Northern Virginia Jeepers Association

Open Discussion (Club Members and Non-Members) => Rigs => Topic started by: Jeepsnbuses on March 06, 2018, 07:41:35 AM



Title: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 06, 2018, 07:41:35 AM
Been swamped for the past week or so trying to pull this together, but as of yesterday I have a TJ.  For free!

Alright, not entirely free, but in exchange for some goods and services my good friend gave me an old 2002 TJ he had sitting around.  Stating the obvious, it was a little worse for wear.

(https://i.imgur.com/9mU1Nzs.jpg?1)

A friend of his wrecked it years ago and for whatever reason didn't bring it to the insurance company for repairs.  Sat on it for a year, then gave it to my friend because he owed him money.  Title history would note me as the second owner.  Sat at my friend's place for years, was occasionally driven around the property, then was eventually parked and left in the woods.  Such a shame.  On Sunday I was able to fire it up and actually drove it out of the woods, then power washed it.  

(https://i.imgur.com/ROlp7lv.jpg?1)

(https://i.imgur.com/N0GBSkC.jpg?1)

(https://i.imgur.com/0mSVuj3.jpg?1)

(https://i.imgur.com/mfbETFP.jpg?1)

(https://i.imgur.com/OLkgafG.jpg?1)

So what does it need?  A lot, but nothing that is unfixable.  

- Body work: both front fenders, a new hood, and somewhere down the line a replacement driver's rocker panel. I tentatively plan to cover up the rust that has started and hopefully it passes inspection. The door locks and closes fine, so I should be good?  Damage pics are below. Would be curious to get opinions of others on these...
- Needs a new soft top and windows. New top frame will come along as well.
- Needs a windshield.
- Needs tires and some new matching wheels.
- Needs new front turn signals.
- Needs the front bumper straightened or replaced.
- The front axle was beaten up pretty bad in the accident. The DS control arm mount snapped off altogether, and the PS control arm mount is about halfway attached.  So a replacement 3.07 D30 is in order.
- Needs a general interior cleaning, of course. Lots of leaves and sticks inside.
- Needs some HVAC controls.
- Needs a new ignition lock cylinder/tumbler.  The key was stuck in there and would start the Jeep, but when I eventually wrestled it out I think something else jammed up inside. Now it won't start. New tumbler it is...I've heard you can re-key them to use your old key?
- The clutch safety switch was toast. I've done the old plug-a-10a-fuse-into-fuse-port-#20 to start it, but would like to fix this correctly eventually.
- The shifter boot is a little loose and needs to be reattached. I think I need a shift bezel.
- General fluids across the board, spark plugs, tune up.

(https://i.imgur.com/5ciFrGY.jpg?1)

(https://i.imgur.com/qQuo9pz.jpg?2)

Note DS control arm below...

(https://i.imgur.com/NXADhSx.jpg?1)

The good. There is some good here. Like I said I drove it out of the woods, drove it around to where I washed it.  It has working heat and has factory A/C, though it was tough to test while it was 45 degrees outside.  The 4.0 is in great shape and felt OK despite running on gas that is no joke 6+ years old. Since it's been sitting around for so long, the frame is awesome. Very awesome.  Plans are to POR15 or undercoat it one way or another, especially if it's just going to be sitting around for a while.  I'm going to Line-X or bed rug the interior as well, once it's all cleaned out and the seats are removed. The carpet has been gone for years and the floor pan rust is super minor.  The mileage is also low.

(https://i.imgur.com/BUZ3nYk.jpg?1)

(https://i.imgur.com/Aa61Nlt.jpg?1)

(https://i.imgur.com/WquXBVp.jpg?1)

Yesterday I picked up a used 3.07 Dana 30, and a used hood. A lot of the research I did on axles told me to "just regear since 3.07 sucks," "junk the Dana 35 while you're under there," etc. I'd really like to just focus on getting this thing roadworthy again, then worry about doing anything to it.  It would be damn cool to have a 72,000 mile, all stock TJ to cruise around in.  Besides, there is way too much work to be done here before I should think about any sort of modification.  Excited to see where this goes!


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: highlandercj-7 on March 06, 2018, 07:54:03 AM
Congrats, that is awesome! Good bones to work with 72K and a solid frame, the other stuff is easy. A good low mile drive line, perfect frame and those hard doors it can easily fetch $4K parted out. That's a huge win!



Title: Re: The Silver Bullet - resurrection of a TJ
Post by: ogre45 on March 06, 2018, 08:06:33 AM
Nice find!


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 06, 2018, 08:34:03 AM
Thanks. The more I look over it and clean it up, I'm finding tiny little things that will be a bear. Looks like a lot of of the bolts in the front axle may need to be cut out due to rust...the front end won't be easy. For whatever reason it seems like the brunt of all rust on the entire vehicle is concentrated in the front axle.  I was able to remove all the control arms from the donor axle without issue though, so I've got that going for me, which is nice.

Busted 30 to be removed:

(https://i.imgur.com/HdhSmAU.jpg?1)


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: highlandercj-7 on March 06, 2018, 08:51:14 AM
The good news is there are tons of TJs with busted frames to score cleaner running gear. I found a good deal not long ago on a Rear TJ 44 and 30 with 373s. I believe $700


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: sirjames186 on March 06, 2018, 08:58:04 AM
Well shoot, I'll have a front D30 geared to 3.73 available cheap in week.  Also have a stock TJ steering setup (drag link and tire rod) for free if you need that.  I was just hanging onto it for a trail spare, needs to boots, but otherwise it works.

It's pretty easy to find bolts for all these things too, so I wouldn't hesitate to just cut the old ones out.  I wouldn't worry about replacing the rocker panel either.  Pull the dents out the best you can, covert the rust with something so it doesn't eat everything, and then cover them with rock sliders.  Way easier than welding in new stuff.  Also, I wouldn't just cover the rust for inspection.  Hit it with a rust converter, Rustoleum makes some in a spray can and it'll save you a ton of work down the road.  I say all this as someone who did that a year ago, and I'm paying for it now.  My passenger rocker panel and a spot on my rear corner are totally rusted out.  It's going to be a pain to get fresh metal in there before I can cover it.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: overhead on March 06, 2018, 09:28:45 AM
hit up scotts jeep yard on facebook, if you don't find it PM me and I'll add you. Scott is here on the board and constantly sells and parts out old jeeps. good guy to do business with.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 06, 2018, 09:47:51 AM
Well shoot, I'll have a front D30 geared to 3.73 available cheap in week.  Also have a stock TJ steering setup (drag link and tire rod) for free if you need that.  I was just hanging onto it for a trail spare, needs to boots, but otherwise it works.

It's pretty easy to find bolts for all these things too, so I wouldn't hesitate to just cut the old ones out.  I wouldn't worry about replacing the rocker panel either.  Pull the dents out the best you can, covert the rust with something so it doesn't eat everything, and then cover them with rock sliders.  Way easier than welding in new stuff.  Also, I wouldn't just cover the rust for inspection.  Hit it with a rust converter, Rustoleum makes some in a spray can and it'll save you a ton of work down the road.  I say all this as someone who did that a year ago, and I'm paying for it now.  My passenger rocker panel and a spot on my rear corner are totally rusted out.  It's going to be a pain to get fresh metal in there before I can cover it.

Thanks, I'll note those suggestions. Like I said I've already got the replacement 3.07 geared D30 and it's pretty rust free. I'd of course prefer to move to 3.73 but for the time being I'm just focused on getting it roadworthy again with the 3.07s.  I probably would've done some more cutting this past weekend but the area in MD where I was at is still out of power, believe it or not. No power tools!

And that's good to hear about the rocker.  My initial impression was that it should be able to pass inspection in its current condition so that's reassuring. 


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 06, 2018, 09:50:09 AM
hit up scotts jeep yard on facebook, if you don't find it PM me and I'll add you. Scott is here on the board and constantly sells and parts out old jeeps. good guy to do business with.

I don't have Facebook! But I'll keep an eye out for him.  I met a real nice guy named Dan in PA this weekend where I bought the D30 and hood, he was also cool.  He's the one on Craigslist with these ads:

https://philadelphia.craigslist.org/pts/d/2000-jeep-wrangler-sahara/6497333734.html

Real good dude and has a total of four TJs right now. Gobs of parts all stored inside and seemed to be very knowledgeable about all things TJ.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: highlandercj-7 on March 06, 2018, 12:46:49 PM
Just a FYI, my Daughters 99 TJ 4.0L Auto (no OD) with 307's and 31's is doing good for that gear. It's also pulling 18-19 MPG It has no problem turning 90 MPH.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 06, 2018, 02:01:51 PM
Just a FYI, my Daughters 99 TJ 4.0L Auto (no OD) with 307's and 31's is doing good for that gear. It's also pulling 18-19 MPG It has no problem turning 90 MPH.

That's nice to know. I'll almost definitely stick with 30"-ish tires for the time being unless a smoking deal comes along for 31s. For something that will primarily see daily duty up and down Reston Parkway I don't have much need for more just yet.  That's some great highway mileage!


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: highlandercj-7 on March 06, 2018, 02:36:36 PM
5 Ravines with 31" BFG's

https://washingtondc.craigslist.org/nva/wto/d/5-bf-goodrich-tires-and-rims/6515096619.html


Four 30x9.50 BFGs on Crawlers.

https://washingtondc.craigslist.org/nva/wto/d/5-tires-and-rims-bf-goodrich/6508977284.html


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 06, 2018, 04:06:59 PM
5 Ravines with 31" BFG's

https://washingtondc.craigslist.org/nva/wto/d/5-bf-goodrich-tires-and-rims/6515096619.html


Four 30x9.50 BFGs on Crawlers.

https://washingtondc.craigslist.org/nva/wto/d/5-tires-and-rims-bf-goodrich/6508977284.html


Thanks. I've been on and off Craigslist constantly since starting this project and say both of these.  I'm holding back for now just because I've already sank some $$ into the TJ this past weekend.  I do like those Ravines in Herndon though......


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 06, 2018, 04:15:56 PM
5 Ravines with 31" BFG's

https://washingtondc.craigslist.org/nva/wto/d/5-bf-goodrich-tires-and-rims/6515096619.html


Four 30x9.50 BFGs on Crawlers.

https://washingtondc.craigslist.org/nva/wto/d/5-tires-and-rims-bf-goodrich/6508977284.html


Thanks. I've been on and off Craigslist constantly since starting this project and say both of these.  I'm holding back for now just because I've already sank some $$ into the TJ this past weekend.  I do like those Ravines in Herndon though......

Darn it couldn't resist.  Sent him an offer, we'll see.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Gr8Dain on March 06, 2018, 06:01:16 PM
Wow. You really could not resist could you. There is not much time between your posts


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: TrailBird on March 06, 2018, 07:24:42 PM
Congrats!  :tu


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 06, 2018, 08:14:35 PM
Wow. You really could not resist could you. There is not much time between your posts

Youíre correct. I havenít heard back from him so it may have been for nothing. May be for the best; the Jeep is far from roadworthy so the tires would just sit for a good month anyways.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: highlandercj-7 on March 06, 2018, 09:43:56 PM
I always liked the Ravines and knew these were close to you 😎


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 07, 2018, 07:35:20 AM
I always liked yhe ravines and knew thise were vlose to you 😎

Yeah I'm a sucker for those as well.  I haven't heard anything back...haha, maybe I offended them? Oh well.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: highlandercj-7 on March 07, 2018, 10:24:54 AM
Damn my FFS typing on the little phone buttons...  :eek


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 19, 2018, 09:58:26 AM
Had hardly any time this weekend to get things done but really wanted to get the TJ off jack stands and get the top on it...especially with the winter weather coming tomorrow and Wednesday.  Wheels and tires look great and the top is nice and snug.  Also gave the outgoing Dana 30 a second coating of PB blaster.  With the good matching wheels and tires on, you can really see the severity of the axle damage.  It's pretty darn good and bent.  Good news is that it does look like I'll actually be able to salvage the existing control arms.

Starting to look like a Jeep again!

(https://i.imgur.com/ZoH7J54.jpg?1)

(https://i.imgur.com/FfkeSnr.jpg?1)


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: sirjames186 on March 19, 2018, 10:01:06 AM
Do you have a new front axle already?  I just swapped mine out and would sell it cheap.  3.73 gears and comes with an aftermaket diff cover.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 19, 2018, 10:05:07 AM
Do you have a new front axle already?  I just swapped mine out and would sell it cheap.  3.73 gears and comes with an aftermaket diff cover.

Yeah, a new matching front was one of the first things I snapped up.  I considered/wrestled with moving to 3.73 but decided to stick with the OEM 3.07 for now.  I'm dying to get this back on the road and just start driving it, and as soon as I add a task like moving to 3.73 I'm only delaying the process.  I'm sure I will eventually be moving to something like a 33"/4.56 combination but for now I have plenty of other repairs to take care of.

But thanks!


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: sirjames186 on March 19, 2018, 10:19:29 AM
Do you have a new front axle already?  I just swapped mine out and would sell it cheap.  3.73 gears and comes with an aftermaket diff cover.

Yeah, a new matching front was one of the first things I snapped up.  I considered/wrestled with moving to 3.73 but decided to stick with the OEM 3.07 for now.  I'm dying to get this back on the road and just start driving it, and as soon as I add a task like moving to 3.73 I'm only delaying the process.  I'm sure I will eventually be moving to something like a 33"/4.56 combination but for now I have plenty of other repairs to take care of.

But thanks!

Good deal!


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: overhead on March 19, 2018, 10:24:02 AM
rockauto has stock control arms for like $20 with bushings, don't reuse the fronts, it's easier to just swap them


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 19, 2018, 02:19:04 PM
rockauto has stock control arms for like $20 with bushings, don't reuse the fronts, it's easier to just swap them

Easier as in one less thing to come back to and replace later on?


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: overhead on March 19, 2018, 02:22:59 PM
rockauto has stock control arms for like $20 with bushings, don't reuse the fronts, it's easier to just swap them

Easier as in one less thing to come back to and replace later on?

yes. You're looking at stuff that's at least 12 years old now, potentially seized bushings that's been hit hard enough to twist an axle but it's just opened c channel. save yourself the headach and replace them. and the track bar. You'll chase issues with it down the way especially with the stock ones being so cheap. you're talking $60, $100 shipped including the track bar.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 19, 2018, 02:24:53 PM
rockauto has stock control arms for like $20 with bushings, don't reuse the fronts, it's easier to just swap them

Easier as in one less thing to come back to and replace later on?

yes. You're looking at stuff that's at least 12 years old now, potentially seized bushings that's been hit hard enough to twist an axle but it's just opened c channel. save yourself the headach and replace them. and the track bar. You'll chase issues with it down the way especially with the stock ones being so cheap. you're talking $60, $100 shipped including the track bar.

 :cheers


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: sirjames186 on March 19, 2018, 02:36:42 PM
rockauto has stock control arms for like $20 with bushings, don't reuse the fronts, it's easier to just swap them

Easier as in one less thing to come back to and replace later on?

yes. You're looking at stuff that's at least 12 years old now, potentially seized bushings that's been hit hard enough to twist an axle but it's just opened c channel. save yourself the headach and replace them. and the track bar. You'll chase issues with it down the way especially with the stock ones being so cheap. you're talking $60, $100 shipped including the track bar.

 :cheers

Yeah as someone who just replaced their control arms, don't even bother fixing them up.  The rubber will be beyond shot, and the bolts will be rusted in. Find some fresh 14mm grade 8 (I know 10.9 for metric technically) bolts and just cut the old ones out.  I ordered a fresh set from fastenal for like $30 and got them zinc coated so they don't rust as bad.  It might even be easier to drill them out a couple thousandths to 9/16ths and use standard bolts from Home Depot, as the 14mm ones were a pain in the butt to find and I had to pay extra for a special order.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: packinnova on March 19, 2018, 04:41:56 PM
THIS THREAD IS AWESOME!  Man I wish I had garage space and more time for another jeep project.  I have 2 on my hands now(one's my DD) plus finally got around to doing the house reno...so...time is well..something I don't have very often right now.  I am lovin this thread though.  Good solid frame, running engine and tranny with only 72k on it.  Hot damn that's a good find.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 19, 2018, 06:52:10 PM
rockauto has stock control arms for like $20 with bushings, don't reuse the fronts, it's easier to just swap them

Easier as in one less thing to come back to and replace later on?

yes. You're looking at stuff that's at least 12 years old now, potentially seized bushings that's been hit hard enough to twist an axle but it's just opened c channel. save yourself the headach and replace them. and the track bar. You'll chase issues with it down the way especially with the stock ones being so cheap. you're talking $60, $100 shipped including the track bar.

 :cheers

Yeah as someone who just replaced their control arms, don't even bother fixing them up.  The rubber will be beyond shot, and the bolts will be rusted in. Find some fresh 14mm grade 8 (I know 10.9 for metric technically) bolts and just cut the old ones out.  I ordered a fresh set from fastenal for like $30 and got them zinc coated so they don't rust as bad.  It might even be easier to drill them out a couple thousandths to 9/16ths and use standard bolts from Home Depot, as the 14mm ones were a pain in the butt to find and I had to pay extra for a special order.

Ahh nice, I was literally thinking of Googling the Fastenal part number earlier today.  You don't still have that, do you? Or is it identical to XJs?  I'm actually going to re-use my adjustable uppers that I had recently purchased for the XJ.

THIS THREAD IS AWESOME!  Man I wish I had garage space and more time for another jeep project.  I have 2 on my hands now(one's my DD) plus finally got around to doing the house reno...so...time is well..something I don't have very often right now.  I am lovin this thread though.  Good solid frame, running engine and tranny with only 72k on it.  Hot damn that's a good find.

And thanks for this, I'm pumped for it too. Like I said I'm just dying to drive the damn thing. Whenever I start it I can tell it just wants to go.


Title: Re: Re: The Silver Bullet - resurrection of a TJ
Post by: sirjames186 on March 19, 2018, 07:12:58 PM
rockauto has stock control arms for like $20 with bushings, don't reuse the fronts, it's easier to just swap them

Easier as in one less thing to come back to and replace later on?

yes. You're looking at stuff that's at least 12 years old now, potentially seized bushings that's been hit hard enough to twist an axle but it's just opened c channel. save yourself the headach and replace them. and the track bar. You'll chase issues with it down the way especially with the stock ones being so cheap. you're talking $60, $100 shipped including the track bar.

 :cheers

Yeah as someone who just replaced their control arms, don't even bother fixing them up.  The rubber will be beyond shot, and the bolts will be rusted in. Find some fresh 14mm grade 8 (I know 10.9 for metric technically) bolts and just cut the old ones out.  I ordered a fresh set from fastenal for like $30 and got them zinc coated so they don't rust as bad.  It might even be easier to drill them out a couple thousandths to 9/16ths and use standard bolts from Home Depot, as the 14mm ones were a pain in the butt to find and I had to pay extra for a special order.

Ahh nice, I was literally thinking of Googling the Fastenal part number earlier today.  You don't still have that, do you? Or is it identical to XJs?  I'm actually going to re-use my adjustable uppers that I had recently purchased for the XJ.

THIS THREAD IS AWESOME!  Man I wish I had garage space and more time for another jeep project.  I have 2 on my hands now(one's my DD) plus finally got around to doing the house reno...so...time is well..something I don't have very often right now.  I am lovin this thread though.  Good solid frame, running engine and tranny with only 72k on it.  Hot damn that's a good find.

And thanks for this, I'm pumped for it too. Like I said I'm just dying to drive the damn thing. Whenever I start it I can tell it just wants to go.

Lucky for you I'm a closet horder lol

(https://uploads.tapatalk-cdn.com/20180320/4453fc3b8b141288b6f9f3bfdfe6741f.jpg)

Save the nuts and washers that come off it though, you'll need those. I reused mine.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: sirjames186 on March 19, 2018, 07:15:27 PM
Also those are just for the lowers, the uppers are a different size.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 19, 2018, 07:26:02 PM
Also those are just for the lowers, the uppers are a different size.

Niceeeeee. Thatís a start. Thanks man


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: zuke on March 20, 2018, 01:55:34 PM
As great as Fastenal is when you need something local and fast, I never ORDER anything from them.... McMaster Carr will get it to you quicker at a much lower price...

Lower Control Arm Bolts and nuts;

https://www.mcmaster.com/#95327a745/=1c1zfd3

https://www.mcmaster.com/#92497a550/=1c1zo55

Upper Control Arm Bolts and nuts;

https://www.mcmaster.com/#95327a643/=1c1zhn8

https://www.mcmaster.com/#92497a450/=1c1znlg

You end up with a lot of extra nuts & bolts this way though, be sure to check package size before ordering multiples!


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RattleTrap55 on March 20, 2018, 03:18:40 PM
Another great source is Bolt Depot - just as fast as McMaster-Carr with even better prices. Bolt Depot's selection is not as complete as McMaster so I use both sources.

https://www.boltdepot.com/Default.aspx


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: zuke on March 20, 2018, 04:15:58 PM
Another great source is Bolt Depot - just as fast as McMaster-Carr with even better prices. Bolt Depot's selection is not as complete as McMaster so I use both sources.

https://www.boltdepot.com/Default.aspx

Nice! I'll be adding this one to my arsenal...


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 21, 2018, 06:15:30 AM
As great as Fastenal is when you need something local and fast, I never ORDER anything from them.... McMaster Carr will get it to you quicker at a much lower price...

Lower Control Arm Bolts and nuts;

https://www.mcmaster.com/#95327a745/=1c1zfd3

https://www.mcmaster.com/#92497a550/=1c1zo55

Upper Control Arm Bolts and nuts;

https://www.mcmaster.com/#95327a643/=1c1zhn8

https://www.mcmaster.com/#92497a450/=1c1znlg

You end up with a lot of extra nuts & bolts this way though, be sure to check package size before ordering multiples!

Yeah no kidding, I have plenty. Have used McMaster several times but never heard of Bolt Depot. Always good to have a backup.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 29, 2018, 08:01:10 AM
Have my hardware, have two new LCAs, and have a replacement ignition lock cylinder that I should be able to re-key for my current key. 

Also have two brand new adjustable front uppers that will go on as well. This should be a good weekend, hopefully I can get this axle swapped without too much heartache. I haven't had any spare time to dive into the project recently, but that's given me plenty of time to soak most of the problem areas in PB. Should come apart OK (**crosses fingers**). If not, out comes the sawzall and cutting wheel.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: sirjames186 on March 29, 2018, 02:18:52 PM
I soaked mine for a week and they still needed some heat to come off. Just FYI.

The lowers were the worst, which I suppose is nice since they are easier to get to. Uppers popped loose with an impact.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 29, 2018, 07:59:45 PM
I soaked mine for a week and they still needed some heat to come off. Just FYI.

The lowers were the worst, which I suppose is nice since they are easier to get to. Uppers popped loose with an impact.

Weíll see how i do. Iím hoping my couple weeks of spraying, the fact that the Jeepís been sitting a while and not been on the road, will all be factors that help me out. Since Iím replacing the lowers altogether I should only have to cut them loose at the body. They look 100% better at those mounts, but who knows. Iíve been fooled before.

Went to start working on it this afternoon. First step was to replace the broken ignition lock cylinder. Tragically, someone had thrown away the one key I had for the Jeep. I havenít figured out who did it, but it was definitely not my fiancť...

Replaced lock cylinder, ignition key is different from the door lock key. Iíll deal with replacing those later. Ignition is all set, Jeep runs on a key again!

All tucked in for the night, ready for the new front end. Bring out the breaker bars!

(https://imgur.com/f2f7kwI.jpg)


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: highlandercj-7 on March 30, 2018, 07:38:20 AM
Take the vin to the dealer and they can cut you the original key. They have a code for the key, with the vin they can look it up and reproduce it.



Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on March 30, 2018, 07:57:58 AM
Or you could drop your original switch off to a local locksmith and they can match it to the tumblers and give you a few keys.  This would probably be cheaper if it is drop-off as opposed to coming to you.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 30, 2018, 08:39:12 AM
And then just re-key my ignition lock cylinder? I do still have all of the pins to re-configure it...may not be a bad idea.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: MZXJ on March 30, 2018, 08:54:04 AM
drop me a pm with the last 8 of your vin. and I will pm you a key code..


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on March 30, 2018, 08:58:47 AM
What I'm saying is to have a key cut to fit the original switch.  This way I would think all of your locks would match.

My BIL is a locksmith.  He rekeyed my ignition to match my tailgate lock (easy to remove) because the PO put a new ignition switch in and didn't bother to rekey it.  I am assuming you still have the original ignition switch and it works fine.  He informed me that as shops go, this would be the least cost if the lock was just dropped off and picked up later.  It actually only took him about 10 minutes to do.

I am also assuming you do not have the key with a chip in it (gray key) because you said it started.  I don't remember what year they implemented the chip key.  Mine is a '98 without it.  You should be able to see the symbol in the gauges when you first turn the key.  If you don't see it, I believe you don't have it.  If it does have a chip this task can get very expensive and the dealer may be the best option.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on March 30, 2018, 09:02:01 AM
drop me a pm with the last 8 of your vin. and I will pm you a key code..

There's a helpful hand!  The LS could also tell you the key code after they figure it out.  I wrote mine backwards somewhere on the Jeep so I could get one made easily in an emergency if I ever lost my keys to include my spare while out of town.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 30, 2018, 09:04:52 AM
What I'm saying is to have a key cut to fit the original switch.  This way I would think all of your locks would match.

My BIL is a locksmith.  He rekeyed my ignition to match my tailgate lock (easy to remove) because the PO put a new ignition switch in and didn't bother to rekey it.  I am assuming you still have the original ignition switch and it works fine.  He informed me that as shops go, this would be the least cost if the lock was just dropped off and picked up later.  It actually only took him about 10 minutes to do.

I am also assuming you do not have the key with a chip in it (gray key) because you said it started.  I don't remember what year they implemented the chip key.  Mine is a '98 without it.  You should be able to see the symbol in the gauges when you first turn the key.  If you don't see it, I believe you don't have it.  If it does have a chip this task can get very expensive and the dealer may be the best option.

Nah, this is a 2002, no chip. But, the original cylinder was broken internally anyways so I did need to replace it.  The universal ignition lock cylinders you can buy at NAPA come with new pins that you can drop in. Pull the old pins out, drop the new ones in in the same order, input and turn your original key, and BAM the new cylinder is "re-keyed." I didn't bother doing this yesterday because the original key had been tossed so I had nothing to key it with, but I suppose I could do it still by just removing the newly keyed pins and inputting the new spares that came with the kit.  I'll get around to it, it would be nice to not have to replace the door lock cylinders.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on March 30, 2018, 09:22:52 AM
I didn't know they did switches like that nowadays.  That sounds pretty cool!  I haven't had to do one in many years.  The old way was just to get a cylinder and use it or have it rekeyed.  Perhaps by getting the code from MZXJ and then getting a key cut, you could put them in the right order yourself sitting at the dining room table at your leisure and may be the best way.  The numbers represent the height if I remember correctly.  You may actually have:

ignition key
2 doors
tailgate
glove box
console
airbag switch

All need the key if you intend to use the lock (or at least open it if it ever happens to get locked somehow).


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: unleashd on March 30, 2018, 09:46:56 AM
I might be looking to rekey mine as well. Just noticed this morning that I can easily pull my key out of the ignition even when the engine is running :)


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Gr8Dain on March 30, 2018, 10:24:55 AM
I might be looking to rekey mine as well. Just noticed this morning that I can easily pull my key out of the ignition even when the engine is running :)

That is a ďfeatureĒ in my scrambler. Allows me to pull the keys out and unlock or lock my center console without cutting the Jeep off. Or unlock the trailer box in the bed. Or let the kid open the front door to get something he forgot and come back. Etc.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 30, 2018, 10:31:09 AM
I didn't know they did switches like that nowadays.  That sounds pretty cool!  I haven't had to do one in many years.  The old way was just to get a cylinder and use it or have it rekeyed.  Perhaps by getting the code from MZXJ and then getting a key cut, you could put them in the right order yourself sitting at the dining room table at your leisure and may be the best way.  The numbers represent the height if I remember correctly.  You may actually have:

ignition key
2 doors
tailgate
glove box
console
airbag switch

All need the key if you intend to use the lock (or at least open it if it ever happens to get locked somehow).

Yeah that's all very true.  Hadn't even thought to consider those other locks. I guess that will be the next step! Luckily it is truly a piece of cake to remove and re-key that ignition cylinder. Better yet the plastic shroud on the underside of my steering column was broken to begin with so it's already been removed and is out of the way.

My steering column also has a little black finger switch right behind the ignition that I have to press in to turn and release the key.  Had no idea that feature was a thing on vehicles this new.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on March 30, 2018, 07:45:07 PM
Axle's out. Everything went...as expected?  Is this how people with JKs and newer Jeeps feel all the time?  Maybe I'm jaded because I went from a CJ to an old XJ and am just used to rust. Either way, this was a piece of cake.

(https://i.imgur.com/1Was4tC.jpg?2)

All nuts and bolts out. Even salvaged the control arm and track bar flag nuts, and the four shock nuts/bolts. I have new bolts but I'll be reusing some of these after cleaning them.

(https://i.imgur.com/g1RCtkW.jpg?1)

(https://i.imgur.com/Pp2SFn3.jpg?1)

Rust got to typical surface areas like the rotors and calipers, but otherwise this whole thing is just as rust-free as it looked when I picked it up.  My friend commented this is a great example of how road wear and tear compares to stagnant rust and sitting. 

(https://i.imgur.com/v1WpbCf.jpg?1)

Even the track bar bushing was perfect. Still solid, no cracking. Will be reusing this as well.

(https://i.imgur.com/nn5MIvF.jpg?1)

(https://i.imgur.com/ghSGVLV.jpg?1)

Where the control arm mount sheared right off in the accident. Nice and violent. 

(https://i.imgur.com/jziI7k8.jpg?1)

Old left, new-to-me right.

Picking up new shocks, rotors and pads, and sway bar links tomorrow.  Then we should be ready to go back in...good progress. No bruised knuckles and no cutting required!

(https://i.imgur.com/HXtVN4E.jpg?1)


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 01, 2018, 08:39:07 AM
Had to jump on a work call last night for 3 hours and shot most of my garage time, but I was able to finagle the new axle mostly into place. Uppers and lowers are in, shocks and springs are in, and driveshaft is connected but straps not fully tightened down. After some Easter church with the family this morning the plan is to finish up steering and redo the brakes, then put the Jeep back on the ground and torque everything.

Also going to wire wheel and anti-seize these hubs. They feel OK but are pretty surface-rusty.

(https://imgur.com/eSYBO48.jpg)

(https://imgur.com/bx4859W.jpg)

For whatever reason I hadnít noticed this bent LCA bracket on the PS frame. It rubs a bit on the tie rod so sometime soon Iíll need to disconnect this end of the LCA, torch the bracket, and knock it back into place. Not sure when this happened due to the accident happening on the other side of the Jeep. DS LCA bracket looks factory fresh.

(https://imgur.com/4dWUl1T.jpg)

(https://imgur.com/lkvfhYF.jpg)


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: overhead on April 01, 2018, 09:07:52 AM
Don't heat and knock it. Just grab a large adjustable and slowly close the jaws on it. Then use that to make it straight.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 01, 2018, 09:14:27 AM
Don't heat and knock it. Just grab a large adjustable and slowly close the jaws on it. Then use that to make it straight.

Think thatís enough? Iíll give it a go.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepride on April 01, 2018, 09:23:41 AM
Don't heat and knock it. Just grab a large adjustable and slowly close the jaws on it. Then use that to make it straight.

Think thatís enough? Iíll give it a go.

Agree, I have used a 2ft adjustable wrench and straighten a couple of my LCA brackets after smashing them on rocks.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 02, 2018, 07:46:33 AM
Got the replacement axle in yesterday and buttoned most everything back up. Starting to look like a Jeep again.  New front brakes, new shocks, new uppers and lowers, new steering components.  The calipers were dirty and rusty but seemed to be working fine. No rips in the piston boots and pistons worked smoothly. Didn't have time to bleed the brakes but it is needed. Might as well replace all the brake fluid while I'm doing that. 

Unsurprisingly, the threads in the yoke of the replacement D30 were pretty crusty and full of debris. There was no way I was going to be able to thread the new strap bolts in without breaking at least one, so I left the front shaft disconnected for now. I'll come back with a tap and die set this week and re-tap the threads and should be good to go. Also going to replace the U-joints in the front driveshaft.

(https://i.imgur.com/qIDRFiE.jpg?1)

(https://i.imgur.com/Mm9yeiA.jpg?1)

(https://i.imgur.com/j2e6DMq.jpg?1)

(https://i.imgur.com/QlcjV5K.jpg?1)

Obviously the body work will be the next big step, but I could actually drive it around like this without much of an issue. Everything feels tight and normal apart from the disconnected front shaft.  I'm looking around for some cheap-ish sandblasting shops in the area to have the hood and fenders done this week.  Sandblasting three loose body pieces should be relatively inexpensive...right?

Probably my biggest annoyance right now is this. In the accident the DS swap bar link snapped off altogether and left this little nub seized in the sway bar. It's going to be a bear to remove.  Plan to keep PB blasting it throughout the week but all my usual tricks were unsuccessful. I'm either going to have to heat the sway bar to try and remove it, or I'll have to cut and drill it out. 

(https://i.imgur.com/hrVzyup.jpg?1)


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: overhead on April 02, 2018, 08:17:02 AM
for the fender and hood and grill. Don't forget to look for just new fenders and what not, It can be a lot cheaper by a substantial amount to just get take offs from someone like scott (crazyskier92?)

as for the nub, get it nice and red hot, place a 2x4 or something to brace the bar against then hit it with a hammer or an air hammer (if you don't have one, I HIGHLY recommend them) the key though is to brace it, because it's a sway bar... It's basically a spring coil it's absorbing all of the energy you're putting into getting it out. I fought mine for 2 weeks before someone told me that. Had it out in two hits.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 02, 2018, 08:20:04 AM
for the fender and hood and grill. Don't forget to look for just new fenders and what not, It can be a lot cheaper by a substantial amount to just get take offs from someone like scott (crazyskier92?)

as for the nub, get it nice and red hot, place a 2x4 or something to brace the bar against then hit it with a hammer or an air hammer (if you don't have one, I HIGHLY recommend them) the key though is to brace it, because it's a sway bar... It's basically a spring coil it's absorbing all of the energy you're putting into getting it out. I fought mine for 2 weeks before someone told me that. Had it out in two hits.

Picked up some nice used fenders from my man Damien in Fburg. All good in that department :tu

I'll give the heat a shot. I wasn't sure if that would negatively affect the integrity of the bar or not, but I guess it should be fine.  No air hammer where the Jeep is but plenty of BFHs.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Davetopay on April 02, 2018, 10:11:54 AM
If it was a wheeling project, I'd just pull the fenders out enough to clear tires and roll around looking like a terrifying ball of tin foil. :lol


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: overhead on April 02, 2018, 10:26:50 AM
for the fender and hood and grill. Don't forget to look for just new fenders and what not, It can be a lot cheaper by a substantial amount to just get take offs from someone like scott (crazyskier92?)

as for the nub, get it nice and red hot, place a 2x4 or something to brace the bar against then hit it with a hammer or an air hammer (if you don't have one, I HIGHLY recommend them) the key though is to brace it, because it's a sway bar... It's basically a spring coil it's absorbing all of the energy you're putting into getting it out. I fought mine for 2 weeks before someone told me that. Had it out in two hits.

Picked up some nice used fenders from my man Damien in Fburg. All good in that department :tu

I'll give the heat a shot. I wasn't sure if that would negatively affect the integrity of the bar or not, but I guess it should be fine.  No air hammer where the Jeep is but plenty of BFHs.

https://www.amazon.com/Ingersoll-Rand-Air-Hammer-114GQC/dp/B000VZAENC/ref=sr_1_3?ie=UTF8&qid=1522682752&sr=8-3&keywords=ir+air+hammer

Seriously, If you have air. It changes your life. My buddy spent 2 hours trying to get a TRE off, broke two pullers and more. I hit it with the gun and it popped straight off. He walked out and left the project for the day after that.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 02, 2018, 11:37:08 AM
for the fender and hood and grill. Don't forget to look for just new fenders and what not, It can be a lot cheaper by a substantial amount to just get take offs from someone like scott (crazyskier92?)

as for the nub, get it nice and red hot, place a 2x4 or something to brace the bar against then hit it with a hammer or an air hammer (if you don't have one, I HIGHLY recommend them) the key though is to brace it, because it's a sway bar... It's basically a spring coil it's absorbing all of the energy you're putting into getting it out. I fought mine for 2 weeks before someone told me that. Had it out in two hits.

Picked up some nice used fenders from my man Damien in Fburg. All good in that department :tu

I'll give the heat a shot. I wasn't sure if that would negatively affect the integrity of the bar or not, but I guess it should be fine.  No air hammer where the Jeep is but plenty of BFHs.

https://www.amazon.com/Ingersoll-Rand-Air-Hammer-114GQC/dp/B000VZAENC/ref=sr_1_3?ie=UTF8&qid=1522682752&sr=8-3&keywords=ir+air+hammer

Seriously, If you have air. It changes your life. My buddy spent 2 hours trying to get a TRE off, broke two pullers and more. I hit it with the gun and it popped straight off. He walked out and left the project for the day after that.

I have access to air, just not where I'm currently working on it.  If I had air at this garage I'd have taken care of this days ago!


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: tomjones20194 on April 02, 2018, 04:32:58 PM
Don't heat and knock it. Just grab a large adjustable and slowly close the jaws on it. Then use that to make it straight.

Think thatís enough? Iíll give it a go.

Agree, I have used a 2ft adjustable wrench and straighten a couple of my LCA brackets after smashing them on rocks.

I use this method too for bent CA brackets. Rocks suck sometimes....


Sent from my iPhone using Tapatalk


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 03, 2018, 07:10:00 AM
Since picking up the hood and two front fenders from Damien I've been doing some research on sanding and paint prep.  From what it sounds like, I am looking at $500+ to blast these three pieces on the outer sides.  Decided to try a DIY solution first since the investment would be low.  Pieces to blast are as follows:

(https://i.imgur.com/oNBZ3z4.jpg?1)

And the outer sides of the two front fenders:

(https://i.imgur.com/3TtSWbB.jpg?1)

Since none of the three pieces have any serious pitting it looks like I should be fine with using glass bead or aluminum oxide media in the 70-80 grit range.  I'm probably going to buy two 50 lbs bags of media because I won't have too effective of a way of recovering it.  I'll have a large tarp to collect some, but I don't have a way of building a blasting cabinet that I foresee as being worth my while.  Also going with the el cheapo Harbor Freight portable blast kit.  Link is here: https://www.harborfreight.com/portable-abrasive-blaster-kit-37025.html . This should be a one-and-done kind of job where I won't have to use any of this junk again. 

I can grab a respirator, shield, and media from HF.  I already have a few spare air dryers that I can drop inline which should help improve my results.  The compressor I'm using is definitely large enough.

Anyone have any experience blasting body parts like these?  Apart from a couple very minor trouble spots that I've found on the inner sides, I will only be blasting the outer sides of these.  Thoughts?  Is this a terrible idea?  Not looking for showroom quality here.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on April 03, 2018, 07:24:29 AM
Why are you making so much work?  This isn't a show Jeep is it?  If that is factory paint, just sand it smooth where any rust or scratches are, prime (with primer-surfacer type), then paint.  You may need to prime and sand a few spots a couple times until the contour is right by building up the primer.

Do make sure to give it a good scuff sanding especially in any grooves so the paint sticks well.  I think I would start with a good detergent wash then drying (especially under the hood).

Are the fenders showing the classic rust-through spot already?  If so, I think they can be purchased new for about $85 each online if you shop around - I need to get some too.  If they are rusting, don't even spend time on prepping them.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 03, 2018, 08:55:50 AM
Why are you making so much work?  This isn't a show Jeep is it?  If that is factory paint, just sand it smooth where any rust or scratches are, prime (with primer-surfacer type), then paint.  You may need to prime and sand a few spots a couple times until the contour is right by building up the primer.

Do make sure to give it a good scuff sanding especially in any grooves so the paint sticks well.  I think I would start with a good detergent wash then drying (especially under the hood).

Are the fenders showing the classic rust-through spot already?  If so, I think they can be purchased new for about $85 each online if you shop around - I need to get some too.  If they are rusting, don't even spend time on prepping them.

You think so?  I was worried about hitting the nooks and crannies sufficiently on the fenders.  I have a palm sander with plenty of various sandpaper grits but didn't think I could do a good enough job with it.  There is one spot on a fender where it is trying to rust through but is far from getting to that point.  I'd really like to salvage these and think I can do so--hence why I bought them as opposed to new replacements in the first place.  To give you an idea of what I have...

- Mentioned electric palm sander
- Grits varying from 80 up to 280-320 range
- Plenty of loose sheet wet sanding paper
- Some loose 3M scuffing pieces

Maybe I'm just not devoting enough time to sanding.  I'll give them all some more time today and see how things look afterwards...perhaps I just need more patience.  Good point about hitting it with multiple layers of primer and sanding in between.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on April 03, 2018, 01:01:02 PM
If it was mine - and advice is free

First inspect those fenders to see if it is the spot where the bracket underneath is contacting them.  If it is, it will be trouble later (or pretty soon).  My driver side is looking pretty rough from the salt of this past winter (which is still on the roads here in NoVa).  I will be looking for one myself.  I would give them a good degreaser wash down at this point before starting to sand them.  Of course don't ding them up more while washing them.

I would use a wire brush by hand to break loose any flaking paint at any bends, seams, or creases.  Any flaking stuff MUST come off.  I've used an Exacto before to just kind of pick it loose.  These usually result from impacts after the fender is put onto the Jeep and used (like smacking branches and such).

Give them a good sanding to smooth the surface over and feather-edge any dings or pit marks.  Maybe with 180-grit first on the orbital (gently) then 220-grit.  Be gentle and don't heat up the paint or it can get gummy.  You don't really need to remove the factory paint totally, it should be stuck good.

Apply build-up type primer to where any bare metal or dings and imperfections are.  Sand lightly again and keep adding primer coats until the depression of the feather edge goes away.  Repeat as necessary until you can give it the final primer coat.

Use 400-grit dry very lightly (no pressure or it clogs the paper) sanding to give it a frosted look all over.  Basically it's a scuff sanding.  Watch the edges and high spots so the primer doesn't get too thin.  Finish up with 600-grit and a little soap and water (in a bowl is what I do) to give it the final sanding.  I usually have the water hose in my other hand to keep flowing water across it when I need it.  600-grit will cut fast when it is in wet mode so be careful you don't leave any bare metal spots.  Air hose it off and towel dry it good.  Final paint a few hours later or the next day at the earliest (unless your paint says otherwise).

Depending on paint type and brand you may need to sand before applying clear coat (if clear coat is required).  Lacking any specific directions from the manufacturer, you would just need to "wipe" it with 600 or 800-grit when the color is dry enough to just give the surface a tooth to grab.  The sheen would just be deglossed.

Good luck and take your time.  You'll probably spend more time on the body from the pix I saw.  Maybe just prep the primer parts (and protect them) then spray the color all on the same day.  You'll use less material that way.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 03, 2018, 01:39:22 PM
If it was mine - and advice is free

First inspect those fenders to see if it is the spot where the bracket underneath is contacting them.  If it is, it will be trouble later (or pretty soon).  My driver side is looking pretty rough from the salt of this past winter (which is still on the roads here in NoVa).  I will be looking for one myself.  I would give them a good degreaser wash down at this point before starting to sand them.  Of course don't ding them up more while washing them.

I would use a wire brush by hand to break loose any flaking paint at any bends, seams, or creases.  Any flaking stuff MUST come off.  I've used an Exacto before to just kind of pick it loose.  These usually result from impacts after the fender is put onto the Jeep and used (like smacking branches and such).

Give them a good sanding to smooth the surface over and feather-edge any dings or pit marks.  Maybe with 180-grit first on the orbital (gently) then 220-grit.  Be gentle and don't heat up the paint or it can get gummy.  You don't really need to remove the factory paint totally, it should be stuck good.

Apply build-up type primer to where any bare metal or dings and imperfections are.  Sand lightly again and keep adding primer coats until the depression of the feather edge goes away.  Repeat as necessary until you can give it the final primer coat.

Use 400-grit dry very lightly (no pressure or it clogs the paper) sanding to give it a frosted look all over.  Basically it's a scuff sanding.  Watch the edges and high spots so the primer doesn't get too thin.  Finish up with 600-grit and a little soap and water (in a bowl is what I do) to give it the final sanding.  I usually have the water hose in my other hand to keep flowing water across it when I need it.  600-grit will cut fast when it is in wet mode so be careful you don't leave any bare metal spots.  Air hose it off and towel dry it good.  Final paint a few hours later or the next day at the earliest (unless your paint says otherwise).

Depending on paint type and brand you may need to sand before applying clear coat (if clear coat is required).  Lacking any specific directions from the manufacturer, you would just need to "wipe" it with 600 or 800-grit when the color is dry enough to just give the surface a tooth to grab.  The sheen would just be deglossed.

Good luck and take your time.  You'll probably spend more time on the body from the pix I saw.  Maybe just prep the primer parts (and protect them) then spray the color all on the same day.  You'll use less material that way.

Thanks Frank I'll give it a shot.

And yeah, the body underneath of the driver's door is a bit messy.  For now I'm just going to brush and sand it down, lay down some rust inhibitor, and leave it. Maybe explore getting it pulled out in the future, or I'll just cover it with a rocker guard of some sort.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 03, 2018, 05:28:50 PM
Did 1-2 hours of sanding on the fender with the "issue." Frank I assume this is the same spot you mentioned...

Outer side (pre-sanding)

(https://i.imgur.com/M8rF9Gr.jpg?1)

Inner side (pre-sanding)

(https://i.imgur.com/5DUKg2L.jpg?1)

It's definitely pitted but is far from going all the way through the steel.  I assume something like this will need to be bondo'd?  Scrubbed it with a steel brush for a bit, hit it with a few minutes of a wire wheel attachment and a flap disk attachment on a cordless drill (low speed), then sanded the area heavily with the palm sander.  Went from 80 grit, to 100 grit, to 120 grit, 180, and 220.  Then hand wet-sanded with 320.  With the palm sander and wet-sanding I did the remainder of the outer side of the fender as well as the bolt spots on the inner side. 

(https://i.imgur.com/L2aHZoq.jpg?1)

(https://i.imgur.com/4QW2BDL.jpg?1)

Again...I assume a spot like that would have to be hit with some bondo if it's going to survive long-term, correct?


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on April 04, 2018, 08:01:36 AM
Both of those spots are the "classic" spot.  Front edge and top center of the wheel well, towards the inner edge.  They suck to do a repair to because of the brackets.  I wonder if it would be better to be welded closed?  Bondo or JB Weld (I like Marine-Tex) would probably be OK to use.  It will probably come back because it flexes right there I guess.  Also, I would make the feather edging area a little larger or that area will still show up as a depression after painting when it is glossy (if it matters).  I've thought of putting the thin black diamond plate material over it just to hide it until they are replaced - redneck fix!

Prep wise, it looks like you are doing great!


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 04, 2018, 09:20:39 AM
Both of those spots are the "classic" spot.  Front edge and top center of the wheel well, towards the inner edge.  They suck to do a repair to because of the brackets.  I wonder if it would be better to be welded closed?  Bondo or JB Weld (I like Marine-Tex) would probably be OK to use.  It will probably come back because it flexes right there I guess.  Also, I would make the feather edging area a little larger or that area will still show up as a depression after painting when it is glossy (if it matters).  I've thought of putting the thin black diamond plate material over it just to hide it until they are replaced - redneck fix!

Prep wise, it looks like you are doing great!

Thanks. I thought about this a little more last night and it occurred to me that it's entirely likely that I end up replacing these OEM fenders altogether in the next 1-2 years with something tubular and aftermarket, so there really isn't much point to me investing all that much time and energy into it haha.  I'll spread some bondo filler on it today, sand it up, and it'll be good to go for my needs.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: overhead on April 04, 2018, 09:30:25 AM
Both of those spots are the "classic" spot.  Front edge and top center of the wheel well, towards the inner edge.  They suck to do a repair to because of the brackets.  I wonder if it would be better to be welded closed?  Bondo or JB Weld (I like Marine-Tex) would probably be OK to use.  It will probably come back because it flexes right there I guess.  Also, I would make the feather edging area a little larger or that area will still show up as a depression after painting when it is glossy (if it matters).  I've thought of putting the thin black diamond plate material over it just to hide it until they are replaced - redneck fix!

Prep wise, it looks like you are doing great!

Thanks. I thought about this a little more last night and it occurred to me that it's entirely likely that I end up replacing these OEM fenders altogether in the next 1-2 years with something tubular and aftermarket, so there really isn't much point to me investing all that much time and energy into it haha.  I'll spread some bondo filler on it today, sand it up, and it'll be good to go for my needs.

I'm not sure why, but this is one of my favorite threads in a while.

https://www.extremeterrain.com/barricade-front-fender-yj-j100300.html?utm_content=XT%20Exterior%20-%20Fender%20Flares%7CBarricade&utm_source=google-pla&utm_medium=shopping&T5_Var3=yellow&T5_Var4=J100300&intl=0&utm_campaign=XTW+Wrangler+Vehicle+Medium&gclid=CPnBiqXqoNoCFcLQswodoSAFMg&gclsrc=ds

https://www.carid.com/smittybilt/xrc-tubular-fender-flares.html?gclid=CjwKCAjw75HWBRAwEiwAdzefxDrEGAbRTai0H5DblgEp8eo5rWFBp4qfcFBaW_yNRtG1iTebEWJ6WxoCpecQAvD_BwE

Both of those are less then you would have spent sandblasting. just saying.
You cut the inner fender from the current good ones to use as the inner fender for these.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on April 04, 2018, 09:36:18 AM
I think perhaps you mean this for a TJ:

https://www.extremeterrain.com/barricade-front-fenders-flare-tj-j100296.html (https://www.extremeterrain.com/barricade-front-fenders-flare-tj-j100296.html)


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on April 04, 2018, 09:37:46 AM
I'm not sure why, but this is one of my favorite threads in a while.

Because it's always fun and gratifying to watch something progress.  Especially when you've been there before.   :wrench


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 04, 2018, 10:07:55 AM
I'm not sure why, but this is one of my favorite threads in a while.

Because it's always fun and gratifying to watch something progress.  Especially when you've been there before.   :wrench

I'm having fun with it because I do feel like I'm bringing this TJ back from its grave. It really was essentially put out to pasture 7ish years ago and has just been sitting.  My friend said I should name it Christine in reference to the 80s Stephen King movie. It's actually pretty fitting, I just hope in fixing the Jeep it doesn't paranormally turn me into some Jeep-bro-douche character like the kid in the movie  :mrgreen For reference...

(http://is2.mzstatic.com/image/thumb/Video/v4/84/aa/4a/84aa4a26-30af-99e1-559f-62e4e353f95c/source/1200x630bb.jpg)

Both of those spots are the "classic" spot.  Front edge and top center of the wheel well, towards the inner edge.  They suck to do a repair to because of the brackets.  I wonder if it would be better to be welded closed?  Bondo or JB Weld (I like Marine-Tex) would probably be OK to use.  It will probably come back because it flexes right there I guess.  Also, I would make the feather edging area a little larger or that area will still show up as a depression after painting when it is glossy (if it matters).  I've thought of putting the thin black diamond plate material over it just to hide it until they are replaced - redneck fix!

Prep wise, it looks like you are doing great!

Thanks. I thought about this a little more last night and it occurred to me that it's entirely likely that I end up replacing these OEM fenders altogether in the next 1-2 years with something tubular and aftermarket, so there really isn't much point to me investing all that much time and energy into it haha.  I'll spread some bondo filler on it today, sand it up, and it'll be good to go for my needs.

I'm not sure why, but this is one of my favorite threads in a while.

https://www.extremeterrain.com/barricade-front-fender-yj-j100300.html?utm_content=XT%20Exterior%20-%20Fender%20Flares%7CBarricade&utm_source=google-pla&utm_medium=shopping&T5_Var3=yellow&T5_Var4=J100300&intl=0&utm_campaign=XTW+Wrangler+Vehicle+Medium&gclid=CPnBiqXqoNoCFcLQswodoSAFMg&gclsrc=ds

https://www.carid.com/smittybilt/xrc-tubular-fender-flares.html?gclid=CjwKCAjw75HWBRAwEiwAdzefxDrEGAbRTai0H5DblgEp8eo5rWFBp4qfcFBaW_yNRtG1iTebEWJ6WxoCpecQAvD_BwE

Both of those are less then you would have spent sandblasting. just saying.
You cut the inner fender from the current good ones to use as the inner fender for these.

These were the exact fenders I was looking at (albeit the TJ version of the Barricades that Frank posted).  Cheap, decent-looking, simple.  Eventually I will go this route but I wanted to stay focused on bringing it back to stock form FIRST, then taking aftermarket steps from there.  This is a 72k mile TJ and above all, I just want to drive it.  I'll be damned if I'm not cruising around town with this top off one month from now.

Also as I've said before knowing me and how I spend $$$, as soon as I change X, I will rationalize why I need to mod Y, then Z, etc.  I will end up in an avalanche of spending that I just can't afford with a wedding coming up in September.  


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on April 04, 2018, 10:35:33 AM
Also as I've said before knowing me and how I spend $$$, as soon as I change X, I will rationalize why I need to mod Y, then Z, etc.  I will end up in an avalanche of spending that I just can't afford with a wedding coming up in September.  

Then paint those fenders with aerosol Rustoleum bed liner.  Probably just 2 cans.  $15 at Walmart.  Ha!  This looks about normal on most Jeeps and would work well with Silver.  I've thought about doing it myself as my fenders are starting to progress with rust.  Maybe just get some of that thin black diamond plate and double-stick tape some patch cut-outs on the rust spots.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: sirjames186 on April 04, 2018, 11:00:51 AM
I'm not sure why, but this is one of my favorite threads in a while.

Because it's always fun and gratifying to watch something progress.  Especially when you've been there before.   :wrench

Ditto!  I'm hooked on this thread, partly because I've been there and want to share the misery, and partly because it's just cool to bring a jeep back from the dead.  Third part includes something like "It's not another JK build" feeling too. lol


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: unleashd on April 04, 2018, 11:15:46 AM
Subscribed Ďcos I have the same situation with my driver side fender


Sent from my iPhone using Tapatalk


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 04, 2018, 01:36:06 PM
Also as I've said before knowing me and how I spend $$$, as soon as I change X, I will rationalize why I need to mod Y, then Z, etc.  I will end up in an avalanche of spending that I just can't afford with a wedding coming up in September.  

Then paint those fenders with aerosol Rustoleum bed liner.  Probably just 2 cans.  $15 at Walmart.  Ha!  This looks about normal on most Jeeps and would work well with Silver.  I've thought about doing it myself as my fenders are starting to progress with rust.  Maybe just get some of that thin black diamond plate and double-stick tape some patch cut-outs on the rust spots.

I'm going with the bondo, especially because it's such a small area. Should take all of two rounds of bondo with sanding in between then these will be ready for primer. Bought one of those silly little rattle-can adapter sprayers too to save my fingers some grief.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Davetopay on April 04, 2018, 05:40:35 PM
Both of those spots are the "classic" spot.  Front edge and top center of the wheel well, towards the inner edge.  They suck to do a repair to because of the brackets.  I wonder if it would be better to be welded closed?  Bondo or JB Weld (I like Marine-Tex) would probably be OK to use.  It will probably come back because it flexes right there I guess.  Also, I would make the feather edging area a little larger or that area will still show up as a depression after painting when it is glossy (if it matters).  I've thought of putting the thin black diamond plate material over it just to hide it until they are replaced - redneck fix!

Prep wise, it looks like you are doing great!

Thanks. I thought about this a little more last night and it occurred to me that it's entirely likely that I end up replacing these OEM fenders altogether in the next 1-2 years with something tubular and aftermarket, so there really isn't much point to me investing all that much time and energy into it haha.  I'll spread some bondo filler on it today, sand it up, and it'll be good to go for my needs.

I'm not sure why, but this is one of my favorite threads in a while.

https://www.extremeterrain.com/barricade-front-fender-yj-j100300.html?utm_content=XT%20Exterior%20-%20Fender%20Flares%7CBarricade&utm_source=google-pla&utm_medium=shopping&T5_Var3=yellow&T5_Var4=J100300&intl=0&utm_campaign=XTW+Wrangler+Vehicle+Medium&gclid=CPnBiqXqoNoCFcLQswodoSAFMg&gclsrc=ds

https://www.carid.com/smittybilt/xrc-tubular-fender-flares.html?gclid=CjwKCAjw75HWBRAwEiwAdzefxDrEGAbRTai0H5DblgEp8eo5rWFBp4qfcFBaW_yNRtG1iTebEWJ6WxoCpecQAvD_BwE

Both of those are less then you would have spent sandblasting. just saying.
You cut the inner fender from the current good ones to use as the inner fender for these.


People can bag on SMitty equipment, but having been involved in an install of both those fenders and the Poison Spider version, I'd take the Smittys. If the powder coat were to be an issue, I'd have them blasted and painted.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 04, 2018, 06:42:50 PM
Making progress. Laid the first round of bondo.

(https://i.imgur.com/sGFhLdI.jpg?1)

Sanded it down after a few minutes. Didn't need more than the first layer for this.  Hit it with 80 then gradually stepped up to 220, then cleaned.  There is a black spot near the center of where that divot was in the steel but it's just some leftover black paint.  Smoothed out nicely.

(https://i.imgur.com/UUMCOIY.jpg?1)

(https://i.imgur.com/RIxGGm3.jpg?1)

(https://i.imgur.com/weZTPX4.jpg?1)

Last picture was a few minutes ago. Sprayed a first round of self-etching primer.  Going to do another with self etching, then spray a few coats of the actually Rustoleum auto primer.  That rattle can spray attachment really is a lifesaver...makes things much easier.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on April 05, 2018, 06:21:12 AM
Good morning, looks like you are progressing well.  Good pix by the way too.

For future reference, Bondo, epoxy, or whatever, should only be applied to bare clean metal.  That's why you need to make the feather edging larger and I wasn't very clear explaining that.  It sticks better and won't be prone to peeling later.  Since these are "short term" fenders probably, I wouldn't worry about it.  It will last for at least a few years and that rust spot/hole will probably start to rear it's head before that anyway.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 05, 2018, 07:22:38 AM
Good morning, looks like you are progressing well.  Good pix by the way too.

For future reference, Bondo, epoxy, or whatever, should only be applied to bare clean metal.  That's why you need to make the feather edging larger and I wasn't very clear explaining that.  It sticks better and won't be prone to peeling later.  Since these are "short term" fenders probably, I wouldn't worry about it.  It will last for at least a few years and that rust spot/hole will probably start to rear it's head before that anyway.

So in the immediate area around these spots I had sanded it down to bare metal.  I probably didn't sand out far enough from the spot (~1/2-1" radius out from the affected area) but it definitely had at least SOME bare metal to grab to.  Same goes for the spot in the front by the signal light housing which was pinhead-sized, and the other scuff towards the back of the fender.  All were down to nice shiny steel. 

I used three coats of self-etching primer followed by something like 3-4 layers of actual auto primer.  I think that should be enough. Coverage looks excellent.  Does it matter that I used self-etching first?  Is that a waste?  Had no real idea but figured it couldn't hurt to use a combination of the two types.

(https://i.imgur.com/GXYvWrV.jpg?1)

(https://i.imgur.com/KbDTR0O.jpg?1)

(https://i.imgur.com/4zu2nGL.jpg?1)


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on April 05, 2018, 07:46:32 AM
I don't think it matters which went down first a hole lot.  Dependent on the type, self-etch is designed to bite into existing paint.  I don't think it means it won't stick to metal any less.  Make sure you give them a good (but light) scuff sanding and wipe down before painting.  This will give something for the paint to grab (tooth) onto better.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 05, 2018, 09:07:40 AM
I don't think it matters which went down first a hole lot.  Dependent on the type, self-etch is designed to bite into existing paint.  I don't think it means it won't stick to metal any less.  Make sure you give them a good (but light) scuff sanding and wipe down before painting.  This will give something for the paint to grab (tooth) onto better.

What sort of light scuff?  I have a few options...scotchbrite pads, and I think 400 or 600 grit loose sheets of sand paper.  Maybe an ultra-high grit wet sanding?


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on April 05, 2018, 09:23:00 AM
I would just dry wipe it with 600.  Don't let the folded edge of the paper leave any gouges or scrapes.  Smack the paper a lot to remove dust build up (you can use an air hose too).  Just do the sanding real light.  Wet sanding can take off paint quick and could leave thin spots in your primer.  Wet sanding can be done and I've done it before when you want a "perfect" paint job that the vehicle merits.  600 or 800 is as far as I go wet sanding because you start to loose the tooth for the paint.  DD need this and show cars don't.  You just need to be real careful - this is the final surface for your paint to go on and paint doesn't really fill in any imperfections.  Air hose and wipe down good before paint.

Make sure you stir your paint well and swirl the gun gently in between strokes to make sure the metal flakes are staying mixed well.  Don't shake the paint.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 05, 2018, 10:04:27 AM
I would just dry wipe it with 600.  Don't let the folded edge of the paper leave any gouges or scrapes.  Smack the paper a lot to remove dust build up (you can use an air hose too).  Just do the sanding real light.  Wet sanding can take off paint quick and could leave thin spots in your primer.  Wet sanding can be done and I've done it before when you want a "perfect" paint job that the vehicle merits.  600 or 800 is as far as I go wet sanding because you start to loose the tooth for the paint.  DD need this and show cars don't.  You just need to be real careful - this is the final surface for your paint to go on and paint doesn't really fill in any imperfections.  Air hose and wipe down good before paint.

Make sure you stir your paint well and swirl the gun gently in between strokes to make sure the metal flakes are staying mixed well.  Don't shake the paint.

Thanks for the pointers. Duly noted.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 05, 2018, 08:46:34 PM
Up with the Jeep again and had just enough time after sitting in 3 hours of DC traffic to replace the front shaft U-joints and centering yoke.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 06, 2018, 10:09:40 PM
Got some good to-doís out of the way today after signing off from work. Went to Advance and rented a TRE press kit and was able to successfully pop that sway bar link end out. No heat required. Iíve tried to be real good about hitting it with the penetrating oil over the past week or so and it really paid off. That plus the press was all it needed. A few hard turns and THUNK!

(https://imgur.com/HQ3f515.jpg)

Crossed some Tís and dotted some Iís like installing new cotter pins where they were needed, torqued down all of the front end nuts and bolts which I hadnít done last weekend, then moved on to some fluid changes. I had been cautiously optimistic that an oil change would improve my oil pressure. It was sitting in the mid-to-low 30s for the past few times Iíve been idling it and never sounded all that healthy. Weíre talking about oil thatís been sitting in this thing for the better part of 10 years, but you donít really know until you change it. Last night I had run it for about a half hour with Seafoam in it, in theory to break some stuff up to be drained out today. I think it helped. I bought the cheapest on-sale oil and filter at Advance to run for 1,000 miles or so then replace with something better, but it made a world of difference. Oil pressure is back up to the mid-40s at idle (thatís okay, right?) and I drained out damn near a full 6 quarts. Iím not necessarily surprised by that, but it was nice to see.

(https://imgur.com/ehYCQQB.jpg)

Then the old family supervisor helped me bleed the brakes and flush the power steering fluid. Itís fun working with grandparents on stuff like this.

(https://imgur.com/Egm9pVV.jpg)

Tomorrow Iím re-tapping/cleaning the threads in the Dana 30 yoke and changing the front end and T-case fluid. Then hopefully driving this thing for a bit. Every time I look at this Jeep I swear it looks better and better. Looking forward to driving this to Show and Shine!


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Gr8Dain on April 07, 2018, 06:44:08 AM
It really IS looking better every time. Canít wait to see it on the road.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Davetopay on April 07, 2018, 09:19:55 AM
(https://vignette.wikia.nocookie.net/xenoblade/images/9/92/He%27s_right_you_know.jpg/revision/latest?cb=20150320192210)


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 07, 2018, 12:12:51 PM
Think Iíve figured out my front driveshaft situation. I couldíve sworn that the threads for the front driveshaft U-joint straps was 1/4-28. I was using my handy dandy Matco tap and die kit but the 1/4-28 tap just wasnít doing it. It would thread through and kinda-sorta felt like it was doing its job, but I would end up encountering more resistance than I was comfortable with when I went to try and thread the bolt it after it. I broke a strap bolt off in a yoke on my XJ a couple years ago and it really wasnít a fun experience...makes me overly cautious now. Probably a good thing.

Got fed up and thought maybe my taps were worn, and I think I was right. Went to Advance and confirmed that the bolt is definitely 100% a 1/4-28 thread. The bolt threaded into the sampler holes at the store like butter, but the tap just sort of slipped in and wasnít grabbing. Guess itís been used well. Unfortunately Advance, Autozone, Pep Boys, and Home Depot all donít carry a 1/4-28 tap. They each have 1/4-20, then jump to 5/16-18. I really, really didnít want to have to drill and re-thread the yoke. NAPA to the rescue! Ordered a $3.49 1/4-28 tap, and paid $11 extra for a tap driver. Should be here in an hour-ish and hopefully Iíll be good to go.

In the meantime, replaced the battery lead ends, replaced the spark plugs, and drained/filled front and rear diffs. Also was a bit bummed to see that my passenger rear brake appears to be leaking fluid. Hopefully just the wheel cylinder. Another fix for another day.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 07, 2018, 04:20:35 PM
Hit a bit of a roadblock with the whole wheel cylinder thing.  It was a bit more than the wheel cylinder...

(https://i.imgur.com/EGP1JVt.jpg?1)

After defeating 7 years of rust that held the drum on, I found a total mess on the inside. Several bits and pieces of hardware rolling around freely inside the drum, and the shoes were toast...looked like a rock or something had torn up the liner.  After pulling everything off I found a severely jacked-up wheel cylinder. 

(https://i.imgur.com/9qWPaGu.jpg?1)

(https://i.imgur.com/N3iWopu.jpg?1)

I'm not quite sure how something like this would happen.  Are the backing plates for these TJ brakes normally bent a little bit like this one?  It looks like some sort of obstruction or damage caused the wheel cylinder to be pressed in and clocked towards the front of the Jeep.  It's a bit tricky to see but in the pic below is the back of the bent backing plate...

(https://i.imgur.com/3yAu7jA.jpg?1)

And this is the opposite side, which looks to me like it's correct. 

(https://i.imgur.com/0EGJ1Xb.jpg?1)

In the image of the bent plate, the wheel cylinder mounting bolt on the right is actually pressed in so far and in such a way that I can't get a socket on the head of the bolt.  Anyone ever seen this before?  Any suggestions on solutions?  I figure I have the following options:

A) Try to manhandle and bend the backing plate back into the position it should be in.  No guarantees that I'll gain access to the head of that one bolt, and I also think this would make re-installing the drum hardware more difficult depending on where mounting holes end up.  Would be imprecise.

B) Replace the backing plate.  I need to service the D35 anyways so this wouldn't be terribly difficult.  Plus the backing plate mounting nuts look clean, rust-free, and ready to come off.  Anyone know where I could find one?  Doesn't seem to have a part number, may need to find some used part on eBay or the forums.

C) Remove the backing plate setup altogether and do a disc brake conversion???


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: sirjames186 on April 07, 2018, 04:43:31 PM
I'd go option C, but if you need it I've got a drum rebuild kit around here somewhere I'll toss in for you tomorrow.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 07, 2018, 06:21:16 PM
I'd go option C, but if you need it I've got a drum rebuild kit around here somewhere I'll toss in for you tomorrow.

Some initial research has me leaning towards sticking with the drums for now so I may take you up on that offer.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: overhead on April 07, 2018, 06:32:25 PM
With a rear 35. Fix it for now and save to do an 8.8 or rear 44 with disk brakes. It's stupid how expensive it is to do disks on a 35.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 07, 2018, 08:14:41 PM
With a rear 35. Fix it for now and save to do an 8.8 or rear 44 with disk brakes. It's stupid how expensive it is to do disks on a 35.

I like this idea. Seems like the cost wouldnít be super exorbitant unless Iím buying a custom manufactured kit, but I donít think the extra effort would be worth it for something that will get tossed in the next year or two.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: overhead on April 07, 2018, 10:27:44 PM
Scott has a rear 44. 3.73 gears $800 with brakes. Cheapest kit I've found for the conversion is $600 plus labor..... $200 means I don't need after market axle shafts for a long freaking while


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 08, 2018, 10:58:17 PM
Scott has a rear 44. 3.73 gears $800 with brakes. Cheapest kit I've found for the conversion is $600 plus labor..... $200 means I don't need after market axle shafts for a long freaking while

$600 for the conversion kit sounds about right based on what I found online. It looked like the easier/cheaper option would actually be to pull the dust shield and hardware from a D35 ZJ and move it over. Direct fit, but I think more effort than I want to put in for a C-clip 35 that wonít be around forever.

Iím down in NC for work and think I have a guy nearby who will sell me a pair of D35 dust shields for $50. Unless I come across a better deal in the next day or two Iíll buy those, clean and replace the other brake hardware, install new shoes and drums, and be done with it.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on April 09, 2018, 06:23:01 AM
I have a brand new master cylinder for a D35 if you need it.  I swapped to an 8.8 so I will never it.  I'm in Lorton.  Swing by on your way home.  I'm just off I-95.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 09, 2018, 06:48:00 AM
I have a brand new master cylinder for a D35 if you need it.  I swapped to an 8.8 so I will never it.  I'm in Lorton.  Swing by on your way home.  I'm just off I-95.

A brand new wheel cylinder?  Just the one?  I will take whatever D35 hardware I can get.  I've gotten over feeling any sort of guilt for taking this stuff off people's hands because it would just be collecting dust forever, otherwise.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: zuke on April 09, 2018, 07:01:52 AM
I will take whatever D35 hardware I can get. 

I've got a whole D35 out of a 98TJ, complete drum to drum, with 3.73 gears, sitting in my shop, nothing wrong with it. Feel free to come take it away!


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 09, 2018, 07:07:53 AM
I will take whatever D35 hardware I can get. 

I've got a whole D35 out of a 98TJ, complete drum to drum, with 3.73 gears, sitting in my shop, nothing wrong with it. Feel free to come take it away!

Alright, PM'd.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on April 09, 2018, 07:08:31 AM
Yes, free cylinder if you want.  Looks like Zuke's got a great offer for you too.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: sirjames186 on April 09, 2018, 07:56:01 AM
I will take whatever D35 hardware I can get. 

I've got a whole D35 out of a 98TJ, complete drum to drum, with 3.73 gears, sitting in my shop, nothing wrong with it. Feel free to come take it away!

Alright, PM'd.

Yes, take that axle, then come get mine and do a full regear to 3.73 for cheap! lol


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 09, 2018, 08:08:59 AM
I will take whatever D35 hardware I can get.

I've got a whole D35 out of a 98TJ, complete drum to drum, with 3.73 gears, sitting in my shop, nothing wrong with it. Feel free to come take it away!

Alright, PM'd.

Yes, take that axle, then come get mine and do a full regear to 3.73 for cheap! lol

Crap. This is an excellent point.  Though I don't think I would necessarily gain much by moving to 3.73...?


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: sirjames186 on April 09, 2018, 08:14:06 AM
I will take whatever D35 hardware I can get.

I've got a whole D35 out of a 98TJ, complete drum to drum, with 3.73 gears, sitting in my shop, nothing wrong with it. Feel free to come take it away!

Alright, PM'd.

Yes, take that axle, then come get mine and do a full regear to 3.73 for cheap! lol

Crap. This is an excellent point.  Though I don't think I would necessarily gain much by moving to 3.73...?

Plug in the numbers and find out:  http://www.grimmjeeper.com/gears.html


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: zuke on April 09, 2018, 08:22:39 AM

Crap. This is an excellent point.  Though I don't think I would necessarily gain much by moving to 3.73...?

From 3.07? Yeah, 3.73 would be a BIG improvement...


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: overhead on April 09, 2018, 08:30:24 AM
You WILL not find another $200 regear that I'd trust. just saying.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 09, 2018, 08:38:08 AM
You WILL not find another $200 regear that I'd trust. just saying.

Oh I'm with this 100%, just thinking aloud here.  Looks like I'll need to carve out some garage space for two additional axles...


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on April 09, 2018, 08:45:39 AM
You would be real happy with 3.73 unless you put 33s on it, then it would be somewhat sluggish.  If you put 32s you would probably still stay happy with 3.73 and I believe they will fit without adding a lift (maybe just 1" spring spacers?).  31s will fit no question and still be peppy.  Most will tell you to go to either 4.56 or 4.88 if you run 33s and then you could even go to 35s.  But then you would need a big lift......

Don't forget to change the speedo gear after you finish whatever you may do.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 09, 2018, 11:46:51 AM
So I'm actually a little hesitant to do another axle swap since I'm only on 30" tires right now.  If I hadn't just bought a 3.07 geared front D30, or if I had larger tires it would be a different story.  But since I will be sticking with 30" tires and the rear D35 for the time being, I may scoop the spare D35 from Zuke and pull what I need just to get this back on the road sooner. 

...unless someone can convince me that 3.73 will be staggeringly better than 3.07 for something that is 95% road and 5% trail.  Those numbers will absolutely change in the future but not as long as I have 30" tires and a rear axle made of glass. 


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: sirjames186 on April 09, 2018, 11:58:39 AM
4 liter engine right?  Which transmission?  If you have the 4 speed with overdrive, you'll want the 3.73 even on 30s.  The overdrive is crazy steep.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: highlandercj-7 on April 09, 2018, 11:59:07 AM
With tires that small, you are golden with the D35 and 307s. My Daughters is that on 31's with a 4.0L Auto (no over drive) and it runs well. 19 MPG and easily can hit 90 MPH. I do not see you having issues with the turdy 5 until you go to at least 33's. Save the $$ and run it!


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on April 09, 2018, 12:00:12 PM
If it was me, I'd get the axles from Zuke and James (not knowing James' price).  Swap them in and call it done.  You already know how to do it and have the tools handy.  Also, all the bolts have recently been in and out.  You have time while waiting for the paint to dry - haha.  There is a market to sell the front 3.07 D30 on CL it seems, and it will probably sell quick (mine went fast anyway).  People always seem to break them (how I don't know) and it's way cheaper to buy a used one than repair one.

But of course it's your time and money not ours.   :?


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: sirjames186 on April 09, 2018, 12:02:13 PM
If it was me, I'd get the axles from Zuke and James (not knowing James' price).  Swap them in and call it done.  You already know how to do it and have the tools handy.  Also, all the bolts have recently been in and out.  You have time while waiting for the paint to dry - haha.  There is a market to sell the front 3.07 D30 on CL it seems, and it will probably sell quick (mine went fast anyway).  People always seem to break them (how I don't know) and it's way cheaper to buy a used one than repair one.

But of course it's your time and money not ours.   :?

Haven't put mine on CL yet, but I'll let it go cheap to a nova member.  Once it's on CL price goes up! ;)


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: zuke on April 09, 2018, 12:10:51 PM
Unless it's the last part of the project, I'd just use what parts you need to make what you have work. Run it the way it is, knowing that you can swap to the 3.73s when needed. I'm always more motivated to make upgrades after I have the vehicle working.

And if you find the thing doing mostly highway duty anyway, you'll get better MPG from the 3.07's But it will suck on hills and offroad on even 31's


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 09, 2018, 01:54:47 PM
If it was me, I'd get the axles from Zuke and James (not knowing James' price).  Swap them in and call it done.  You already know how to do it and have the tools handy.  Also, all the bolts have recently been in and out.  You have time while waiting for the paint to dry - haha.  There is a market to sell the front 3.07 D30 on CL it seems, and it will probably sell quick (mine went fast anyway).  People always seem to break them (how I don't know) and it's way cheaper to buy a used one than repair one.

But of course it's your time and money not ours.   :?

Haven't put mine on CL yet, but I'll let it go cheap to a nova member.  Once it's on CL price goes up! ;)

Yeah I can appreciate that.  The generous offer is noted but I think I'll stick with the 3.07 setup for now.  And Frank you're right that it wouldn't be difficult at all--knocking on wood, it sounds like rust and broken bolts won't be much of an issue on this Jeep.  I'd rather keep what I have instead of adding extra steps.  I guarantee you I'll be moving to something like 4.56 or 4.88 in the future, but until I run down these current tires I'm not going to rush anything.  Remember...wedding in September for me so I'm literally hemorrhaging cash as it is.  

Unless it's the last part of the project, I'd just use what parts you need to make what you have work. Run it the way it is, knowing that you can swap to the 3.73s when needed. I'm always more motivated to make upgrades after I have the vehicle working.

And if you find the thing doing mostly highway duty anyway, you'll get better MPG from the 3.07's But it will suck on hills and offroad on even 31's

Butttttttt John I'll still gladly take that Dana 35 off your hands and pull what I need!


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 11, 2018, 08:10:17 PM
Squeezed a used Dana 35 into the back of my pristine 3,000 mile Mazda CX-5 rental car this afternoon thanks to Mister Zuke. Awesome shop man, thanks again. Hope to visit again soon!

Will be taking advantage of the good used parts and spare D35 hardware, Iím sure.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on April 12, 2018, 06:46:14 AM
You went to Walmart didn't you!


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: JKrazy on April 12, 2018, 01:36:12 PM
Awesome find!  Awesome build.  I wish I had the knowledge and tools to purchase and build a "project" Jeep!

 :wrench :cheers


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 12, 2018, 02:20:36 PM
You went to Walmart didn't you!

Lowes! And yes. As I told Zuke, the measures we go to in order to avoid losing time in traffic...


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 15, 2018, 06:58:10 PM
Mega-noob question, but can anyone direct me to where I can find the paint code on my TJ? Or just tell me what color this is? Iím betting itís either bright silver metallic or silverstone metallic but swear I canít find the barcode tag anywhere. Not in the typical door sill location?


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: highlandercj-7 on April 15, 2018, 07:08:47 PM
It's not the silver. IMHO it looks better it is the more gun metal grey color. My Dads was the same and he had it painted to match the silver of the 05 ruby doors he bought. I didn't like that as much as the original color. Try looking under the hood for the build codes. I think it's:

Silverstone Metallic S5 2000-2002 Jeep Wrangler TJ


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 15, 2018, 07:14:36 PM
It's not the silver. IMHO it looks better it is the more gun metal grey color. My Dads was the same and he had it painted to match the silver of the 05 ruby doors he bought. I didn't like that as much as the original color. Try looking under the hood for the build codes. I think it's:

Silverstone Metallic S5 2000-2002 Jeep Wrangler TJ

I was also leaning more towards the silverstone metallic. Iíll check the hood.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: zuke on April 15, 2018, 09:16:49 PM
If you go to this page;

https://jeep.custhelp.com/app/jeep/eqlisting_detail/

and put in the jeeps VIN code, It gives you the jeeps original build sheet, which has the color name(But not the paint code).


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 16, 2018, 05:54:30 AM
If you go to this page;

https://jeep.custhelp.com/app/jeep/eqlisting_detail/

and put in the jeeps VIN code, It gives you the jeeps original build sheet, which has the color name(But not the paint code).

There it is.  I already have this build sheet but must have scrolled right past that by mistake. Thanks


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: sirjames186 on April 16, 2018, 07:19:02 AM
I bought a can of this stuff and it matched my paint perfectly.  They go off the paint name too, instead of the color number since you already have that info...  http://a.co/8TnJ0bf


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 16, 2018, 07:53:31 AM
I'm actually going with the stuff from these guys: http://www.automotivetouchup.com/ . I used it a few years back on my CJ and it worked pretty well.  The touch up paint in the pic below starts in the center of the rocker beneath the door and goes back to the rear of the Jeep.  Midway in the rocker forward is factory paint.  It blended extremely well I think, and I didn't use any sort of clear coat in that case (plan to use it this time).  It's pricey at around $19/can but should do the trick.

(https://i.imgur.com/EyGhHYQ.jpg?1)



Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 17, 2018, 04:10:03 PM
Started to work on the hood prep today.  Lots of work.  More work than expected.  At first glance the hood looks OK at best, but the small little pieces of surface rust here and there proved to be a real bear to iron out.  I think I did a pretty good job and I can still see some peeking out here and there as I'm laying down primer. 

(pre-sanding)

(https://i.imgur.com/nUFu7DN.jpg?1)

You can see all the little surface spots.  Not that deep, but on a big flat piece like a hood I knew they were going to stick out unless I really sanded them down.  I started at it and after at least an hour, I wiped the thing down.  I could still feel a bunch of small divets all over the place, which annoyed me.  That was at this point:

(https://i.imgur.com/OSmCIWn.jpg?1)

I kept telling myself that this was really only going to look decent if I prepped as best I could, so I kicked the grit on the sander back down a notch and went at it again despite not wanting to.  At this point I basically had to focus on little individual spots, or groups of spots, one at a time, with the sanding disc at kind of an angle to maximize direct pressure and get as much off as I could.  I pretty much went across 2/3 of the hood in little 3" x 3" sections.  I'd press and sand down the little sections then run my hand over them until they were smooth and glass-like.  After at least another hour I swept it off with a broom and sprayed it down.  It cleaned up a lot and I think that additional lengthy run-through with the sander will pay off.  Now that I've begun to lay down some primer I can still see some tiny spots here and there but I'll get over it.  After I lay down a few more layers of primer, then the layers of base coat, then some top gloss, hopefully they will disappear a little more.  After additional sanding:

(https://i.imgur.com/4gtEVFY.jpg?1)

Lesson learned: hoods are huge. Much bigger than I thought.  I am chewing through primer like crazy and am going to run out to grab more in a few minutes.  I almost definitely didn't buy enough base coat to cover this hood, let alone the fenders.  In hindsight, I should have waited and bought someone else's used silver hood.  This is almost definitely more work than it's worth, but I keep reminding myself that I'm probably building character or something. More pics to come. 


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 17, 2018, 09:04:16 PM
Made some more progress this afternoon and things are looking better. I may actually be able to sand down the primer in any areas that bother me to really smooth it out before the base coat comes out. Streaky from the spray gun in a few spots, but Iím also putting more primer in areas that are going to see more road rash and rocks than others...spots like the dip from the top of the hood down to where it meets the grille, and the front lip that surrounds the top of the grille itself. Iím feeling a little better about it now but still plan to put a few more coats of primer down tomorrow.

Iím without a doubt going to need gobs of base coat for this hood, however it should grab and hold nicely.

(https://imgur.com/eN3xfnW.jpg)

(https://imgur.com/D9uMzxL.jpg)


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on April 18, 2018, 06:22:40 AM
I am chewing through primer like crazy and am going to run out to grab more in a few minutes. 

Looking pretty good!

This is why I usually buy at least a quart (sometimes 2) of "Primer surfacer" from Mattos or some other paint supply place instead of aerosol cans.  They don't really go far and don't have that much cellulose fiber in them for building up and filling in.  When you think you have sanded enough, you can then lay a heavy coat on, and then use a large flat sander so you just hit the high spots.  When you are satisfied, you do it again.  Then you may even decide to do it again.  Looks like you are doing pretty well - its definitely a learning experience.

You will probably get by with a quart of color and a quart of clear.  Don't forget any additives you may wish to add (like hardener, reducer, UV, etc.).  Don't you want to remove the bumpers and nozzles from the hood?


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 18, 2018, 09:39:55 AM
I am chewing through primer like crazy and am going to run out to grab more in a few minutes. 

Looking pretty good!

This is why I usually buy at least a quart (sometimes 2) of "Primer surfacer" from Mattos or some other paint supply place instead of aerosol cans.  They don't really go far and don't have that much cellulose fiber in them for building up and filling in.  When you think you have sanded enough, you can then lay a heavy coat on, and then use a large flat sander so you just hit the high spots.  When you are satisfied, you do it again.  Then you may even decide to do it again.  Looks like you are doing pretty well - its definitely a learning experience.

You will probably get by with a quart of color and a quart of clear.  Don't forget any additives you may wish to add (like hardener, reducer, UV, etc.).  Don't you want to remove the bumpers and nozzles from the hood?

Yeah, it's on the to-do list for today.  At the time when I started this it was starting to downpour outside and the tool I needed was inside my truck.  Really just my laziness getting the better of me.  I'll be popping them out today.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 20, 2018, 06:22:48 AM
Heading to MD to work on it today.  My OEM paint hasn't been delivered yet, so this weekend will be all mechanical once again.  To-do list:

- install the new front sway bar links with disconnect pins
- install shift bezel to keep the boot in place
- remove brake backing plates and any other useful drum brake hardware from the Zuke D35
- rebuild the currently installed Dana 35 with new shoes, cylinders, hardware
- refill rear end
- bleed brakes
- re-tap the front yoke and re-install the front shaft

Then maybe take it for a drive.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 20, 2018, 08:50:03 PM
The Jeep is starting to fight back. Got myself into a pretty solid pickle tonight...

Pulled the C-clips and shafts from Zukeís donor D35 with no issues. Removed the backing plates and all was going great. Went to do the same to mine to move the backing plates over and this happened:

(https://imgur.com/meeQ9kP.jpg)

(https://imgur.com/Qu1SI1o.jpg)

Somehow the cross pin bolt just...sheared right off. Iím not really sure how this happened and donít think itís a fault of my own. Maybe it spent all these years sitting in the carrier side that was suspended out of the oil? Could it even deteriorate or rust in conditions like that? I used a 1/4Ē drive wrench and the right size socket; definitely didnít put too much power onto it. Funny thing is it felt like it broke pretty much as soon as I turned it.

In the pic above, Iíve already tried to chisel and tap what remains around to thread it out. Itís going, but itís painstakingly slow. Iím lucky to get 1/16 of a turn at best. Before I get frustrated and do something stupid, anyone have any clever ideas or suggestions? Would really prefer to use this axle and not swap in the 3.73-geared D35 if I donít have to. At this point I canít even pull the carrier itself out to work on this on a bench because the cross pin prevents me from pulling the axle shafts.

In my book I consider this a tricky one. Any thoughts or suggestions would be greatly appreciated.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: zuke on April 20, 2018, 09:15:23 PM
I'd bet that it was torqued in too tight previosly, and the crack was just waiting for you.... Drill a small hole and use an easy out if you can, but it's probably going to be slow going no matter how you do it....


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: overhead on April 20, 2018, 09:50:16 PM
At that point. Do the axle swap. You're gonna chase a headache for however long you're gonna put into it. If you've bought em swap em


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 22, 2018, 07:38:52 AM
I got it out.

Went out and bought a Dremel, then bought a diamond tip engraving point for it. Carved a channel in the center that would accommodate a flathead screwdriver, then drilled into it again with a cobalt bit. Doing both of those things seemed to fracture the integrity of the screw enough to allow me to snag it with a tiny pair of needle nose pliers and spin it out. Thank the Jeep gods.

(https://imgur.com/mCQjmyn.jpg)

Then I could finally remove these backing plates! And holy moly were they jacked. I thought the one on the passengerís side was bad. Check out driver:

(https://imgur.com/ykeEPLP.jpg)

And then both bad plates compared to a good one (top). Whatever happened to these things, theyíve lived a hard life. I prompt retired them to the garbage bin.

(https://imgur.com/3qXSPXm.jpg)

Backing plates, brake lines, and wheel cylinders are on. Axle is back together but I just ran out of time fighting that cross pin screw. Feels like I got next to nothing done but at least that screw is out.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: highlandercj-7 on April 22, 2018, 07:58:21 AM
Great googly moogly, what in the world ate the plates up like that. :eek

As for the pin I have seen that several times on the turdy 5. I have drilled and tapped them, and used a punch as you did. Fortunately enough they are usually loose after they snap and are easy enough to work with. Some of them do not even have a bolt they used a roll pin. Glad you were able to salvage it.



Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 22, 2018, 10:23:56 AM
Yeah the plates were really destroyed. I had only pulled the passenger brake apart and initially thought it was in the worst shape. Driverís side didnít disappoint! The side-by-side comparo with the good backing plate is pretty amazing.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: zuke on April 22, 2018, 10:47:41 AM
I'm amazed the thing even still rolled!


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on April 30, 2018, 07:48:31 PM
Checked off some crucial to-dos this afternoon. Refilled the rear, installed and adjusted all new rear drum hardware while cursing up a storm, re-tapped the threads in the yoke of the front end, and installed the front sway bar end links. Oh, and popped in a shifter boot shroud! No more floppy loose boot.

Iíve been neglecting an important item...a battery. I pretty much always have to jump this thing and itís taken a toll on the battery (though itís the old one out of my XJ). Thatíll be next along with a brake bleed, then itís on to body work.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on May 12, 2018, 02:59:23 PM
Painted the hood today. Results were...meh. Body work and paint/prep is difficult and the hood is much bigger than it looks when youíre doing the work. Basically what Iíve ended up with is instead of a black beat-up hood, I now have a silver beat-up hood. Haha. One of these days Iíll probably come across an identical-ish colored hood on Craigslist and jump on it. Oh well.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on May 14, 2018, 06:57:03 AM
Send a note to Scott and Damien.  They part out all the time and would probably call you as soon as they have one.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on May 14, 2018, 03:33:37 PM
Going to try malleting-out my outgoing hood as well. It isnít worth anything to me at this point so I figure itís worth a shot.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on June 16, 2018, 12:57:31 PM
Finally got my hands on this again for a few hours today. Wedding planning and attending other peoplesí weddings for the past four weeks has taken all my Jeep time away.

Did some final brake adjustments and bled the system. I also noticed that the rear diff appeared to be seeping more than I would like, so I evacuated the very new fluid, cleaned both surfaces off a little better, and refilled. Done. Replaced the hood with the used one I recently painted. Itís far from perfect but actually looks better than expected. It isnít dented like the old one, so Iíve got that going for me. Pulled all the seats out and vacuumed/washed the floor. Years of outdoors and weathering had built up in there so it was necessary. Went over the front end again and torqued down all the nuts, end links, shocks, control arms.

TOOK IT ON THE ROAD! For the first time i took it around the neighborhood. Needs a very obvious alignment but otherwise it felt like how youíd expect a 70,000 mile Jeep to feel. Went through 4 of the 5 gears and it really felt great.

After a few hard-ish stops to check the brakes, the both fronts started smoking. Got home, pulled the wheels off to cool them down. From what I could tell, the calipers didnít look to be seized and everything looked pretty normal. Iíve done plenty of brakes in my life, cleaned off the oils, pads in correctly, etc. Am I missing anything? Maybe they just need to be bedded in and driven a little farther for mfr coatings to burn off? I honestly canít think of anything I missed and donít think the calipers are stuck. To test, Iíll pull the calipers off and have the fiancť hit the brakes to see how they do, but i specifically checked their condition when I did the front brakes a few weeks ago and they looked fine. Itís also worth noting that while I was driving it around it didnít feel like either brake was dragging. Power was good and it wasnít tugging to either side.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: sirjames186 on June 16, 2018, 01:04:20 PM
Any smell associated with the brake smoke? Could just be some oils on there burning off like you mentioned.  Might be worth another test drive to see if it happens again and for any obvious pad wear.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on June 16, 2018, 01:43:41 PM
Any smell associated with the brake smoke? Could just be some oils on there burning off like you mentioned.  Might be worth another test drive to see if it happens again and for any obvious pad wear.

See, thatís what I was thinking too. Especially since there wasnít any pulling feel to one side or another while i was off and on the brakes on that test drive. When I initially did the brakes weeks and weeks ago, I never had a chance to actually drive it or work them in...come to think of it that was probably back in March. Long time ago. Iíll drive it around again and see what happens.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: RFH_98TJ on June 18, 2018, 06:49:26 AM
Were these brand new disks?  If so, did you clean off the coating they are shipped with?  New pads will still have the fresh paint on them and will smell for the first few days until it is baked/burned on.  As for smoke, I can't say I've seen any after just a simple pad replacement.  I'd say drive it NORMAL and see if anything shows up.  No pulling to either side probably means it is just the paint on them burning off.


Title: Re: The Silver Bullet - resurrection of a TJ
Post by: Jeepsnbuses on June 18, 2018, 07:58:36 PM
Were these brand new disks?  If so, did you clean off the coating they are shipped with?  New pads will still have the fresh paint on them and will smell for the first few days until it is baked/burned on.  As for smoke, I can't say I've seen any after just a simple pad replacement.  I'd say drive it NORMAL and see if anything shows up.  No pulling to either side probably means it is just the paint on them burning off.

Yeah, my fiancť complains all the time about the volume of half-empty Brakleen cans sitting around the garage. They were definitely clean.

Must be just the paint or the new materials. Was just making sure I didnít miss anything unusual...though I know a lot of this crosses over to XJís, this is still the first TJ for me!