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Thread: CJ7 Re-build V2

  1. #131
    My Offy and headers are back from coating! Nice job considering the shape they were in.

    Sent from my Pixel 2 using Tapatalk
    1985 CJ-7 Custom (Flat fendered CJ,YJ,XJ,TJ...)
    Picked n Parted 1987 YJ
    Sold 1998 XJ
    RIP 1981 CJ-7 Limited Edition Laredo

  2. #132
    Header and manifold installation on the IL6 258. Turned out to be a bit of a challenge to get them both to seal up against the gaskets. The manifold flange is thicker than the header flange and 8/12 fasteners bridge both flanges.
    They were held down by rusty grade 5 hex head bolts and stacks of 7/8 and 1" bent up washers. Not very effective and ugly. The exhaust gasket failure was below the worst two of these washer stacks.

    I tried trimming down some thick lock washers and grinding washers to fit. Half way through the install they were slipping and popping off the flange. That's not going to hold long under heat and vibration.

    Back to the drawing board.

    Needed something to make up 3/32" difference between the two flanges to give equal pressure and a flat 11/16 mating surface for the bolt head.
    For strength I wanted at least 1/8" thickness over the aluminum manifold flange. I'm going with stainless bolts (12 point) so 316 stainless is my choice for the new washers.

    A little mockup, a sketch, and call to a jobber resulted in some pretty slick little shim washers. Finish was rough with tooling marks everywhere. Undercut was sloppy. But I got them fast.

    Sent from my Pixel 2 using Tapatalk
    1985 CJ-7 Custom (Flat fendered CJ,YJ,XJ,TJ...)
    Picked n Parted 1987 YJ
    Sold 1998 XJ
    RIP 1981 CJ-7 Limited Edition Laredo

  3. #133
    The part is 1/4" thick.
    Needed some cleanup.
    One would need some additional material removal to bring the undercut into the bolt hole.

    I picked up longer bolts to compensate. I was worried about clearance on 3 of the 12 fasteners but made it work with wrenches.

    Worked out pretty well.

    Sent from my Pixel 2 using Tapatalk
    1985 CJ-7 Custom (Flat fendered CJ,YJ,XJ,TJ...)
    Picked n Parted 1987 YJ
    Sold 1998 XJ
    RIP 1981 CJ-7 Limited Edition Laredo

  4. #134
    Fit in place...

    Sent from my Pixel 2 using Tapatalk
    1985 CJ-7 Custom (Flat fendered CJ,YJ,XJ,TJ...)
    Picked n Parted 1987 YJ
    Sold 1998 XJ
    RIP 1981 CJ-7 Limited Edition Laredo

  5. #135
    Getting closer.

    Sent from my Pixel 2 using Tapatalk
    1985 CJ-7 Custom (Flat fendered CJ,YJ,XJ,TJ...)
    Picked n Parted 1987 YJ
    Sold 1998 XJ
    RIP 1981 CJ-7 Limited Edition Laredo

  6. #136
    Out of order photo shows the gasket blow out.

    Sent from my Pixel 2 using Tapatalk
    1985 CJ-7 Custom (Flat fendered CJ,YJ,XJ,TJ...)
    Picked n Parted 1987 YJ
    Sold 1998 XJ
    RIP 1981 CJ-7 Limited Edition Laredo

  7. #137
    Quote Originally Posted by DamnCj View Post
    Out of order photo shows the gasket blow out.

    Sent from my Pixel 2 using Tapatalk
    If I was going to do it again I would want access to an air compressor so I could use a cookie grinder to cut through the old baked on gasket.
    Using razor blades while bent over the grill roadside got old fast.
    Probably looked like Jeep porn gone wrong.....

    Sent from my Pixel 2 using Tapatalk
    1985 CJ-7 Custom (Flat fendered CJ,YJ,XJ,TJ...)
    Picked n Parted 1987 YJ
    Sold 1998 XJ
    RIP 1981 CJ-7 Limited Edition Laredo

  8. #138
    Got smart near the half way point and pulled out the brass wire brushes, my nifty tight access battery drill, three batteries, and presto!

    Sent from my Pixel 2 using Tapatalk
    1985 CJ-7 Custom (Flat fendered CJ,YJ,XJ,TJ...)
    Picked n Parted 1987 YJ
    Sold 1998 XJ
    RIP 1981 CJ-7 Limited Edition Laredo

  9. #139
    By the way, for tool transport check out my new socket roll.....

    Sent from my Pixel 2 using Tapatalk
    1985 CJ-7 Custom (Flat fendered CJ,YJ,XJ,TJ...)
    Picked n Parted 1987 YJ
    Sold 1998 XJ
    RIP 1981 CJ-7 Limited Edition Laredo

  10. #140
    VROOOM!!!!

    Sent from my Pixel 2 using Tapatalk
    1985 CJ-7 Custom (Flat fendered CJ,YJ,XJ,TJ...)
    Picked n Parted 1987 YJ
    Sold 1998 XJ
    RIP 1981 CJ-7 Limited Edition Laredo

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