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  1. #1

    Tim's CJ-5 Conversion to 6 Project

    Recently purchased a CJ5 for a new build project. This will be my third build and am hoping this thread will help with the build process.

    Overall goals: Full frame off restoration, conversion to CJ-6, and convert fully capable rock crawler. Plus keep project timeline within a 6 month window.

    I purchased this jeep from a college kid who had only had it for less than a year. Other than that, the history of this jeep is unknown. Was sold as a '74 with an AMC 304 V-8.

    Once the jeep was home, I started a complete diss-assembly to find that:

    The body is from a 1968 Tuxedo CJ-5.
    --> Now stretched 20" to be a CJ-6
    The axles are from a post '82 (56" wms) Dana 30 with detroit, Model 20 open, 4.10's.
    --> Now a front Dana 60 and rear 14 bolt with 5:13's and Detroits
    Fenders and windshield from a different year.
    --> Genright Rube Fenders
    Hood is a replacement.
    The V-8 is actually a swapped in rebuilt 401.
    --> Now with TBI kit
    Transmission: T15
    --> Swapped to AMC TH400 with Manual valve body.
    Transfer case: 20
    --> Dana 300 with 4:1 kit and twin stick
    Frame has a partial VIN stamp for a '75.
    --> Frame stretched 20", only retained front and rear most portions.
    Original Wheelbase: 83.5"
    --> Stretched to 109"
    33x12.50R15 BFG Mudders
    --> 40x13.50 Trepedors on Walker Evans
    Spring Under, Skyjacker 2.5 inch lift.
    --> Spring over with YJ springs.

    May 2013:






    October 2012:

    ( Stretched CJ 5 )

    Here she was December 2011:


    Some tear down pics:









    Last edited by goofyjumper; July 2nd, 2013 at 07:35 PM. Reason: Add new stats.
    '14 Harley Fat Bob Summer DD "Vivian"
    '13 JKU Rubi Winter DD "Sheldon"

  2. #2
    Getting some body work:





    Lonely drivetrain outside.







    Stretching 20" to make it more family friendly and to match CJ-6 length.



    EDIT: Prior to cutting the body in two, I tack welded little pieces of steel throughout the body as known reference points with distances marked on them to other locations. (Pre and post stretch measurments.) Additionally, I braced locations that I thought may bow in or out once they were cut. The cut is taking place on a frame I build on two saw horses and each piece of the tub is on it's own sled that I can adjust up/down, in/out, and left right.
    Last edited by goofyjumper; January 20th, 2012 at 09:29 AM.

  3. #3

    Join Date
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    so what's the plan? Keep the 401 or go vortec?
    1994 Toyota FZJ80 - elocked, 3in OME lift, 315/75-16 KM2s, Warn 8274.

  4. #4
    tjjared413's Avatar
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    Quote Originally Posted by cmd11 View Post
    so what's the plan? Keep the 401 or go vortec?
    x2 on that and whats else are you doing to it?

    keep it up looking like a good start...
    rig- 04 TJ -it has round tires and tow rig- 04 chevy d-max
    game on western slope! game on.........

  5. #5

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    Another oddity, that dash is '76 and up.

    At least the AMC 20 has had one-piece axleshafts installed.

    Will be interesting to see how this one progresses.

  6. #6
    Quote Originally Posted by cmd11 View Post
    so what's the plan? Keep the 401 or go vortec?
    I'm planning on keeping the 401 and I have a Howell TBI kit on the way for it.

    It is getting power brakes and steering.

    Axle upgrades, trying to source chevy dana 60 and 14 bolt. Likely going full width. If I want it running again by summer then I likely will swap to SOA with 1.5" YJ leaves outboarded, shackle reversal, and maybe frenched perches.

    Would like to do 38"-40" tire setup and trim the heck out of the fenders.

    Will be replacing the T15 with a 4 speed that has a granny gear.

    Critical Items: Rebuild a portion of the frame and box the remainder. Source new axles.

  7. #7
    tjjared413's Avatar
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    Quote Originally Posted by goofyjumper View Post
    I'm planning on keeping the 401 and I have a Howell TBI kit on the way for it.

    It is getting power brakes and steering.

    Axle upgrades, trying to source chevy dana 60 and 14 bolt. Likely going full width. If I want it running again by summer then I likely will swap to SOA with 1.5" YJ leaves outboarded, shackle reversal, and maybe frenched perches.

    Would like to do 38"-40" tire setup and trim the heck out of the fenders.

    Will be replacing the T15 with a 4 speed that has a granny gear.

    Critical Items: Rebuild a portion of the frame and box the remainder. Source new axles.
    sounds good !!! ill be keeping my eye on this one

  8. #8
    Wulf's Avatar
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    I misread the title and thought you were gonna be swapping in a 6.0 Chevy



    Looks good so far!
    8 Hz WAN IP

  9. #9
    Almost makes me miss my '73 CJ-5! Almost. Of course, that included a '76 dash, '79 windshield and clamps, etc...
    ☻/ This is Muhammad.
    /▌ 
    / \ Copy and paste him
    Jim - www.yuccaman.com - '04 LJ Unlimited

  10. #10

    Join Date
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    one of these days i am going to duplicate my CJ back to about 1995. 401, T18, and 35s.

  11. #11

    Update

    Did a steel run at Hinton Steel. Good place and easy to work with. Thank you to those on this board that pointed me in their direction.


    Started re-connecting the two pieces of the body tub after pulling them apart.



    Still need to figure out how to reproduce the top rail. Add floor panels. Then bondo the sides to hide the welds and then she will be a CJ-6 tub!
    Last edited by goofyjumper; April 6th, 2012 at 09:06 PM.

  12. #12
    tjjared413's Avatar
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    nice work so far!.. that lip on top of the tub is what your talking about?? how about some 1/4" round rod to match up that body line.... then back to flat plate? 1/4 rod is easy to work with and cheap.

  13. #13

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    See if you can find a tub that's trashed that someone would be willing to give away. I've found two pre-76 tubs on this board for purposes like you need one for.

  14. #14

    Fab the lip on the tub...

    Ok, messed with various scraps around the garage and figured out how to fab the lip on the top of the body tub.



    I found that 3/4" square tub matched the inner sheet metal and then rolling 16 gauge over the square tub I could match the profile of the original tub.

    I then created a sheet metal brake using the bench vice and angle iron.



    I folded the 16 gauge to the appropriate shape, ripped a piece of square tubing in half long ways, and then combined the two pieces.

    Then it got all welded together. I'll smooth out the joints with a little body filler once all the metal work is done.



    Now to do the passenger's side!

  15. #15
    tjjared413's Avatar
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    that looks good!! nice job... from the pics before last it looked to have round edges.

  16. #16

    Bondo!

    Been lazy the last few days. Worked a little on extending the floor pan, patching holes in the body tub, and tonight started applying body filler to contour the lines of the body tub with the 20" portion that I added.






    Anyone know a source for a Chevy Dana 60 and a Corporate 14 bolt?

  17. #17

    Updates

    Been doing a lot of bondo and sanding.... and more bondo and sanding to straighten out the body tub....



    Decided to cut out and fill the old side fuel tank filler hole.



    Almost have the floor done.



    And the other side....


  18. #18
    trailblazer's Avatar
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    Nice body work. Very clean.
    custome scrambler 350 700r4 dana 60 14 bolt 4.88s 4 link front and rear

  19. #19

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    Quote Originally Posted by trailblazer View Post
    Nice body work. Very clean.
    x2, cool build
    If you cant fix it with a hammer, it must be an electrical problem

  20. #20
    tjjared413's Avatar
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    Quote Originally Posted by toyossan View Post
    x2, cool build
    x3 man keep it up!

  21. #21
    Thanks, everyone!

  22. #22

    Painting

    Finished all of the metal work on the body tub, primed it and coated with truck bed liner. Need to add some color to it now.




    Last edited by goofyjumper; March 1st, 2013 at 01:40 PM. Reason: Update Images

  23. #23

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    Looks good, what bedliner did you use?
    1951 M38/327/TH350/D300/D44's

  24. #24

    Final Paint.

    Quote Originally Posted by InsaneJ View Post
    Looks good, what bedliner did you use?
    Duplicolor's Bed Armor. General kit you get from Pep-Boys. One gallon double coated the outside and inside. Triple coated the bottom.

    After paint and bottom:






    Keywords Stretched CJ5 CJ-5 CJ6 CJ-6 one tons 14 bolt dana 60
    Last edited by goofyjumper; June 16th, 2012 at 09:58 PM. Reason: Keywords added for reference.

  25. #25

    Frame Stretch.... The beginning.

    This week I finished the body and moved it outside and brought the frame and drivetrain back inside. Removed the tires/rims, axles, transmission, and transfercase. Sold them all. Also removed the engine and started removing all the old odd stuff from the frame.

    Axles just prior to going to their new home:



    T-15 and Dana 20 on their way out the door. Once pulled, I discovered that when the new clutch was installed they never put in a pilot bearing and the input bearing on the T-15 was completely shot.


    Big mess in the garage as the engine was taken out and prepped to be put on a stand.

  26. #26
    tjjared413's Avatar
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    looking really good!

  27. #27

    58...59.... 60!

    Acquired a Chevy Dana 60 today!


  28. #28
    tjjared413's Avatar
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    i love 60's!

  29. #29

    Framing.....

    Have been doing a ton of work on the Jeep but haven't had time to update this thread. So I have acquired a replacement transmission and transfer case. A Cherokee Chief TH400 and an 80's CJ-7 Dana 300. The Transmission has already been rebuilt, but I will have to do the transfer case. I replaced all the seals in my engine and checked all the tolerances. I highly recommend the seal kits that come from Summit Racing. The kit had every seal imaginable in it. Including the copper ring for the oil plug.

    I have also finished stripping down the frame. I then made a level frame jig, took tons of measurements, and cross braced critical parts of the frame.



    Next I cut up the frame



    And then I started putting the frame back together mixing new pieces with old pieces. This is where I am at right now.



    When I am done with the frame, it should be 20" longer to match the body.

    ( Stretched CJ 5 Frame )
    Last edited by goofyjumper; April 10th, 2012 at 12:28 PM. Reason: Keywords added for reference.

  30. #30
    tjjared413's Avatar
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    how good did that feel to cut up a frame... lol


    keep up the good work man!

  31. #31

    14er.... in my garage.

    Been a few days.... So here is the update:

    Continued to work on the frame, got the bulk of it back together with 2"X4" tubing and M.O.R.E. frame reinforcement skins. Also boxed the old sections that were just C-channel.



    Acquired a SRW mid 80s 14 bolt with a detroit.



    Started diss-assembly of the dana 60 to get it ready to have new locker and ring and pinion installed.



    Waiting on parts from Ruff Stuff Specialties and a mix up on an order from Quadratec.

  32. #32

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    looking good, like the way you built the frame.

  33. #33

    Boing!

    Little update:

    Rims arrived courtesy of help from Rokmen. They were very helpful when it came to ordering Walker Evans beadlocks. Would definitely do business with them again.



    Also have received a bunch of suspension parts lately and are messing with where everything will be mounted/welded up.



    Hopefully gears and lockers will show up by this weekend and I can get the axles done and suspension brackets welded in next week.
    Last edited by goofyjumper; March 14th, 2012 at 08:38 AM.

  34. #34
    tjjared413's Avatar
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    nice!!!!!!

  35. #35
    tantonio's Avatar
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    Looks great.....not going with Links/Coil Overs?.....just curious....I want some Walkers!!

  36. #36
    jeepn4evr's Avatar
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    Looks good, am jealous.

    Just outta curiosity why cover up the under seat gas tank hole? I always thought it would be kind of sweet to have an extra tank on mine for a reserve type set up if needed.

    Where in Littleton are you, I wouln't mind seeing this in person, not to meniton it looks like you have a pretty good garage setup as well.
    Restored 1974 CJ5 with some stuff. Need help to add some more stuff. Any takers?

  37. #37
    Quote Originally Posted by jeepn4evr View Post
    Looks good, am jealous.

    Just outta curiosity why cover up the under seat gas tank hole? I always thought it would be kind of sweet to have an extra tank on mine for a reserve type set up if needed.

    Where in Littleton are you, I wouln't mind seeing this in person, not to meniton it looks like you have a pretty good garage setup as well.

    I got rid of the under seat tank hole because after looking into the idea of putting a tank under the driver seat, especially the ones designed for that, I was worried that if I ever rolled the rig, I would end up getting a gas bath. I am looking at getting GenRight 23 gallon fuel cell for safety reasons.

    I'm over by Simms and Bowles. PM me if you want to stop by some time.


    For those of you wondering how I got this project approved by the WIFE: I sold my 2010 STi, bought a beater daily driver with 160k miles on it for cash, and then told her, "Hey, this will be cheaper than the STi was."

  38. #38
    Quote Originally Posted by tantonio View Post
    Looks great.....not going with Links/Coil Overs?.....just curious....I want some Walkers!!
    No coils for this phase of the build. As we all know, the initial build is expensive! Maybe links and coils in a couple years. I've built the frame so that it should be a fairly easy transition in the future.

  39. #39
    Quote Originally Posted by tjjared413 View Post
    nice!!!!!!
    Thanks!

  40. #40
    tjjared413's Avatar
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    Quote Originally Posted by goofyjumper View Post
    For those of you wondering how I got this project approved by the WIFE: I sold my 2010 STi, bought a beater daily driver with 160k miles on it for cash, and then told her, "Hey, this will be cheaper than the STi was."

    .... i know all about this!

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