008, 05:12 AM
ob1jeeper
 
Posts: n/a
Lookin' forward to watching this come together...

PS: Pics please...
  #9  
Old 07-25-2008, 08:07 PM
cu4whln's Avatar
cu4whln cu4whln is offline
350 Buick
 
Join Date: May 16, 2008
Location: Canton, Mi USA !
Posts: 1,047
OK - no pictures .. yet. The camera battery was dead....

Made some progress - got all the interior out.. headliner too!. What a dusty mess. I vacuumed it out. I am thinking I will wash out the interior tomorrow with soap and water.

Basically, I am getting prepared for a full body inspection - looking for problem areas that need work before the serious paint work begins. Oh, did I mention a paint job is in the near future??

So - where can I get a good replacement headliner ? Can I make a replacement out of some other material ? I plan to do some interior work as well. I am looking to make it nice, not perfectly original.

Same questions for the rear panels - mine are a little water damaged...This is a 2 door btw.

Is the rubber for the windshield and side glass still available? I see most of the weatherstripping is available.. thats cool !

OK - tomorrow pictures.... must order floorpans soon.
__________________
It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness"
1985 CJ : Renegade -locked and loaded
2001 XJ : Driver 1998 XJ 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief


"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280
  #10  
Old 07-25-2008, 08:35 PM
threepiece threepiece is offline
350 Buick
 
Join Date: Sep 17, 2005
Location: Farmington Hills Mi.
Posts: 1,195
Hello neighbor, I'm happy to see a real FSJ enthusiast in this neck of the woods. I would like to offer myself as a resource for you. I have been playing with these things for nearly thirty years. I visit Canton often (perhaps you have seen a bright blue Wagoneer around) and will be there this weekend. Feel free to let me know if you would like me to stop by. I'm starting my fourth buildup myself.
Dan
  #11  
Old 07-25-2008, 09:33 PM
cu4whln's Avatar
cu4whln cu4whln is offline
350 Buick
 
Join Date: May 16, 2008
Location: Canton, Mi USA !
Posts: 1,047
Hi Dan -

Absoulutely ! I am in need of advice and opinions. I know so much about "other" Jeeps.. but hardly anything on the FSJ.

How are your leak tracing skills ??

I live at Ford and Beck... send me your phone number.. would love to have someone knowledgeble look it over
__________________
It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness"
1985 CJ : Renegade -locked and loaded
2001 XJ : Driver 1998 XJ 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief


"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280

Last edited by cu4whln : 07-26-2008 at 08:59 PM.
  #12  
Old 07-26-2008, 08:17 PM
cu4whln's Avatar
cu4whln cu4whln is offline
350 Buick
 
Join Date: May 16, 2008
Location: Canton, Mi USA !
Posts: 1,047
testing file size...
and notice, I cut myself - again !

All the interior stuff is out and stacked in the cargo area.

1979 Cherokee Chief - coming apart



__________________
It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness"
1985 CJ : Renegade -locked and loaded
2001 XJ : Driver 1998 XJ 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief


"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280

Last edited by cu4whln : 05-05-2009 at 08:14 PM.
  #13  
Old 07-26-2008, 08:32 PM
cu4whln's Avatar
cu4whln cu4whln is offline
350 Buick
 
Join Date: May 16, 2008
Location: Canton, Mi USA !
Posts: 1,047


Looks like the welder is coming out.... definately need a driver side patch.. and might just do the passenger too.. it's kinda getting thin.

Rear areas have some surface rust... some grinding and prep - good to go.
__________________
It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness"
1985 CJ : Renegade -locked and loaded
2001 XJ : Driver 1998 XJ 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief


"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280

Last edited by cu4whln : 10-28-2008 at 09:33 PM.
  #14  
Old 07-26-2008, 08:36 PM
cu4whln's Avatar
cu4whln cu4whln is offline
350 Buick
 
Join Date: May 16, 2008
Location: Canton, Mi USA !
Posts: 1,047


Chero got it's first bath - on the inside !

Yep - took the hose and cleaned off 30 years of dirt.. I did this to basically do a very complete sheet metal inspection. As I plan to remove the body - I want to know what to expect.

I could not believe how much dirt/sand was trapped in the flares and rear quarters..... that is a formula for rust ! Luckily, there seems to be none. A fair amount of crap in the bottom of the doors too.

So far - no big surprised - I knew about the driver floor before purchasing. The pass floor ? Well, not really !

Overall - thats it for rust repair. Some body work too . .

Funny, I ran the hose into the cowl.. and guess what ? ! Water ran into the inside of the vehicle ! Who would have thought !!
__________________
It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness"
1985 CJ : Renegade -locked and loaded
2001 XJ : Driver 1998 XJ 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief


"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280

Last edited by cu4whln : 01-25-2009 at 09:27 AM.
  #15  
Old 07-27-2008, 03:16 PM
ob1jeeper
 
Posts: n/a
Lookin' good... From the pics, I don't see much of an issue with the pass floor, but then again, even the pics of hte driver floor didn't show extent of rust...

Keep up the momentum buddy...
  #16  
Old 07-27-2008, 08:07 PM
threepiece threepiece is offline
350 Buick
 
Join Date: Sep 17, 2005
Location: Farmington Hills Mi.
Posts: 1,195
Do your Jeep (and yourself) a favor. Lift the rear and remove both wheels. There is a hole about one inch in diameter on the wheel housing (outer I believe) directly behind the rocker panel, it should have a plastic plug. Remove the plug and use a small flashlight to look for contamination all the way down to the front end of the rocker. Two of my Jeeps (Arkansas and Arizona) had enough dirt to fill a two gallon bucket each!!! I spent over an hour on each rocker using a custom scraping tool made from 3/16" steel rod about 6 feet long, with a piece of sheet metal shaped to fit the bottom of the cavity tack welded to one end. I also used a plastic tube about four feet long attached to a compressed air blow gun. I finally used water to flush out any remaining debris and made sure all the drains were totally clear.
Dan
  #17  
Old 07-27-2008, 09:30 PM
cu4whln's Avatar
cu4whln cu4whln is offline
350 Buick
 
Join Date: May 16, 2008
Location: Canton, Mi USA !
Posts: 1,047
Dan -

Good advice ! So.. when you come over and lend me that cleaning tool ??

. . . and of course show me how to use it??
__________________
It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness"
1985 CJ : Renegade -locked and loaded
2001 XJ : Driver 1998 XJ 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief


"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280
  #18  
Old 07-27-2008, 10:06 PM
royaustin2000 royaustin2000 is offline
Member
 
Join Date: Feb 09, 2008
Location: Bend Oregon
Posts: 68
It does my heart good to see someone doing what I had hoped my son and I would. Keep the pictures coming. Thanks
  #19  
Old 08-03-2008, 07:50 PM
cu4whln's Avatar
cu4whln cu4whln is offline
350 Buick
 
Join Date: May 16, 2008
Location: Canton, Mi USA !
Posts: 1,047
Progress report..

Have pulled the heater and blower motor.. all the various stuff on the fender wells. Basically everything I can, but keep it running to get it up on the trailer in a couple of weeks.

Have pulled all the interior, starting to work on the dash stuff. So, I have a 82 FSM.. it's not super clear on the IP removal? Do ya really have to take out the windshield to get the crash pad out??? What? Can I drop the metal portion of the IP after the colum drop and get it off?

Don't want to pull the glass til it's in the shop inside. Not that a little more water inside is going to hurt it ! LOL. I am marking all the hardware and storing it inside the Jeep. I am using plastic tubs to hold the interior stuff, underhood stuff, IP stuff. At least it will all be grouped somewhat together when I put it all back together. It is coming all aprt for paint.

Oh, the body is coming off for frame cleanup/refresh and an engine update. Some type of fuel injection engine- no more carb heat issues! Any body want a decent 360 / 400/ Q-Trac [with part time kit] 92 K miles

The body is solid - but needs the front floorpans. Geez- I can see why these things leak- all kinds of sloppy plastic fasteners just poke through the firewall with no real sealing ability. And then there's the body calk.

Or the lack of body calk. What are you guys using to reseal the cowl and various seams? Some PO literally used a can opener to make a hole in the pass cowl to run an antenna wire?? Yea, it just pours water onto the floor. Yikes !

Have pulled the cowl.. wiper set up next.....

Having fun - and no blood for 2 days !



__________________
It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness"
1985 CJ : Renegade -locked and loaded
2001 XJ : Driver 1998 XJ 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief


"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280

Last edited by cu4whln : 05-05-2009 at 08:16 PM.
  #20  
Old 08-04-2008, 09:58 AM
ob1jeeper
 
Posts: n/a
Quote:
Originally Posted by cu4whln
Progress report..
Have pulled all the interior, starting to work on the dash stuff. So, I have a 82 FSM.. it's not super clear on the IP removal? Do ya really have to take out the windshield to get the crash pad out??? What? Can I drop the metal portion of the IP after the colum drop and get it off?

Don't want to pull the glass til it's in the shop inside. Not that a little more water inside is going to hurt it ! LOL. I am marking all the hardware and storing it inside the Jeep. I am using plastic tubs to hold the interior stuff, underhood stuff, IP stuff. At least it will all be grouped somewhat together when I put it all back together. It is coming all aprt for paint.
Having fun - and no blood for 2 days !
Sorry to be the one to confirm what the Serv Man stated... But this old gal does NOT have a "roll-out" IP like today's vehicles do... ...

Back when this vehicle was designed, and being built, the IP sub-structure was a weldment collection of several stamped parts, welded into the body structure, then painted, overlayed with the wiring harnesses, guage packs, glove boxes, then finally the "dash pad" before the w/shield was installed, with the glass seal covering the lower front edge of the dash pad...

Sorta sucks given what's available in today's assembly methods, but that's how it's put together...

HTH...
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