Juggy Rebuild

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OrangeSpear
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Juggy Rebuild

Post by OrangeSpear » Mon Mar 18, 2013 12:26 pm

Since the Scrambler build thread, i have been burnt out on keeping a build thread updated.

Well here i am again, and it is time that i share some of the progress on rebuilding my Green Juggy :mrgreen:


List of things to change:
[*]motor swap to TBI
[*]new brake lines
[*]new fuel lines
[*]larger fuel cell
[*]Clock D300
[*]add a fuel pump for the TBI
[*]add frame for belly up skid and add skid
[*]mount Air bumps in front
[*]add front shocks
[*]add front shock hoops
[*]redo the front end/ winch mount area
[*]move old faux air bump cans to rear
[*]new MC and brake booster from a 1995 C2500
[*]redo rear end for holding tools and air tank
[*]redo front suspension - change leafs, all mounts and shave down the power steering ram.
[*]electrical -add lights (rock lights, brake lights, run lights), center console winch control, emergency shut off switch


This is all that comes to mind as of now. This rebuild has been going on since 09/2012

Before rebuild:
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Re: Juggy Rebuild

Post by OrangeSpear » Mon Mar 18, 2013 12:29 pm

{there will be gaps in photographing progress, i just didnt always take a picture every step of the way}

First thing to do was pull the old motor.

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Re: Juggy Rebuild

Post by OrangeSpear » Mon Mar 18, 2013 12:37 pm

These are the Faux air bumps that will be moved to the rear.

Also removed leafs, shackles, and cut off mounts

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New front mounts (hoping that the bump can will be in the correct spot for the new airbumps)
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(hoping that the bump can will be in the correct spot for the new airbumps)

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New 4inch FOA Air Bumps
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Time to remove everything from the rear

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Old shock mount placement. 3 our of the 4 shocks were blown.

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halltrail
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Re: Juggy Rebuild

Post by halltrail » Mon Mar 18, 2013 12:40 pm

Cory, you will have all this done by sat may 5th. Im using the force on you.
99 TJ, 3spd auto, 4.5" BDS Lift, JKS 1.25" BL/1" MML, SYE, 36" TSL Bias, D44 rear - ARB locker, HP44-spool upfront, 4.56 gears, Hydro assist.

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Re: Juggy Rebuild

Post by OrangeSpear » Mon Mar 18, 2013 12:50 pm

New motor with TBI is in. [motor is mounted and attached to Trans. Not wired in yet] Also redoing the front cross member.

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The old 1/2inch thick plate that was used as a winch mount on the front. But it was welded to 2 square blocks on the frame. Didnt seem very safe. So my idea was to use this plate and cut to size and make this the new cross-member.
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Boxing the front in.
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Cross member is in and testing the placement of a front hoop.
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Faux air bumps are out and we are realizing that the cans need to be moved froward 5 inches. well damn
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Soooo out with the Plasma Cutter [i love and hate this tool, The finger of God]
While i was there i cut some frame rot out too.
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New patch welded in.
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Can tacked welded for testing placement
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Re: Juggy Rebuild

Post by OrangeSpear » Mon Mar 18, 2013 12:50 pm

halltrail wrote:Cory, you will have all this done by sat may 5th. Im using the force on you.
The plan is to be at KOH RC on April 11th.

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Re: Juggy Rebuild

Post by OrangeSpear » Mon Mar 18, 2013 12:54 pm

I really need to point out that this couldn't have all been done without those that have come out and helped turn wrenches and help with the electrical wiring of things.

Thank you Ryan and Jason!

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Re: Juggy Rebuild

Post by OrangeSpear » Mon Mar 18, 2013 1:02 pm

New fuel cell, fuel cell mount and rear shocks relocated.

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It was very important to me to have that rear tailgate. I love the look of CJ tailgates and i need somewhere to put my cooker when im on the trail and need a place to cook my hamburger.
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New rear cross member, shackle mounts and shackles in this photo.
This rear 4x4 steel tube with the sticker on it used to be bolted to the rear cross member. Old cross member was cut out. Then we took this 4x4 and cut slots into so that it would slide over the frame and become the cross member once welded into place. [didnt take a lot of pictures of this process and this is actually weeks after the crossmember part had been done.]
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In with the new faux air bump for bump stops and out with the old red bump stops.
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Re: Juggy Rebuild

Post by JeepGuy21 » Mon Mar 18, 2013 1:13 pm

Glad to see that your making progress!

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Re: Juggy Rebuild

Post by OrangeSpear » Mon Mar 18, 2013 1:56 pm

Dana 300 is clocked. I didnt take a photo yet of how much floor had to be cut out for the rotation to fit.

Now that the D300 is clocked the belly up skid frame can go in.
The skid spans 6inches past the rear output all the way up past the oil pan.
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Time to get the front shock hoops in and axle mount tabs.
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BBCS 15inch Shocks
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Also added Drings to the front.
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Re: Juggy Rebuild

Post by OrangeSpear » Mon Mar 18, 2013 2:04 pm

Starting to wire the motor in.
Both shock hoops are in, shocks are in, added 8 inches to the bottom of the front hoop to make it taller to match the height of the grill. [The extension is not butt welded. there is dom inside the hoop and the 8 inches is welded to the original hoop and dom inside.
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Got the Air Bumps charged with nitrogen, Thanks AOI. time to install.
Had to drop the suspension to allow room for them to come in from the bottom.
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Re: Juggy Rebuild

Post by OrangeSpear » Mon Mar 18, 2013 2:21 pm

Next is my arch nemesis.... Brakes.

The original brakes on this was never meant for axles this big, brakes this big, nor tires this big. Thus i never really stopped with much efficiency.... quickly. After much research i decided against going with a HydraBoost setup. I went with a brake setup for a 1995 C2500 with a 'JB6' MC and a dual diaphragm brake booster. I dont remember what the psi is on the booster but it was over double what the original was.

Time to make it fit.
The push rod was way to long and none of the holes lined up.
Drilled new holes.
Cut the rod down to size.
Threaded it and welded the original CJ brake 'O' to the end of the coupling nut. Now the length is adjustable.
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Still dont know if this works, even though i had others with a very similar setup to mine, suggest this setup.
Jeep runs but doesnt have drive shafts yet, so i cant really test the brakes.

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Juggy Rebuild

Post by PINKY » Mon Mar 18, 2013 2:52 pm

Good job
'82 CJ-8 Scrambler 5.0EFI

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Re: Juggy Rebuild

Post by OrangeSpear » Mon Mar 18, 2013 2:55 pm

PINKY wrote:Good job
awww thanks. This wouldnt be possible without support from a super awesome loving wife :popcorn:




score!!!!!!!!!

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Re: Juggy Rebuild

Post by OrangeSpear » Mon Mar 18, 2013 3:09 pm

When im out on the trail, i like to carry tools and spares. So now i need a way to store those items.
In the past they all got thrown in the back and strapped down. I carried a spare drive shaft, spare front L and R axle shafts and one rear axle shaft. Also carried every tool that i could think I may need and an air tank.

Time to make those fit.

Made a rack to hold the shafts (zip ties are for mock up)
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A frame to hold storage boxes.
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Need to make this stuff accessible

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