'84 CJ7 Expo build

[korisu56]

Hey folks, lurker here. I'm building my CJ7 to be a decent all around overlander. I won't be making crucial cross-continental adventures, but I will be attempting a 3 week trip in a little over a year. I have several small ones planned to build up experience and stock equipment needs.

Platform:

1984 CJ7
-4.2l (converting to 4.0 head to get fuel injection)
-Dana 300 Twin Sticked
-T5 Trans
-Dana 30/AMC 20 (open/open)

Modifications as of now:
-Belly Up
-Aftermarket rollcage
-Front bumper with grill hoop and recovery points
-Rear bumper tied in with recovery points and hitch receiver.
-Bench seat w/ harnesses
-CB setup

Proposed/Projected:
-Roof rack (obvious with jeep's space issues)


I'm open to ideas and my next few posts will be a c&p of my build thus far.

[korisu56]

Start point:

http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs093.snc1/4681_1141732390905_1455316519_30359600_1951307_n.j pg

http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs113.snc1/4681_1141732670912_1455316519_30359607_1858016_n.j pg

[korisu56]

Cage was first to go. Refuse to wheel with my wife and dogs with crappy OEM roll bar. Found a steal and jumped on it.

http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs171.snc1/6420_1167158506542_1455316519_30444917_2474443_n.j pg

http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs171.snc1/6420_1167158386539_1455316519_30444914_2140963_n.j pg

[korisu56]

Installed a bench seat because of its overall better comfort and natural barrier for puppies. Maintained adjustablility and fold feature. Ugly, but does the trick and when I can pony up for a good custom cover, will do.

http://i299.photobucket.com/albums/mm317/korisu56/CJ%20working/CIMG0431.jpg

http://i299.photobucket.com/albums/mm317/korisu56/CJ%20working/CIMG0451.jpg

[korisu56]

I like the simple front bumpers. I got a grill hope for rollover protection and recovery points up front. Rear has recovery and is tied-in to the frame to counter weak rear crossmember.

http://i299.photobucket.com/albums/mm317/korisu56/CJ%20working/CIMG0428.jpg

http://i299.photobucket.com/albums/mm317/korisu56/CJ%20working/CIMG0430.jpg

http://i299.photobucket.com/albums/mm317/korisu56/CJ%20working/CIMG0436.jpg

http://i299.photobucket.com/albums/mm317/korisu56/CJ%20working/CIMG0437.jpg

[korisu56]

Belly up is by far one of the best things I've done. SOOO much more clearance and a better piece of mind. Has a rear cross member that holds up the tranny/tcase. Therefore I can drop down the plate without having to support the drivetrain.

http://i299.photobucket.com/albums/mm317/korisu56/CJ%20working/CIMG0443.jpg

http://i299.photobucket.com/albums/mm317/korisu56/CJ%20working/CIMG0442.jpg

[korisu56]

As it sits.

http://i299.photobucket.com/albums/mm317/korisu56/CIMG0452.jpg

[shamus275]

I could be wrong but those bumpers look like the work of Rob and Damien...Good, choice if that's where you had them done!

[BigAl]

1984 CJ7
-4.2l (converting to 4.0 head to get fuel injection)
-Dana 300 Twin Sticked
-T5 Trans
-Dana 30/AMC 20 (open/open)

I'm open to ideas and my next few posts will be a c&p of my build thus far.

For ease, reliablility and horsepower, I would get a donor cherokee and drop the whole motor and tranny in. With a just a head conversion, you have to rig a cps in your existing bell housing or buy an expensive part to fit the front of the crank. I think you get more HP from a 4.0. If you go ODBI, I can help you with the wiring

[korisu56]

I could be wrong but those bumpers look like the work of Rob and Damien...Good, choice if that's where you had them done!

It's 100% correct. They also did the belly up and the bench. I come up with what I want and they build it. At my last duty station I had a shop on post I could work at, alas that is no more. I have to pay for the silliest of jobs, so I just have them knock out everything.

[korisu56]

For ease, reliablility and horsepower, I would get a donor cherokee and drop the whole motor and tranny in. With a just a head conversion, you have to rig a cps in your existing bell housing or buy an expensive part to fit the front of the crank. I think you get more HP from a 4.0. If you go ODBI, I can help you with the wiring

It's funny that you mention a XJ motor. I actually have a lead on a complete one from a '92 that is HO with harness. We'll see what MVC says as far as cost of the 4.2/4.0 combo. I like the combination idea of utilizing the benefits of both motors.

[BIGdaddy]

very cool. I'd rock a cj, if i didn't have 3 kids. with the three of you, you should be just fine as far as gear.

I'd recommend a drawer system that slides out below a platform that the dog can sit on. you can put lease/harness mounts on the platform and pad it for your furry friend.

Roof racks are a personal choice, i've found, but check out the Bajarack line that's sold by SierraExpeditions. Its light, strong, and aerodynamic for sure. with that taking your light bulky stuff, and maybe a swing away holding your water supply, you'll probably have a good amount of room inside for food, kitchen, etc...

Good luck, and nice rig so far!

[korisu56]

I will definitely check out their rack. The drawer system doesn't sound like a bad idea. As of now, most of what I need stored in drawers (recovery/tools) is stored in bags and rides almost under the bench. I can take pics if you want of that, but my rollcage elevates the seat of the floor, so if I'm creative I can use that entire area as my "drawer". I will just secure whatever I store there to the roll cage and call it good. We'll see. :)

[korisu56]

Also, I ordered a 5 gallon water jug and holder from okoffroad.com. I was thinking of drilling the can holder just inside the tailgate so all I'd have to do is drop the gate for water. Thoughts?

[BIGdaddy]

Also, I ordered a 5 gallon water jug and holder from okoffroad.com. I was thinking of drilling the can holder just inside the tailgate so all I'd have to do is drop the gate for water. Thoughts?

okoffroad is a great site. I like how all their prices are "out the door" prices, with shipping included...

that seems like a solid plan. When you flip down the tailgate. voila, there's the water. And when the water is stowed, the tailgate is securing it in a sustainable way. (Sitting on the floor,as opposed to hanging 40ish lbs off the outside of the tailgate, if I'm picturing your setup correctly)

[korisu56]

Sounds like you are. When I get back from AZ I should have it sitting there at home. I will attempt to mount it quickly because I have a trip planned from 06-10Jan in George Washington National Forrest. Pics will follow installation.

[korisu56]

Brought the CJ out for a 3.5 days trip in George Washington National Forrest. What a blast.

http://hphotos-snc3.fbcdn.net/hs194.snc3/20150_1301782352054_1455316519_30824804_5485056_n. jpg

http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs194.snc3/20150_1301782392055_1455316519_30824805_1342381_n. jpg

http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs174.snc3/20150_1301781832041_1455316519_30824793_4540564_n. jpg

[wacker12]

What in the world did you do for 3.5 days in GW?

Just messing with you. I use to camp out there a few years back when I was in Maryland. I really like the bench seat, is it Toy, S10? what?

[korisu56]

Haha. Those 3.5 days were spent trying to get firewood. People kinda screwed up by not bringing things that they said they would (chain saw) so we spent lots of time driving up and down Long Run Rd (rd used loosely) looking for wood we can burn. I can crosspost trail report if you think it'd be wanted.

The bench seat comes out of a Mazda b2200. Was one of the best mods I've ever done. Was really comfortable for me and the passenger.

[GPER]

When you do the 4.0 head conversion are you using epoxy or steel plugs to plug the water jacket holes and any ignition upgrades????

[korisu56]

When you do the 4.0 head conversion are you using epoxy or steel plugs to plug the water jacket holes and any ignition upgrades????

This project got dumped due to the cost of it. It was going to run me about 1400 to do it and I found a 4.2 installed for 500. Once that engine is done, I will likely do a 4bt. I know I bounced around, but I will be carrying a lot of weight on that CJ and I think I'm going to need some oomph for it.

We were actually just going to weld the water jacket holes up. For every writeup, there seems to be a different way to do it. I've seen people melt packing peanuts, epoxy, weld, jb, etc. I was just going to weld and grind down, call it good.

[Joaquin Suave]

You might want to look at and possibly reinforce your front frame rails. I was shocked to find that my Scramblers frame was cracked in several places. There are several companies that offer laser cut plates. sorry I don't remember who though.

[korisu56]

No sweat. I met the guy that "rebuilt" it in '02. He had it all the way down to the grill and engine. The frame is still solid, however when I get to my next location I will do a frame off. When I get deployed, I'm sending it to my friends at Mountain Valley Customs in PA to do some very intense expo mods and do exactly this.

[Ford Prefect]

having done it myself in my CJ, I would HIGHLY recommend building a deck over the entire rear end of the jeep. run a two by four length wise down either fender, and then another on each end and perhaps a two by two across the mid section. Use some 5/8ths OSB (or if you can use aluminum) and cover that with some shag carpet. With that setup you will have a very large amount of space under the deck that no one can get into without effort, you have a great place for your dog (which you can put in some I-bolts to hook the leash/belt to) and you have a lot of storage under the back deck. For jeeps, especially a cj, the low COG is an important factor. If you end up still feeling the need to install a rack on top, you will have less up there, and you can keep all of the really heavy stuff inside on the floor.

If you go XJ engine, then get yourself an auto tranny as well. This will change a lot for you with the drive shafts and such, but wow it sure is nice to have that engine and tranny set up. (would love to do it to my cj, but the wires scare me too much.) If you decide that you want more tire space, seriously give consideration to tub fenders. They open up your wheel wells a lot, and still keep the COG low. Gen-right has a really nice "high-line" set up, that if I ever get an unlimited I am going with for sure! You can run 37's on stock suspension! This is not to mention the fact that the entire fender set up costs less than any lift kit would cost to aford the same tire size.

You have a nice setup there, good luck on your trip.

by the by, yeah, all of the Posts are going to charging you five bucks just to use the bay for half an hour, and all of that. Used to work on my car back at Ft. Belvour for free. Sure miss those days.

Brian

[korisu56]

by the by, yeah, all of the Posts are going to charging you five bucks just to use the bay for half an hour, and all of that. Used to work on my car back at Ft. Belvour for free. Sure miss those days.

Brian

When did you work on your car at Belvoir? I used to have a hook up there and used to work on my TJ all the time for no worries. They charged 5 bucks a hour for the lifts and the flat bays were only a buck or two an hour. May have changed.

I'm doing tubes front and rear with YJ HD springs to handle the weight. I'm putting a roof rack on top, but only to handle the relatively light cot-tent my wife and I will use. Fuel and water will be as far below the belt line as possible.

As far as the shelf, I can't do it with my dog's kennel in there. I have two smaller dogs, but leashing or harnessing is an absurd attempt at best. A small kennel that they can both sit and lie down in is the best bet for them, so we're adapting. I'm putting a lot outside though, like a shovel mount (in front of driver door) and my splitting maul will be run along the rear fender. Pics to come :)

[korisu56]

Today I dropped the CJ off for paint and a new-to-me 4.2. I will put a better engine in eventually, but one of those deals fell in my lap that I had to jump on for my April trip. Pics to come of dismantling.

[korisu56]

Went to MVC yesterday. Shane and I broke down my CJ all the way to the basic for paint and engine swap. It's gonna be sick.

http://i299.photobucket.com/albums/mm317/korisu56/P1210010.jpg

http://i299.photobucket.com/albums/mm317/korisu56/P1210011.jpg

http://i299.photobucket.com/albums/mm317/korisu56/P1210012.jpg

http://i299.photobucket.com/albums/mm317/korisu56/P1210020.jpg

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http://i299.photobucket.com/albums/mm317/korisu56/P1210023.jpg

http://i299.photobucket.com/albums/mm317/korisu56/P1210029.jpg

http://i299.photobucket.com/albums/mm317/korisu56/P1210030.jpg

[Tommy6145]

Chris... That cage looks much better then the last time I saw it. I almost wish I had kept it. I like how you worked out the wiper motor issue.

[SKT]

Staying tuned to this build, and looking forward to the progress!

[korisu56]

@Tommy: you should see what I have in store for that cage. I'm modifying it to meet the electrical needs of the CJ. Gotta keep them electrical units dry :)

@SKT: Thanks man. I can't wait to see her again. In a couple weeks I should be going back up to put her all back together. Pics will be posted same day :)

[GPER]

TJ flare are an easy way to open up the wheel wells also, and I see you have manual brakes. You might want to think about power brakes to help stop all of the extra weight. I did the 90 YJ power booster upgrade on mine and am very happy with it. Just a thought while you have it apart here is the link.
http://www.terrainstompers.com/forum/viewtopic.php?t=2992

[korisu56]

Thank you for the insight. I would love to move to a hydro clutch and power brakes, but this engine swap and paint/liner (surface rust on PO's mako showing) has drained my jeep account for at least a few months. Luckily, it's simple enough to get back into and will be replaced shortly.

I'm already set on tubes. They're stronger and I like the all metal look. TJ flares ARE indeed a great way to open the wells up though. The tubes will be custom fit to the CJ, so it won't be a bolt on application without my specific CJ in mind.

Again, thanks for the link. Will put it in my folder for the future.

[korisu56]

Going to get her on Friday.

http://i299.photobucket.com/albums/mm317/korisu56/P3150036.jpg

http://i299.photobucket.com/albums/mm317/korisu56/P3150037.jpg

http://i299.photobucket.com/albums/mm317/korisu56/P3150040.jpg

[korisu56]

The extent that Mountain Valley Customs guys take care of their customers. Do I have a story for you guys today....

I'm still supposed to be camping tonight. I drove the 180 miles to MVC on Friday to pick up my CJ and drive another 180 miles NW to Allegheny National Forest. While at MVC, the CJ got a new-to-me 4.2L and a paint job. Pics will be posted in my build thread later. I was there long enough to bleed breaks and drive the CJ off the lift and onto my dolly.

After the 2nd leg of my trip, I pull into the campsite and link up with Zach (j33per on MJ). I still need groceries so we unload the CJ and fire her up. First time fire, purrs like a kitten. I drive 2 miles and start getting a loud tap and lose all oil pressure. Noooooo!

I call Rob, Matt, and Damien (MVC) and they all immediately start the impossible task of tele-trouble shooting an engine problem. Then the ridiculous part starts:

Matt loads his personal jeep up at midnight with his kid brother and his oldest son and drives the 180 miles out to middle of nowhere to change an oil pump in a field.

They work from 0400-0800 with only breaks being to warm their hands up by the fire. When Matt went to pour the oil back in, we took a whiff and smelled fuel. Not good. Fired up, same noise with no pressure. Weak. I go to take a 2 hour nap and prep for the drive back to MVC. When I get back in reception range, I get a text from Rob to call ASAP.

Rob ordered a crate 4.2L to replace the troubled engine. 4 years/1 million mile warranty to make everything right.

If you've read this far, you know that this was not something that they had to do. They could've just bandaged the motor I bought and sent me on my way.

:beer: Here's to you guys.

[korisu56]

Sooooooo, items done this time by MVC:

- Paint
- Bedliner the interior
- New 4.2L
- Twin stick knobs thrown on there while it was there
- Mounted the water can mount
- Cut the glove box lid to fit
- Relocated fire extinguisher mounts so they were more accessible
- New clutch

While it was there, I came up and helped out on it a couple of times. A few small things I did were to replace all the gauges and lights with some out of a donor. Everything works great now, and she's hoppin and poppin. Great to be driving her again.

http://i299.photobucket.com/albums/mm317/korisu56/CJ%20working/P4100048.jpg

http://i299.photobucket.com/albums/mm317/korisu56/CJ%20working/P4100047.jpg

http://i299.photobucket.com/albums/mm317/korisu56/CJ%20working/P4100050.jpg

http://i299.photobucket.com/albums/mm317/korisu56/CJ%20working/P4100049.jpg

http://i299.photobucket.com/albums/mm317/korisu56/CJ%20working/P4100051.jpg

http://i299.photobucket.com/albums/mm317/korisu56/CJ%20working/P4100052.jpg

[korisu56]

Wow. Been a while since I posted up over here.

It's at MVC getting all new gauges and dash. I need my CJ to be my daily driver and in order for that to happen, I need to know how much gas I have and what the engine temp is. I'm also having the cage done so that I can put a stereo in there and regular seatbelts


the boys at MVC cut away the top three supports for these little guys. The stereo will be mounted here
http://184.72.239.143/mu/aefc63af-4041-c6f8.jpg

The space-inefficient X-member was cutout for a simple harness bar
http://184.72.239.143/mu/aefc63af-4050-4e24.jpg

This shows the original setup:
http://i299.photobucket.com/albums/mm317/korisu56/0717091432.jpg

[sgt rock]

looks like a great project! love the build!!

[korisu56]

Also bought my fridge finally

http://i299.photobucket.com/albums/mm317/korisu56/DSCN1488.jpg

http://i299.photobucket.com/albums/mm317/korisu56/DSCN1489.jpg

http://i299.photobucket.com/albums/mm317/korisu56/DSCN1491.jpg

http://i299.photobucket.com/albums/mm317/korisu56/DSCN1492.jpg


http://184.72.239.143/mu/aefc49ae-c300-840b.jpg

[korisu56]

@sgt rock Thanks buddy! It's a labor of love that will hopefully pick up this winter

[wely]

I have been wondering where u were. Please keep us up to date. Remember we luv pics!

[korisu56]

Thanks wely, it's been slow going this last year. However, I graduate in 10 weeks and my permanent job starts in November. Christmas will be good to us this year hopefully :)

After the dash, cage, stereo, seatbelts, fridge....:

1-Tires & one-piece axles. She needs new ones. Same size will suffice until I'm ready to lift/lock/gear
2-Winch, pullpal and front bumper. Not happy with current one
3-Storage. My grandfather is an excellent woodworker and I would like to learn from him. Will capitalize on this opportunity to build lockable and waterproof storage for our jeep.
4-Rock sliders
5- 3" Black Diamond lift, 32" tires, Ox lockers