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Project CJ Rebuild

     Ok, here's the deal.  I've got a 1977 CJ-5 that is showing signs of old age.  I've waffled back and forth, to be honest, about whether to rebuild it or just sell it off and start over with a new TJ.  In order to give you an idea how I reached my conclusion on what to do, I figured I'd give you a rundown of what the CJ is like right now, being honest about the good points and the bad points of the "old girl", and then I've done some research on the costs associated with rebuilding it and those associated with buying a new TJ and making it comparable as far as off road capabilities go.  Now, one note here, the guy I four wheel with the most drives a Hummer, so it's important to me to be able to have a very capable off road rig.  So, without further ado, here's the scoop on the project.

The Good, The Bad, and The Ugly

    Ok, let's start with the good.  The drivetrain is pretty solid, a 304V8, a Holley Pro-Jection system feeding it, sucking air through a big K&N Filtercharger.  New Headers and Dual Exhaust get the gases out the back.  Tranny is a T-18 4-Speed that I'm told has a 6:50-1 low gear in it.  Rear Axle is a Dana 44 with a Detroit Locker and Chromolly Axles, Front Axle is the stock Dana 30 with a Lock-Right Locker and Warn Hubs.  The suspension consists of Rancho RS-9000 adjustable shocks all the way around, and last summer I installed new leaf springs for a 2 1/2" lift.  The tires are 33x12.50-15 TSL Thornbirds mounted on a set of American Racing rims.  I also recently installed a new 3-core radiator with an electric fan that kicks on when things heat up, so I can now keep my cool even while trail crawling in Moab during the summer.

     Now the bad...  (In my own defense, let me say that I bought this Jeep used, and kid who I bought it from was somewhat of a hack)  The electrical system is probably my biggest complaint.  Somewhere there's a drain on the battery, so if it sits for more than a week or so, the battery is dead.  Also, sometimes the Ampmeter looks like a windshield wiper blade, wildly seesawing back and forth from about 8 to 16 amps.  It does level out when cruising, but at night I can actually see the headlights fluctuating in brightness when idling.  I've cleaned up the wiring a lot since I got it, but when I first got it the wiring harness in the engine compartment was full of chopped wires, bad splices, etc.  The engine leaks some oil, mostly around the pan gasket and the oil pressure sending unit, which is one of those that uses the little plastic tube to run true pressure to the oil pressure gauge.  Also, at times when idling for a long time, I'll notice a slight amount of oil smoke out of the exhaust.  Recently my heater fan quit, someone stole the stereo out of it a while back and a dumb little thing, but there's no windshield washer fluid resevoir or pump.

     And of course, the ugly.  The body has suffered a bit of rock rash, and there's some serious rust coming through the right front fender.  The Windshield frame is totally rusted out on the bottom, where it sits against the rubber padding between it and the tub.  On-road manners had to be put in the ugly category, cause that's how I feel when I'm in freeway traffic.  It seems as if the combined slop of 20+ years of use has added up to some pretty bad road manners, and once in a while I feel like I'm not the one deciding which lane I'm going to be driving in.  Couple that with the "torque steer" affects of the Detroit Locker in the rear, and things can get down right scary at times.  As a result, I'm more and more often finding myself reluctant to drive the thing on a daily basis. 

     So, to summarize the current state of affairs, the body is getting to look pretty rough, the electrical system sucks, big time!  The handling is downright dangerous, the garage floor is a mess from leaking oil, there's not many creature comforts cause the heater doesn't work and there's no stereo, but other than that it's a great Jeep.   Now lest I sound totally disgusted with it, let me say this thing is a rock crawling monster, and it's never let me down on a trail yet.  And as I get older, I also find that some of my tolerance for things is slipping away.  I'm a bit of a perfectionist, and it's time for these complaints to go away. 

     To see the cost comparison of my possible options, let's continue this on the next page -->