frame up cj5 --> cj6 Conversion Build - Pirate4x4.Com : 4x4 and Off-Road Forum
 
Pirate4x4.Com : 4x4 and Off-Road Forum  

Go Back   Pirate4x4.Com : 4x4 and Off-Road Forum > Brand Specific Tech > Jeep - Hardcore Tech
Notices

Reply
 
Share LinkBack Thread Tools Display Modes
Old 03-22-2017, 03:54 PM   #1 (permalink)
Wheeler
 
Join Date: Mar 2017
Member # 743857
Posts: 259
frame up cj5 --> cj6 Conversion Build

I was going to wait until the project was further along before starting a build thread but then I realized that I might be missing out on some valuable advice from people along the way.

Concept- Let me start by saying this is not designed nor will it be used as a rock crawler. The idea behind this is to have a jeep to be used as a recreational / camping / expedition type vehicle that I can drive comfortable on the road at highway speeds, is plenty capable offroad, reliable, and can fit multiple people / dogs and or camping gear. That being said, this is a ground up full custom build.

In order to achieve these things (which are all counterintuitive to a cj5 haha), the only logical answer was to cut it in half and stretch it. So, I will be turning this cj5 into a cj6. To complement the 20 in. increase in wheel base, I will be upgrading to Dana 44’s from the scout II which will offer about a 7 or 8 in. increase in track width. The increase in length and width as well as keeping it as low as possible (SUA) while running 35’s should help with stability on (and off) road, while the increase in length allows me to carry more gear and people.


The project vehicle is a 73 cj5.

Body/frame-
Custom built frame extended to match CJ6 specs
Body cut and extended 20 inches (CJ6 length)
Narrow the wheel wells to increase width of the bed and allow for wider rear seat.
Tube front and rear fenders (no comp cut)
Full roll cage with 4 seats

Drivetrain-
AMC 304
T-18
Dana 20
Dana 44 front and rear from Scout II (I am well aware of the castor issue, I will be cutting and turning the C’s to correct castor as needed)
4.10 gear ratio (mainly because one of the axles already has 4.10)
Probably a locker of some kind in the rear.

Suspension/steering-
35x12.5 tires
Outboard YJ OME leaf springs SUA
Sway bars (if needed)
Saginaw power steering
Power brakes disk front / drum rear

Almost every piece of this build will be made by me. Everything from the frame, to the bumpers to the dash, roll cage ect. (I did cheat a buy leaf spring hangers from rough stuff) It just seemed that the effort to make them myself was not worth the 35 bucks a pair that they sell them for. And I can’t promise that I won’t cheat and buy some premade tabs and little crap like that. I could make them myself, but again, it’s not worth my time for the amount it costs to buy them.


Here is a little teaser pic to hold your interest until i can find time to start uploading pictures. Hopefully tonight.
Attached Images
 

Last edited by jri93; 04-01-2017 at 10:29 PM.
jri93 is offline   Reply With Quote Quick reply to this message
Old 03-22-2017, 06:14 PM   #2 (permalink)
Registered User
 
Join Date: May 2005
Member # 47783
Location: DC
Posts: 517
Cool build. Might have some answers to your concerns in the Willys section..
__________________
2a in the works.

Last edited by *xj-man*; 03-22-2017 at 06:15 PM.
*xj-man* is offline   Reply With Quote Quick reply to this message
Sponsored Links
Old 03-22-2017, 07:45 PM   #3 (permalink)
Registered User
 
Join Date: Dec 2011
Member # 205697
Posts: 31
move the tank up.

Raise it up, box it in in the rear tub. You will not loose that much room and you can put the axle where ever you want.

That is my plan for my CJ7 to LJ stretch.
spookylynx is offline   Reply With Quote Quick reply to this message
 
Old 03-22-2017, 08:50 PM   #4 (permalink)
Wheeler
 
Join Date: Mar 2017
Member # 743857
Posts: 259
Thats a thought. I will have to see when i mock up the suspension how much room there is and how much i would need to move it up.
jri93 is offline   Reply With Quote Quick reply to this message
Old 03-22-2017, 09:04 PM   #5 (permalink)
Wheeler
 
Join Date: Mar 2017
Member # 743857
Posts: 259
Getting it home and torn down.

Kind of funny to think that the whole portion in the last pic is basically being thrown away. All i am really using from this thing is the body, motor, tranny and transfer case.
Attached Images
   

Last edited by jri93; 03-22-2017 at 11:02 PM.
jri93 is offline   Reply With Quote Quick reply to this message
Old 03-22-2017, 09:20 PM   #6 (permalink)
Wheeler
 
Join Date: Mar 2017
Member # 743857
Posts: 259
There was (still is) a lot of body work, filling in holes people have drilled all over the place over the years, repairing rusted areas ect. I won't bore everyone with a million pictures. But here is an idea of the amount of bondo i am dealing with.. Almost the entire passenger side of the car has about a 1/4 in. thick layer.

Also, i don't know what these cut outs above the rear wheels are for, but i filled them in so that i can run tube fenders.
Attached Images
  

Last edited by jri93; 03-22-2017 at 11:30 PM.
jri93 is offline   Reply With Quote Quick reply to this message
Old 03-22-2017, 09:33 PM   #7 (permalink)
Wheeler
 
Join Date: Mar 2017
Member # 743857
Posts: 259
Bodywork gets boring so i took some time to pull the engine apart. The bottom end looks to be in great condition. Cylinders look good. So I decided just to give it a good paint job and not pull it apart any further. A couple of the valves look sunk in so i will probably take the heads in to get worked on.
Attached Images
  

Last edited by jri93; 03-22-2017 at 10:57 PM.
jri93 is offline   Reply With Quote Quick reply to this message
Old 03-22-2017, 09:34 PM   #8 (permalink)
Wheeler
 
Join Date: Mar 2017
Member # 743857
Posts: 259
It was fun messing with the engine a little but back to the real work.. The body was in worse shape than i had realized when i purchased it. Not only was there a crap ton of bondo, but there had been some seriously shoty repairs made to the underside. I did my best to clean up and cut out rust and old weld, then i reinforced all the body mount locations and added some additional supports under the floorboards.
Attached Images
  

Last edited by jri93; 03-22-2017 at 11:08 PM.
jri93 is offline   Reply With Quote Quick reply to this message
Old 03-22-2017, 11:13 PM   #9 (permalink)
Wheeler
 
Join Date: Mar 2017
Member # 743857
Posts: 259
I did not start out the build with the intent of building a new frame. However after getting the body off of the old frame and finding it to be bent to crap and cracked with multiple bad weld jobs i decided building one from scratch would be less work than trying to fix the original and much better.

Thanks to some other threads on this site, i was able to find some specs for building it. Pretty easy. I have not fully welded anything yet until i am sure it is all good to go.
Attached Images
  
jri93 is offline   Reply With Quote Quick reply to this message
Old 03-22-2017, 11:15 PM   #10 (permalink)
Wheeler
 
Join Date: Mar 2017
Member # 743857
Posts: 259
This is my new toy. Can't wait to use it.
Attached Images
 
jri93 is offline   Reply With Quote Quick reply to this message
Old 03-22-2017, 11:19 PM   #11 (permalink)
Wheeler
 
Join Date: Mar 2017
Member # 743857
Posts: 259
Picked these up from a guy locally. Scout II Dana 44's. supposedly one of them has 4.10 in it already but that has yet to be confirmed. I think this will be a nice increase in width without being as extreme as a full width axle. I know i will have to cut and rotate the C's to correct castor.... No biggie.
Attached Images
 
jri93 is offline   Reply With Quote Quick reply to this message
Old 03-22-2017, 11:33 PM   #12 (permalink)
Wheeler
 
Join Date: Mar 2017
Member # 743857
Posts: 259
I finally made the leap of faith and cut the body in half. Started getting it set on the frame for mock up.
Attached Images
  
jri93 is offline   Reply With Quote Quick reply to this message
Old 03-22-2017, 11:39 PM   #13 (permalink)
Wheeler
 
Join Date: Mar 2017
Member # 743857
Posts: 259
Some goodies..... spring hangers, body mounts, and plates for finishing up the frame all ready to go.

I also quickly realized i a was going to need a sheet metal brake, so i built a cheap one with some scrap angle iron. It works good enough.
Attached Images
  

Last edited by jri93; 03-22-2017 at 11:40 PM.
jri93 is offline   Reply With Quote Quick reply to this message
Old 03-22-2017, 11:43 PM   #14 (permalink)
Wheeler
 
Join Date: Mar 2017
Member # 743857
Posts: 259
Started filling in the body.
Attached Images
  
jri93 is offline   Reply With Quote Quick reply to this message
Old 03-22-2017, 11:49 PM   #15 (permalink)
Wheeler
 
Join Date: Mar 2017
Member # 743857
Posts: 259
I had bent some little pieces while patching body parts but the transmission tunnel was the first real test for the sheet metal brake. 23 in. long 16 gauge sheet metal.
Attached Images
  
jri93 is offline   Reply With Quote Quick reply to this message
Old 03-22-2017, 11:58 PM   #16 (permalink)
Wheeler
 
Join Date: Mar 2017
Member # 743857
Posts: 259
So anyways this is where it sits as of now. Next thing will be to finish filling in the sides of the body and then get the leaf springs mocked up. I will continue to post updates as progress is made.
jri93 is offline   Reply With Quote Quick reply to this message
Old 03-24-2017, 07:12 AM   #17 (permalink)
Registered User
 
Join Date: Mar 2016
Member # 657282
Posts: 20
Awesome project and nice job on the body strech so far
Tjohnson619 is offline   Reply With Quote Quick reply to this message
Old 03-24-2017, 10:33 AM   #18 (permalink)
Wheeler
 
Join Date: Mar 2017
Member # 743857
Posts: 259
thanks! Also I want to add that this is my first Jeep build so any advice is appreciated. I did a good amount of research prior to starting but i'm still learning.
jri93 is offline   Reply With Quote Quick reply to this message
Old 03-25-2017, 09:07 PM   #19 (permalink)
Wheeler
 
Join Date: Mar 2017
Member # 743857
Posts: 259
I was able to get the sides buttoned up today, not finished obviously, just tacked in. Funny how they shipped the leaf springs, just loose like this, not even in a box haha.
Attached Images
   
jri93 is offline   Reply With Quote Quick reply to this message
Old 03-25-2017, 10:52 PM   #20 (permalink)
Granite Guru
 
rochead's Avatar
 
Join Date: Aug 2012
Member # 225516
Location: Manteca,Ca
Posts: 810
rochead is offline   Reply With Quote Quick reply to this message
Old 03-27-2017, 05:13 PM   #21 (permalink)
Wheeler
 
Join Date: Mar 2017
Member # 743857
Posts: 259
A couple more tacks and ground down.

I decided after looking at the tub more closely that I can cut into it fairly easily in order to make clearance for the tires in the front of the wheel well, this way I don't need to mess with moving the gas tank.
Attached Images
  
jri93 is offline   Reply With Quote Quick reply to this message
Old 03-27-2017, 05:28 PM   #22 (permalink)
Registered User
 
Join Date: Mar 2017
Member # 743665
Posts: 75
Very nice. I have been looking at a lot of build threads lately as I am getting ready to start my own Land Rover project. May not be the same but alot of ideas on some of the custom stuff I will be needing to do. Looking forward to seeing how your project goes.
dsfloyd is offline   Reply With Quote Quick reply to this message
Old 03-28-2017, 08:48 PM   #23 (permalink)
Wheeler
 
Join Date: Mar 2017
Member # 743857
Posts: 259
Here is a direct comparison of the front axles from the scout D44 and the stock D30 from the cj5 incase anyone is interested.
Attached Images
  

Last edited by jri93; 03-28-2017 at 08:49 PM.
jri93 is offline   Reply With Quote Quick reply to this message
Old 03-29-2017, 06:53 PM   #24 (permalink)
Registered User
 
Join Date: Mar 2017
Member # 743665
Posts: 75
Definitely will add some beef and not too much width. Will look good.
dsfloyd is offline   Reply With Quote Quick reply to this message
Old 03-31-2017, 11:39 AM   #25 (permalink)
Snooty Poser
 
BeatCJ's Avatar
 
Join Date: Nov 2006
Member # 83100
Location: SW Washington State, NO NOT DC!
Posts: 1,130
Crap. I have a blasted tub that needs a little rust repair, a new step brace and two new wheelhouses. I really should do this. Crap.

Yours looks great, damn you!
__________________
When holding a cat by the tail, you will learn things that cannot be discovered any other way

Quote:
Originally Posted by PONY_DRIVER
The older I get the more I realize mayhem is for young people who don't have to get up and go to work in the morning.
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
BeatCJ is offline   Reply With Quote Quick reply to this message
Reply

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Pirate4x4.Com : 4x4 and Off-Road Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.

** A VERIFICATION EMAIL IS SENT TO THIS ADDRESS TO COMPLETE REGISTRATION!! **

Email Address:
Insurance
Please select your insurance company (Optional)

Log-in


Thread Tools
Display Modes

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On



All times are GMT -7. The time now is 06:24 AM.


Powered by vBulletin® Version 3.8.8 Beta 4
Copyright ©2000 - 2019, Jelsoft Enterprises Ltd.
Search Engine Optimization by vBSEO 3.6.0 ©2011, Crawlability, Inc.
User Alert System provided by Advanced User Tagging (Pro) - vBulletin Mods & Addons Copyright © 2019 DragonByte Technologies Ltd.
vBulletin Security provided by vBSecurity v2.2.2 (Pro) - vBulletin Mods & Addons Copyright © 2019 DragonByte Technologies Ltd.