TECHNICAL FORUMS => Project Builds => Topic started by: ollllllo on July 02, 2010, 09:28:06 PM
Title: CJ Buggy
Post by: ollllllo on July 02, 2010, 09:28:06 PM
My CJBuggy Build thread. I guess it’s a bit over due. But hey, better late than never.
This is technically my 3rd CJ7. It started life as a daily driver from the southern tier. I bought it from a friend of a friend for $400.00 in 2004. He said it had a broken transmission. My buddy crawled under it while I put it in gear, saw that the rear drive shaft was turning. So I put it in 4 wheel drive and drove it on the trailer. Needless to say the owner was dumfounded. It was the typical AMC20 2-pc rear axle that had stripped its splines.
During the early stages of a frame off restoration I found a much better CJ7 tub and frame from Pennsylvania. So this Jeep got shoved out in the weeds.
After I began wheeling my pretty, fully restored CJ7, my non 4x4 having friends wanted to accompany me offroad. That was when I decided to put this CJ7 back together. Utilizing whatever leftover parts I had lying around, the CJBuggy was born.
I had initially figured it would only see occasional use. But it had become so much fun that I found myself driving it more often and pawning off the “Street CJ” to my friends. Then the inevitable happened. During a trip to Rausch Creek, I discovered their plans to start the RCROCS Rock Crawling Series. It was geared towards amateur competitors looking to try out the sport. I couldn’t resist.
4:88 gears, Chromoly shafts, HD Warn hubs, welded spider gears, and 1pc rear shafts were ordered. A 6-point, WEROC spec cage was built. (not a very pretty one) Some 5-point harness’ and we were in business.
Here is how it rolled off the trailer for my first event. • 4” 4WD Hardware HD leaf springs SUA • 35” Mickey Thompson Baja Claws (2ply side walls) • Stock I-6 (140k) Weber carb., T-5 Transmission, stock clutch, stock Dana 300 (w twin sticks) • Stock drive shafts • 8 gal. Summit fuel cell • Fiberglass tub • Dana 30 front axle (Alloy USA chromoly shafts) 4:88’s welded, Warn HD hubs, stock disc brakes, tubes bolted to housing • AMC20 rear axle (Superior 1pc. Shafts) 4:88’s welded, drum brakes, tubes bolted to housing
Title: Re: CJ Buggy
Post by: ollllllo on July 02, 2010, 09:40:43 PM
Ready for RCROCS
Title: Re: CJ Buggy
Post by: ollllllo on July 02, 2010, 09:46:49 PM
As you can see...the Jeep didn\'t like to flex. It was too light. So sometime in the summer of 2009, with the inspiration I received from Smike\'s CJ5, I got the idea to build a custom 4-link suspension.
Up until this point I had always been more of a restore it / buy it type of guy.I had always spent more time researching a part to bolt on than it would have taken me to build it from scratch. But things were about to change.
My photos of the re-build are limited but here is the list.
• Dana 60 front, 35 spline chromoly outer shafts, Yukon drive flanges, 5:13’s welded, stage 8 fasteners, Double high steer arms • GM 14 HBolt rear, 5:13’s welded, • Corvette master cylinder w/ 4 wheel disc brakes • H1 double bead locks with cut Magnesium run flats. • 39.5“x 18” Boggers • Custom four link front, 2”x 2.50” wall DOM links, Johnny Joints both ends • 2”x16” Sway Away Air shocks • Full Hydraulic steering • Propane conversion (complete with AUX input) • Flex a lite electric fans • 1/4” steel flat belly skid • Clocked Dana 300 • 4” SUA rear springs w/ Custom U-bolt flip • 110” wheelbase
Thanks to a ton of hard work from my fellow club members...I made it to BIGDOGS Virgina for the Main Jambo with the now Bigger and Better CJBuggy!
Title: Re: CJ Buggy
Post by: ollllllo on July 02, 2010, 10:16:51 PM
After breaking my T-5 Transmission on the Jeeps\'s maiden voyage, I decided to replace it with an automatic. I just so happened to have another CJ7 parts Jeep with an auto. Here is how we removed it!
Title: Re: CJ Buggy
Post by: ollllllo on July 02, 2010, 10:20:10 PM
Now after a full year of wheeling the New and Improved CJBuggy, it was time for some long over due changes.
First order of business... New Cage!
:gun:
Title: Re: CJ Buggy
Post by: ollllllo on July 02, 2010, 10:31:08 PM
NEW Rockrings while I contemplate cage design!
Hard work on beat up old wheels.
Thanks for all the help Smike! :rockstar:
Title: Re: CJ Buggy
Post by: ollllllo on July 02, 2010, 10:37:29 PM
New Seats!
Title: Re: CJ Buggy
Post by: smichaelR22 on July 04, 2010, 07:25:49 AM
i like the cage lines in front
Title: Re: CJ Buggy
Post by: Wingman on July 04, 2010, 10:58:24 AM
You must have a stockpile of that green paint!
It\'s looking great!
Title: Re: CJ Buggy
Post by: Camo1Ton on July 06, 2010, 11:46:31 AM
I like the return to the rear hoop on the horizontal roof bars. Really sweet job guys.
Title: Re: CJ Buggy
Post by: MrMindless on July 08, 2010, 04:52:09 PM
cage is looking fantastic Erik.
Title: Re: CJ Buggy
Post by: ollllllo on July 19, 2010, 11:02:04 PM
More cutting, notching and grinding tube this weekend.
\"1400 series pumps are identical to the 1300 series pumps in appearance, but the looks are deceiving. These pumps are manufactured with completely different internal components than the 1300\'s. The heart of the 1400 pump is a larger ring and rotor which displaces more fluid per revolution. This makes this pump the pump of choice for Rock Crawlers that operate at low engine RPMs and have extensive steering modifications.\"
And Im switching to Synthetic Power-steering fluid
Title: Re: CJ Buggy
Post by: ollllllo on July 28, 2010, 05:29:29 PM
New propane tank mount. Previous version had support bars extending out to rear down bars and it prevented me from putting much of anything behind the seats for trail riding. (cooler, grill, etc.)
Title: Re: CJ Buggy
Post by: ollllllo on July 28, 2010, 05:32:36 PM
More cage work!
Title: Re: CJ Buggy
Post by: ollllllo on July 28, 2010, 05:46:19 PM
Progress!
Additional support & start of seat sub frame. Now that i have some tabs to work with im thinking i will need to re-make the front cross tube in order to raise the seat front. Its too low right now.
Title: Re: CJ Buggy
Post by: ollllllo on July 28, 2010, 05:48:46 PM
as it sits today!
Title: Re: CJ Buggy
Post by: JCJ on July 28, 2010, 10:42:35 PM
That\'s pretty slick, cant wait to see it in action..
I\'ve got a feeling that hanging out with you guys is is going to coast me a ton of money.. :hook1:
Title: Re: CJ Buggy
Post by: Wingman on July 29, 2010, 06:16:34 AM
Consider it an investment...
Nice job, Erik!
Title: Re: CJ Buggy
Post by: jimsh on July 29, 2010, 08:21:30 AM
The build looks awesome, eventually i\'ll be able to check it out on the trails. Maybe the next time you guys go down to north cumberland, I would really like to see it before they build it.
That ton of money issue has crossed my mind.
I\'m giving serious thought to not building my tj and starting on a buggy. It is looking like it would cost me less over the long run.
I sense my wife is not going to be very happy about these thoughts. lol
Title: Re: CJ Buggy
Post by: ollllllo on July 29, 2010, 09:25:49 AM
Yes, it would definetly be more economical to build a buggy than a TJ, but then unless its a street legal buggy, you have to tow it everywhere. I do enjoy my other CJ7 that is street legal and fairly capable off road. Driving on a weekend, local wheeling, and maybe some fingerlakes scuba diving. But in the end...they are still both always gonna be CJ\'s.
Title: Re: CJ Buggy
Post by: MrMindless on July 29, 2010, 01:14:25 PM
Cage looks mean, I like it.
Title: Re: CJ Buggy
Post by: ollllllo on July 31, 2010, 09:42:59 AM
Take two. This design allowed me to recline the seats for a more comfortable position. Harness mounts are installed also.
I had a friend stop over and ask how come I hadn\'t used \"double shear\" tabs for my seats? He said its the norm in stock cars. Now I can understand why some racing organizations might require them on harness mounts, but seats too? Anyone ever hear of that?
This JEEP sees mostly trail riding and the occasional Rock Crawling competition, I didn\'t feel that Double Shear tabs were necessary at such slow speeds.
Title: Re: CJ Buggy
Post by: ollllllo on July 31, 2010, 09:54:52 AM
Cage is done (for now) and painted!
Probably going to add door bars in the near future.
Off to get the inside of the tub sprayed with bed liner...
Thanks Custom Truck Creations!
Title: Re: CJ Buggy
Post by: smichaelR22 on August 01, 2010, 04:35:18 PM
looks good!
Title: Re: CJ Buggy
Post by: gmshades on August 01, 2010, 05:47:02 PM
That\'s one killer project! Hopefully I\'ll get a chance to wheel with ya, when I finally have a motor back, haha.
Title: Re: CJ Buggy
Post by: smichaelR22 on August 02, 2010, 07:23:36 AM
what did you use for cage paint? i rattle canned the buggy in a hurry and it looks like junk (like i new it would) after the race...
Title: Re: CJ Buggy
Post by: ollllllo on August 02, 2010, 01:37:47 PM
Nason by DUPONT 422-05 Chassis black
Prob got it from NU-Way at some point during one of my CJ rebuilds. 3 chassis & misc cage painting and I still have about 1/3 gallon left. Its amazing stuff. flows like water into every nook & cranny with a brush, yet dries like glass. looks like you sprayed it when your done. I painted by Buggy cage 3-4 years ago, and only now did it finally need another coat. and thats after trailing it open during the winter too. Salt sux!
Title: Re: CJ Buggy
Post by: Camo1Ton on August 02, 2010, 08:42:26 PM
Its got some real attitude now. Looks awesome
Title: Re: CJ Buggy
Post by: ollllllo on August 02, 2010, 10:43:35 PM
[color=009900]Thanks Guys! [/color] Worked hard on the cage design.
Tonight was plumbing the new PSC Hydraulic steering system.
Replacing one of the electric fan blades, a fin broke off one last trip to rausch. (good thing its a twin blade setup, i just un-hooked the broken fan and wheeled the rest of the day with only minor cooling issues.
Another long overdue project... was to remove the Highsteer arms. I bought them last year right before Big Dogs Main Jambo Trip to WInchester, VA but (I believe it was Mindless that pointed it out) the bolt holes that attach them to the knuckle were not countersunk from the manufacturer. As Mindless explained, similar to a wheel lug, without the taper to the bolt hole and nut, there would be extreme lateral force applied to the studs. HUH! I never would have given it a thought. Thanks Mike. So without the proper size countersink at the time, I bolted them up and we went wheeling. Everything seems to have held up fine, but upon removal, I found that one stud was slightly misaligned with the holes in the arm. But it was easilly persuaded back in-line. A quick call to the Victor Fastenal store, and I now have nice counter-sunk holes!
Check out the size of that countersink! 3/4\" - 1-1/2\"
Title: Re: CJ Buggy
Post by: ollllllo on August 02, 2010, 10:48:09 PM
By the way...
Royal Purple Synthetic Power Steering Fluid comes in PINTS not Quarts.
Buy extra, I didnt!
Title: Re: CJ Buggy
Post by: ollllllo on August 02, 2010, 10:51:33 PM
Best center console EVER! 5 bucks @ Garage sale!
Title: Re: CJ Buggy
Post by: gCracker on August 03, 2010, 08:13:48 AM
Looks like elbow banging territory???
Quote
ollllllo wrote: Best center console EVER! 5 bucks @ Garage sale!
Title: Re: CJ Buggy
Post by: ollllllo on August 03, 2010, 10:50:30 AM
Nope its at the perfect angle and height.
I have been running this same box in the buggy since I built it. Previously it was installed level and worked out very well. It only takes a new passenger once or twice hitting their elbow and then they remember its there.
I\'m so used to it, I love it. You could fit a small body inside, and it would never open even if you roll. LOL
Just need to figure out drink holders now!
Title: Re: CJ Buggy
Post by: MrMindless on August 03, 2010, 10:59:33 AM
do you have enough shifter room to stick something to the bottom of the box?
I run a cooler in the Dakota in the same place, I\'ve been meaning to throw a couple Bar Bouy type drink holders on the front of it....
Title: Re: CJ Buggy
Post by: ollllllo on August 03, 2010, 11:46:34 AM
I had bar bouys in my boat. They were amazing how well they worked. But that is prob what I\'m gonna do.
I miss my boat... :storm:
Title: Re: CJ Buggy
Post by: ollllllo on September 04, 2010, 09:51:27 AM
Well its finally time to start the rear 4 LINK suspension!
at least the springs broke on the last day of a 3 day weekend of wheeling.
I loosened the U-bolts and pinched one of the broken leaves within the remaining leaf pack and used it as a sort of splint. I attempted to weld the leaves together to make one main leaf, but I was soon reminded how spring steel reacts to welding. I made it 10ft down the trail and everything fell back apart!
so the final rescue design consisted of one 1/4\" bolt drilled through the leaves, two ratchet straps, and a 6\" c-clamp.
We were on Cemetary trail which is on the South property of Rausch Creek ORP, so the ride back to the trailer wasnt terrible but it was long and slow! The whole recovery & repair took about 2 hours.
Title: Re: CJ Buggy
Post by: ollllllo on September 04, 2010, 10:18:46 AM
I chose to go with RUFF STUFF Specialties 4 link kit.
they offer the kit with either tube chassis brackets or square frame brackets. It also includes an axle truss. (i haven\'t received it yet) I chose to use 2\" x .250\" DOM tube for links to keep them the same as my front links.
Title: Re: CJ Buggy
Post by: Camo1Ton on September 04, 2010, 12:18:51 PM
I was just checking out their kits last night. Sounds like a good setup. Can\'t wait to hear more about it, first hand info on install and such. What size heims are you using?
Title: Re: CJ Buggy
Post by: ollllllo on September 04, 2010, 05:38:56 PM
Im using RuffStuff\'s 1.25\" Heat & Cryo Treated Chromoly Heims with Stainless High Misalignment, Zink Plated Jam nuts, and 1.5\" Tube ID Weld Bungs. They are part of the kit.
and I think its safe to say I\'m now a tad beyond the point of no return! :hack:
Title: Re: CJ Buggy
Post by: Wingman on September 04, 2010, 09:00:40 PM
Ha! That point came and went a long time ago. :bike:
Title: Re: CJ Buggy
Post by: ollllllo on September 07, 2010, 04:34:29 PM
