78 Jeep CJ-5 Frame
Replacement
page 2
Rocker Guard Fabrication and Roll Bar
Frame Mounts
The Jeep originally had round nerf bars.
I tried in the past to use rocker guards that attach to the
body but the fiberglass is not a very good mounting point
for heavy steel. I am forced to make something that
attaches to the frame. I used 2X3 square tube with 2X2
mounts to fabricate custom rock guards. I temporarily
put the body on and lined it up to ensure the guards would
look correct and not be any lower than they needed.
After everything was lined up and fitted it was all welded
up, cleaned up, and POR-15 applied.
body on for fitment |
test fit |
guard finished |
I wanted to attach the roll bar to the
frame for some added safety. I used some 1.5" tubing
and some plate and fabricated mounts that bolt to the frame
and extend up into the rear fender wells. My Jeep's
roll bar is an earlier style that mounts entirely on top of
the rear fenders. I also placed mounts for the front
section of the roll bar on top of the center mount on the
rocker guards. I left about 1/2 inch above the rear
roll bar mount for installation of a polyurethane bushing to
absorb some vibration and not put excess stress on the body
during flex.
drivers side mount |
drivers side mount front - installed
|
drivers side mount rear - installed |
Reassembly, clean up, painting, new
exhaust, and rear bumper
With everything painted and dry I was
ready to start re-assembly. I took the opportunity to
clean everything up after years of mud. I also gave
almost everything a fresh coat of paint too. A new
stainless steel brake line kit was installed.
ready for assembly |
parts cleaned up
and painted |
ready for the body |
rolling chassis |
Single Exhaust System
Years earlier I installed Hedman headers, I grew tired of
the constant leaking gaskets and the lack of room under the
Jeep from the mufflers and pipes. I decided on a
single exhaust with the original manifolds. I used 2
inch primaries from the manifolds and ended them in a 2 inch
to 3 inch Y collector from Flowmaster. (See above
photos) From there there the exhaust is a single 3
inch all the way out. There is a 3 inch performance
catalytic converter and a 3 inch Flowmaster muffler. I
custom made the entire exhaust using mandrel bends cut apart
and re-welded.
rear view |
new single exhaust
the collector, cat,
and muffler |
|
tech
After
all the areas needing repair, restoration, and fabrication
were complete I gave the frame a thorough coating of
POR-15.
From the POR-15
website "POR-15® is a high-tech, high
performance rust-preventive coating designed for application
directly on rusted or seasoned metal surfaces. It dries to
an incredible rock-hard, non-porous finish that won't chip,
crack, or peel, and it prevents rust from recurring by
protecting metal from further exposure to moisture."
This stuff is great - tip: wear gloves
See the
reviews
section for a review of POR-15 products.
Finished
pictures
ready to roll! |
rear view |
3" exhaust |
front |
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