Grant's 1973 CJ-5 rebuild on a $1000 budget challenge!

[RustyAutoholicGuy]

Hey Guys,

I got my 73 CJ-5 over the weekend knowing it had bad rust on the body, I thought it was going to be something I could easily cut out and repair, but its not. However I think I can get it back on the road and safe. So here is the challenge!

TIMELINE:
12/20/2013 - Video walk around of the 1973 CJ5
12/23/2013 - Drum Brakes Part 1 - Front Drums
12/29/2013 - Moved the CJ-5 into the garage and I got more parts!
12/30/2013 - Decided to repair the CJ-5 body and estimated budget update!
12/31/2013 - Disassembly begins!

With a budget of exactly $1000, can I get this Jeep CJ-5 back on and off the road running safely?

I have to admit this is very ambitious of me to be trying but I'm up for the challenge. I have some advantages going my way, I own most of the tools I need, I have a welder, air compressor with assorted tools, so that will cut down on cost significantly. So first here are some pictures of what I am working with:

Me being a positive person, I am going to go with what I have going for me so far:

The Good:
New Battery
New Radiator
New Stainless Steel Brake Lines
AMC 232 I6 starts and runs
3-Speed manual transmission works
Transfer Case works
Dana 44 in the rear works
Dana 30 in the front works
Frame is solid surprisingly just a little amount of surface rust
Tow bar

The Bad
Engine has a miss
Body is beyond saving
Brakes haven't been hooked up
Tires are bad
Its leaking gasoline from the carburetor.
Alternator is probably bad
Gastank looks really rusty
No Vendors
No Tailgate
Roof leaks . . .

I'm sure I will run into other problems but that is what I currently have to work with at the moment.

The biggest problem right now is the tub. I was going to get another CJ-5 body but I've decided I'm going to take the plug and do my best to save this one. Should be interesting!

Again starting today I'm limiting myself to $1000 to get this Jeep running safely again. This means no upgrades really, resorting to going to junkyards to find some parts, searching craigslist for deals, etc.

The biggest problem right now is the tub.
Also I will be setting up a Justin.tv account and I will be streaming live every time I'm in my garage working on the CJ-5. Not sure if anyone would be interested in that, but I thought it would be something interesting to try.

Let me know what you think!
-Grant

 

[HAPPY]

I'm watching this build. You will be surprised how resourceful you can be when you have to. lot of your issuees can probably be solved with just a thorough cleaning and minimal parts purchase. Good luck!!

 

[cj777]

Looks like a great project. Reminds me of my '74 when I first got it. I will definitely be watching this build. BTW, I've got a gas tank for a cj5 you can have if you want it.

 

[RustyAutoholicGuy]

I'm watching this build. You will be surprised how resourceful you can be when you have to. lot of your issuees can probably be solved with just a thorough cleaning and minimal parts purchase. Good luck!!

I agree! Its going to take a lot of time to get this CJ5 back on the road safely, but I'm confident I can do it!

Looks like a great project. Reminds me of my '74 when I first got it. I will definitely be watching this build. BTW, I've got a gas tank for a cj5 you can have if you want it.

Yes please that would be a great! Mine is really rusty, and I'm worried about the inside of it was well! I can't thank you enough!

 

[RustyAutoholicGuy]

First video of my Jeep CJ5 . . . so you can see just how rough it is!

 

[RustyAutoholicGuy]

Hey Guys,

Got all the parts to do the brakes this weekend. I've got the front on and now have to take a look at the back. I made the decision to spend the money to do the brakes correctly, which set me back about $140 in my budget, I'll get the exact figures later today because I have to return some of the brakes back for core cost etc.

First off let me say I've never really done drum brakes before. Most of my vehicles have been newer or my best friend that has taught me almost everything about cars usually does the drums for me because we tag team working on our vehicles.

First off, the front took me way long than I expected, and because to me brakes are the most important part of any vehicle build, I decided to go brand new for everything, might not have needed to do that but when it comes to safety I decided it was worth it. Also I decided to something in this build which will probably blow out my budget completely but I just don't care. I'm going to be replacing every single bolt I take off the Jeep with a Stainless Steel bolt so I don't have to worry about them rusting anymore. Here is what I bought:

2x Drum Brake Hardware kits for the Front and Back
2x Drum Shoes, one set for the front and one for the rear
4x Drum Brake Wheel Cylinders
2x Brake Lines for the rear, truck came with new ones for the front
4x Stainless Steel bolts for the wheel cylinders (front only so far)
Carburetor Gasket
Carburetor Rebuilt Kit
Haynes CJ5 repair manual
Brake Parts Cleaner

I have to admit getting the front drums tore down took way longer than I expected. I've never dealt with locking front hubs before and they were so dirty that I couldn't see all the flat head screws that keep them on locked onto the axle shaft (apologies if I'm calling the parts wrong). Next I had to deal with spindle nuts that had been beaten to crap at some point in there life. Also there was no gasket on the locking hub either and I don't have any so I will be having to get some as well. Also I need to repack all the hub, etc with new grease which I didn't have because I didn't know I would need it to get into the drum brakes. Here are some pictures before and after. The old brakes actually looked good, but I just didn't want to risk them not working so I replaced everything.

And finally it put back together for the passenger side

By the time I finished the other side it was dark but I'm going to have to tear back into the drums, I know I don't have them set correctly, and I have to repack everything with grease, so I will get more pictures then!

Thanks to a member on here I will be getting new spindle nuts as well which I will be installing as well! I will be posting more information and pictures soon!

Thanks
Grant

 

[RustyAutoholicGuy]

UPDATE!

I found a complete Felpro Engine Gasket Kit on eBay for a total cost of $40 shipped! I need to update the budget but I believe I have spent right at $200 bucks right now, which to me is worth it, again I don't regret replacing what I did on the brakes. Also I got my DD rebuilt and is finally out of the garage, so today I moved the CJ-5 into the garage, the battery died on me so I had to glide it into the garage, here is a video of my wife filming it.



Thanks
Grant

 

[GotWood]

Looks like a great project. If you were closer, I'd donate a battery to the project. Of you know anyone traveling thru the Hickory area let me know and i could meet them.

I will be the first to rain on your parade though... The budget is a great start but obviously you have never owned a Jeep (Just Empty Every Pocket) before. I have no doubt you can reach your goal within or close to your budget, but don't ever think you will "finish". The first day you drive it down the road and hit a trail it will be fine, but the second time your mind will wander into the realm of the dreaded upgrade, and at that point it is over! There has never been a Jeep on this site that was finished.

Good luck, and I hope to see you on the trail someday.

 

[RustyAutoholicGuy]

I think I do know someone in Hickory so that is highly appreciated! I've actually owned a 99 Cherokee before but I never got to off-roading that truck, it always stayed on the road as it was my Daily Driver. I've been debating just getting another tub for this thing but I was looking at it tonight, I need to price the metal, but I might just try to salvage this tub, cut out the bad and weld in new!

 

[RustyAutoholicGuy]

Yet another update! I will be posting a budget up later today/tonight when I get a chance. Here is my rough estimate on my budget so far!

125ish for all new brakes. I needed it and I feel better knowing I have brand new brakes on the entire Jeep.
$40 on Felpro Complete Engine Gasket Kit. I got this on eBay and it was Best Offer, I got it for $40 shipped.
$60ish for Haynes CJ5 manual and carburetor rebuild kit, though I might be returning the carb kit I'll explain later
$100.13 4 feet x 10 feet 20 gauge sheet metal being shipped to my house.

325.13 ish out of my $1000 budget which leaves me with about 675 left in the budget to get this CJ5 back on the road.

I decided last night I would save my CJ5 body and do all the rust repair. I have a welder, I have cutters, and when I found a 4 feet x 10 feet piece of sheet metal for right at $100 shipped I knew that was going to be the way to get to get the body of the Jeep fixed. That should be more than enough metal to fix everything on the body.

I'm picking up a bead roller and bender brake so I can shape the sheet metal and give it more strength. This will also allow me make a new battery tray for my CJ-5 as well.

While I wait for metal and tools to come in, I will be pulling the 258 out and rebuilding it. While I have the engine out of the Jeep I will probably lift the body of the frame so I can clean the frame up and hit it with paint to prevent anymore rusting.

I'm trying to figure out the order in which I will be doing all of this. Right now the engine runs really rough and leaks oil and coolant badly so I want to get that fixed before anything else. I think being able to move the CJ5 around on its own power is one of the most important things right now. What do you guys think?

-Grant

 

[HAPPY]

Well it needs to run pretty good to put it on the road / wheel it. I would say go ahead and get that sorted out. That may take most of the remaining budget, depending on what needs replaced.

 

[RustyAutoholicGuy]

Well it needs to run pretty good to put it on the road / wheel it. I would say go ahead and get that sorted out. That may take most of the remaining budget, depending on what needs replaced.

Well in a way I lucked out. The Jeep already runs, granted it has a minor miss to it, but it does run, and there are no knocks in the motor. Also the oil pump seems to be great because when I go to crank it, after about 1 ~ 2 seconds the oil light goes off in the CJ5 so I'm thinking its in ok shape. I think I'll get the motor rebuilt for under $200 honestly.

-Grant

 

[HAPPY]

Go through the ignition system before you tear the motor down. It could be something as simple as a plug wire or plug problem.

 

[RustyAutoholicGuy]

Go through the ignition system before you tear the motor down. It could be something as simple as a plug wire or plug problem.

All the ignition looks new, and the engine is leaking oil pretty badly as well, so this a great time to take it apart and see how it looks!

-Grant

 

[RustyAutoholicGuy]

Hey Guys,

So today was a great day! Went to harbor freight got a cherry picker, picked up an engine stand yesterday, and I started tearing down the engine bay. I have to say this is the SIMPLEST vehicle I have ever worked on. I just need to pickup a chain set from advance auto parts tomorrow and I will be able to pull the engine out tomorrow! Here are some pictures of my progress!

Thanks
Grant

 

[HAPPY]

Does that Pole Position game in the back ground work?

How much was that cherry picker? I need to pull the motor in my Galaxie for rebuild and I need to pick one up also.

 

[BUCKEYE PERFORMANCE INC.]

I have a new set of front cj-5 floor pans that im sure I could let go cheap if your interested.

BUCKEYE PERFORMANCE INC. 828-779-2242.

 

[RustyAutoholicGuy]

Does that Pole Position game in the back ground work?

How much was that cherry picker? I need to pull the motor in my Galaxie for rebuild and I need to pick one up also.

Yes and no, it sometimes work, I just got it in and I haven't had time to rebuild it yet. Such a great game though! I had a coupon for Harbor Freight so it was $139.99 before take which I thought was a great price!

I have a new set of front cj-5 floor pans that im sure I could let go cheap if your interested.

BUCKEYE PERFORMANCE INC. 828-779-2242.

Heck yes I'm interested I will give you a call tomorrow! Thank you so much!

-Grant

 

[HAPPY]

Do you restore and sell games? Or just collect? I have thought about hunting a few for the cave.

 

[RustyAutoholicGuy]

Do you restore and sell games? Or just collect? I have thought about hunting a few for the cave.

Both actually, I'm looking to reduce the number of games I own, mostly because I don't play most of them, I have about 25 ~ 30 right now. What are you looking for?

 

[RustyAutoholicGuy]

Another update. So after looking up the VIN with a decoder turns out I have a 232, not a 258 like I thought, so its only a 3.8L not a 4.2L, thankfully the engine gasket kit I had purchase fits both motors!

 

[RustyAutoholicGuy]

MAJOR UPDATE!

So due to my parents getting a divorce and having to help them both move out of the house, I got side tracked. Anyways I snagged a very nice score two days ago for this CJ-5 Build, though its eating the majority of my budget, but I think its completely worth it!

Fully Dressed and running 258 out of a 82 CJ7 for $100

 

[grapehead]

that 258 will save you time and money, but is the ignition setup the same? when did they switch from points to electronic ignition?

where in durham are you? my shop is near 70/98, i am usually up there on weekends, i'd like to see this thing in person.

 

[RustyAutoholicGuy]

that 258 will save you time and money, but is the ignition setup the same? when did they switch from points to electronic ignition?

where in durham are you? my shop is near 70/98, i am usually up there on weekends, i'd like to see this thing in person.

I'm right off Old Oxford Rd. I should be home Saturday Afternoon and Sunday morning if you want to come stop by! Warning my garage is a complete bomb right now, trying to get everything cleaned up and out of the way so I can work on Jeep again :-(