This is a very exciting new build for a gentelman in Idaho.  In the upcoming months this beauty will be fully torn down and rebuilt to his wants with our input. 

It already features a completely rot free body and the sought after Dana 44 Rear differential.

It ultimately will have all 3 seats heated, a small lift and a 4.6 Liter stroker motor with EFI!

Please follow along!

10/17/12...Getting started

(showing off our new to us forklift)  The fellow walking away is my 86 year old father who is the shop supervisor and part of the reason we moved the shop to be closer to he and my mom.

He's a little camera shy ;)

The lift does what we wanted it to!

Ok, get to work....  The new shop is laid out for business.  3 lifts and tear down bins, parts shelves and rebuild carts.  More lighting will be coming in the next few weeks.

The shown Scrambler will be starting one step behind the 86 CJ7.  It is another fun build with some unique customer request to make a one of a kind head family head turner!

The pallet racking and parts bins are full up on only 76 to 86 CJ parts...

Work starts...10/16

In the tear down process we document each item needed for going back together so hopefully it minimizes waiting on parts.  With the new shop we have more space to store new parts.  Therefore we hope to buy most needed parts up front to minimize waiting time and potentially shorten the time this family is waiting on their vehicle.  That said, my shop isn't about speed or hard delivery times.  We want to be efficient but we do this because we enjoy it and it needs to be right as we want to be proud of what we deliver. 

If we wanted a lot of stress and forced hard deadlines making compromises of quality for profitability, I'd go back to the global custom automation business I was tenured in that I left on my own terms to do this.  That company changed leadership 8 years into my employment and focused on growth to satisfy shareholders and compromised quality. It suffered because of this and became a bad and unhappy place to work.  People want to do a good job and be proud of what they build and business will follow.   

Fyi, I am an OSU business graduate and mybackground is working with robotics and multi million dollar custom assembly equipment.  I worked as a mechanic while attending college. 

We may take time away from each project to do something else just to stay fresh.  This isn't to say we want jobs lingering endlessly at all.  We just want it right and to enjoy the job at hand!

The above comment is directed to no one other than just setting a tone for what our shop is about.  This customer has given us ample time to build a Jeep to be proud of for life and that is our goal.  If it comes together quickly, that will just be a product of planning, experience and a bit of good fortune.

10/16/12  One day of disassembly...

 Perfect rot free body...  They tear down so much easier that starting with something rusty. 

Items to go to sandblast...

Items for subassembly rebuild...  (steer column, heater box, PS pump, driveshafts, etc...)

 10/17  Tear down completed

No rot CJ!! Just grease and some undercoating and only minor surface rust.  No bubbling!

Both differentials largely stripped and ready for blasting and chassis paint.  Love that widetrac 44! (close one)

Done at sandblast! Beautiful straight, clean sheet metal to build a better than new CJ.

Super hard chassis black paint applied to all non cosmetic parts

Original stright floors!

New Golen built 4.6 Liter AMC/Chrsler hybrid engine.  This engine will rev quicker, run smoother and provide considerably more HP and torque than either the tough 4.2 or the proven 4.0.  It also is largely a direct bolt in and looks original.  This engine has a 3 year unlimited mile warranty.  I am admitedly excited to fire this up!  I've had a home built stoker before and loved it.  I expect this one to be even better as I know the compnents are superior. 

If you choose to contact Golen from this info, Please do us a favor and let them know you saw it here.  We small businesses need to network to survive and thrive!

More info about Golen c....

Pro turned flywheel with a new ring gear installed ready to install

New Poly lifetime engine mounts and the ever important HD ground strap with external lock washers bridging the engine to the frame so we don't have electrical grounding gremlins later ;)

 New Centerforce clutch installed which will handle the additional horsepower of the stroker engine.

You'll notice the oil filter in place....Ok, not a big deal but as you do these hybrid swaps there are some things that take time....like getting the right valve cover for the 4.0 head, and the oil filter adapter.  We were told to use all our 4.2 parts but you must use a 4.0 filter adapter and 4.0 oil filter.  The 4.2 adapter and 4.2 filter aren't made right for the 4.0 block.  The 4.2 oil bypass is in the block and not in the filter.  The 4.0 oil bypass is in the filter....good to know.  We had to figure this out for ourselves.

Lots of bling on this engine per customer request....  100 amp one wire alternator and chrome Saginaw keyway alternator.  Lots of replaced grade 8 bolts throuout and painted parts for detail sake.

We also purchased a new thermostat housing which will have a port for temp sender for the electric fan(s)

New Banks Stainless steel header being used with the original 4.2 intake and power steering brackets. 

We are using the 4.2 intake so we can run the simple and proven Howell EFI.  That said, the widdling reqired on the PS brackets and the fiddling to get the intake in place correctly was somewhat maddening.  Notice the custom washers for the increased gaps between the intake and exhaust bolts as the originals are way too small to bridge the gap and vacuum and exhaust leaks are maddening...

Now that it's in place we're in great shape but if I had it to do over, I would have used the more expensive and complicated Mopar port fuel injection kit due to the intake manifold.  I wasn't made aware of the fitment issues up front but it is behind us now.

Clearance is clearance....

New Stainless lines....  You'll notice the strap on the lift.  That is to keep the frame in place as the frame is front heavy and may want to fall off of the lift otherwise.  It is a precaution. 

The shown valve cover has been a nuisance in that the 4.0 valve covers either say 4.0 on them or are extremely dull in appearance.  We opten for this early flawed version of the 4.0 because it can be stipped of it's marginal factory paint (chipping in the box) and have the integrated rubber seal removed.  We opted for the $45 dollar valve cover gasket over the $5.00 one for years of leak free use.  Notice the cover blasted and the new gasket....

 Jeep tub in primer and just about ready for paint!

New USA Made HD U-joints made by Moog. One of the few companies not to sell out to China. Pay a little extra, get a little more and support the home team.

 11/16/12

Installed in both front axles and driveshafts...

Rebuilt T5 transmission ready to go in...

...and Dana 300

We're using a BDS 2.5" lift kit because it comes with military wrapped springs and doesn't ride like a stagecoach.  Lastly, their springs and components are North American made where some of the other lifts like Rubicon Express are now Chinese.

The paint on springs from the manufacturer is sfficient for something that doesn't get seen but we want a longer lasting finish so these are fully blaseted and hard coat chassis painted for life. 

Before picture....

Springs, u-bolts, hardware etc come with identifying stickers from the manufacturer in the new kits.  You will often see these under a newly lifted Jeep and they look like you didn't care.  Take a few minutes with some Goof Off or Acetone to clean these parts before you bolt them on...  Before and after pictur shown...

Installed Photo of blasted and hard painted springs, new grade 8 hardware from Rudy w locking nuts, HD Spring Hangers and HD short Shackles.  T5 Transmission and Dana 300 also installed with crossmember.  Body should be back from paint very soon! :)

NOTE: ALL PHOTOS CAN BE ENLARGED IF YOU MOVE YOUR CURSOR OVER THE BOTTOM RIGHT AND CLICK

Things are looking good with all new Grade 8 hardware, bushings and parts installed. It takes a lot of stocked hardware to restore a Jeep!

Note the engine is always covered when it isn't getting a photo shoot ;)  You need to make sure debris doen't enter the engine via the carb intake or the oil ports in the head...

 12-5-12

We finally got the valve cover back from machining.  All 4.0 valve covers either say "4.0" on them or are very bland so we bought an early cast unit and had it engraved to quietly and tastefully denote the actual displacement of this custom engine.  Also attached with SS button head fasteners

Throttle body and SS K&N air filter installed...

Dana 30 front differential fully rebuilt with all new bearings, seals and spider gears...

All new CV USA made CV joints, ball joints and tie rod ends.  Also sway bar links with poly bushings...

The customer wanted extra braking power so we have picked up a set of USA made slotted front disk brake rotors now installed with all new USA made Timken wheel bearings, spindle bearings and seals.  It should help the Jeep stop a few feet shorter than stock. 

We have installed new premium Superwinch lock outs which is a mistake on my part and they will be removed. Hopefully someone will learn from my error that I knew better than to do. This Jeep is getting stock Laredo chrome wheels and this lock-out has too large of a profile at the end to fit thru the stock AMC center cap. These Superwinch hubs will work with common aftermarket wheels with a non-tapering center cap.   The originals were in good working order and this Jeep won't be used in hardcore offroad situations. 

1/8/13

Baby steps..  Back at it.  Rear brake linesandc  over installed... Retainer clips on order.

Rear brakes Done with all new hardware, riveted brake shoes and sandblasted hard parts where appropriate.

Note it's a good idea to use some antisieze on the self adjusters for long life of movement.

1/11/13

New ceramic (why Ceramic?  Because they don't produce brake dust like other pads and therefore the wheels stay clean).  Also, reman calipers and Stainless steel brakelines.

Almost did a "file photo" from the other build but that would be weak....  We use synthetic caliper grease on the slider bolts for long life...

Detail stuff.  Cool little original decal for the lock out hubs. 

Before picture (without decals)

After:  With decal and brakes...

1/14/13

Shocks installed

 1/23/13

Some new shoes (tires) for this sweetheart...

Some gorgeous original Laredo wheels and center caps from this Jeep all cleaned up and ready to install...

New U-joint caps and bolts for the install of the driveshafts...

A few gratuitous shots of the driveshafts installed.  Keep in mind this Jeep is a Rudy's CJ all original sheet metal.  This customer had the wisdom up front to 'start with a little more Jeep than most'....meaning not start with something rough. 

Note I finally got my stainless hes plugs in for the differentials...

Some sheet metal going on...

And showing off the new tires and installed wheels...

This body squared away for install on the frame quicker than any before.  A little antisieze on the body mount bolts...

1/27/13.... and off to Linex...

 3/5/13

Doors hung!  The customer requestd a full compliment of stainless steel accessories.  Kentrol is the premium product in the ss market and all we use for a build of this quality.  They fit better, have a better shine and generally include better fasteners.  In general, just better.

YJ family style sport bar installed per customers request

New tail lights and ss accessories...

Windshield frame, new wiper motor, linkage, cowl seal and hinges installed.  Also, washer squirter, new hose and some duct work

3/6/13

Heater ductwork not just installed but restored.  New heater core and new heat tape everywhere to promote better than original airflow. All internal cables and ducts lubricated for smoothest operation possible.  Also, note the computer for the new fuel injection tucked away in the stock holster where the antiquated original 1986 computer originally went.  This will keep it clean and dry and reasonable accessable. 

 3/7/13

Tailgate installed. Well gapped with all new hardware and seal.

Fender support cross braces installed and customer requested stainless battery tray.  Original wire loom support painted and installed.  Also original jack and mount.

Rampage H4 headlight conversion as the customer requested better headlights than stock for the darkest road trips.  The advertisement is up to 60% more light than conventional sealed beam lights.  These bolted right in and use the stock wiring.

3/16/13

New radiator finally installed.  We started with an electric fan unit from Summit racing that I was pretty sure shouldn't fit but the catalog and salesman insisted would.  Yeah, not even close.  The 6 cylinder engine is just too long.  We have now opted for a USA made Griffin aluminum unit and new mechanical fan with thermal clutch.  The pros are consistent operation as I've seen many engines ruined by electric fans that fail. 

Even this unit required custom install although as it was plenty thick. 

The below is what the fan shroud on the left originally should look like and the one in the right is the modified unit so that it sits flush against the radiator. 

Installed

The above build documentation got cut short due to a need to accelerate the build schedule.

The below photo was sent by the buyer from Idaho about a year after I delivered it.

I heard from them 3 years after it was delivered and they said it's running better than ever!