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Thread: Project Warhorse

  1. #11
    Member warthog_cj7's Avatar
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    Quote Originally Posted by liftedon37's View Post
    This is going to be a awesome tow rig.
    Can't wait for that part. Still a long road to travel and the excitement is still there. Trying to spend 1-3hrs every work day evening. But summer weekends (and wheelin) are startin to fill the weekends. Might have to burn a week of vacation for some quality time...
    Dan M.

    '85 CJ-7, 4.0L,T18,4.10s,35s,Fully locked,winch,cage

  2. #12
    project Roadkill brian613's Avatar
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    thats gonna be killer when done.. taking on any kind of rebuild is a major undertaking and very time consuming keep us posted on the progress
    project Road Kill
    Quote Originally Posted by DevilDogSoldier View Post
    NOTHING good happens after 10pm, except in the bedroom.
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  3. #13
    Member warthog_cj7's Avatar
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    Haven't been able to apply a lot of time to this project lately due to work and other wheeling events. But this has been a kind of hard portion to tackle.

    Doing the floor in back of the cab where I had to channel it has required a lot of thinking of best way to tackle and keep rigidity. I have made up a few mock ups in cardboard and tried a few pieces o metal that are now scrap material.
    Here is what I have to deal with to make it over where the frame is and still keep clearance.


    Finally figured out how to make a short piece of hat channel work and then put a plate on the underside of it for rigidity. The problem was the hat channel is on the inside and not able to sit on the underside like a CJ or YJ.


    Here is what the support piece looks like welded in. The top piece I can't weld in until I get the floor sheeting done.

    Been working on the passenger side this week and finally got it all tacked in. Final welding will be after I get the driver side done and flip the cab over to work the underside. Still need to hammer some of the areas underneath for better fit on topside and more welding. Wanted to keep it flat across the backside and then have a gradual slope to the front. The portion that meets the back of the cab will be delt with when stand up the cab for under massaging.
    Dan M.

    '85 CJ-7, 4.0L,T18,4.10s,35s,Fully locked,winch,cage

  4. #14
    Junior Member dosomething's Avatar
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    Keep up the good work man it's going to be a sweet ride when you get her done.
    dosomething or get over it

  5. #15
    Member warthog_cj7's Avatar
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    Well with summer time activities and wheeling in full swing, time has been limited and maintaince to the other vehicles in the fleet has taken up the remaining time so not a lot has been done.

    So I've had some available time this week and been knocking out the floors in the Kaiser. I've now got the inside complete enough so I can flip the cab and massage the metal underneath some and finish off welding. Then flip back and finalize the inside.
    Here is the paperboard template for the driver side.

    Then the metal piece majority formed and sitting in place. Will use the body hammer while welding to fine tune while laying spot welds.

    Last night I finished up the holes and laid a few spot welds on the support across the back. Tonight I patched on the backside of the cab where I had cut the slots higher than needed. It looks like I did rivets, the spot welds on the back side burning through the old military paint. I am So happy to get this portion completed, it has been a big test to my sheet metal working skills, but I have learned so much.

    Yesterday I took the time to lay on the board most of the list of items I've had bouncing around in my brain housing group to get some organization to them and also to not forget some. There's still a lot more I keep remembering after I walked away from the board.
    Dan M.

    '85 CJ-7, 4.0L,T18,4.10s,35s,Fully locked,winch,cage

  6. #16
    Administrator korisu56's Avatar
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    Just caught up. Looking great Dan

  7. #17
    Member warthog_cj7's Avatar
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    Thanks Chris.
    Been squeezing in some progress. Work is stupid hard and severely busy, nice to do something that requires little brain use, just manual labor to form the edges prior to welding. Both forearms sure hurts each evening from the precision hammering, but the results are favorable. The hammerforming processes from prior to laying the panels on topside have turned out better than expected. Nice to see some good results with something...

    Pulled the cab section off the frame and stood up on driver side for access.
    Underside of the rear panels majority welded, still need to take care of the outer edges and driver outer edge needs a gap filler due to how close I ended to the frame rail. Can see a little hammerforming at the bottom of the picture to gain additional space for the frame rail after some strategic spot welds to help with the expansion.


    Front pass floor, from underside complete, plus got opportunity to weld additional from 1st time I replaced the floor from 4yrs ago, when I was going for the mud truck. Funny how plans change, I think I'm going for a better option that will see more useage. Just FYI, I still need to clean up all the welds with air grinder, I'm just trying to blast through the prep/welds for now (this is actually easy and enjoying something not super hard as I move along). Then proceed to the clean up. Still debating should I sand blast or not. May just do it so done right, but I know this 43 yr old steel will need some more patches if I do...



    Driver side partially done, need to address the upper side, but need to flip the cab to other side to gain access to weld correctly.



    All the underside is now welded up and the hole in the rear. Inside floor is majority done, just have to flip so can get to the last remaining.



    Just have a few holes to patch in the firewall, other side of inside floor and done w/ cab. I did get the Dodge firewall opening that fits for the electrical connection graphed in. Now can use the inside & engine side electrical assembly and connector will correctly fit.

    Dan M.

    '85 CJ-7, 4.0L,T18,4.10s,35s,Fully locked,winch,cage

  8. #18
    Member warthog_cj7's Avatar
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    Been awhile since posted on this thread. Goofed off most the winter and worked on rest of fleet to keep it rolling. Started back up on this project in April. Here is pics to catch up.

    Got the bed flipped over so could work the underside.



    Prior owner had welded small tabs on the bottom of the fenders to attach rubber to, like mud flaps, but of course all 4 corners rusted out and needed replace.







    cleaned it up some, doesn't have to be super pretty. This will be underside and I'm not building a friggin show truck.


    Got center section of bed tacked in



    All burned in. Also added extra strip where the body mount will sit on frame, but hole will have to wait till flip over on frame to line up.

    Dan M.

    '85 CJ-7, 4.0L,T18,4.10s,35s,Fully locked,winch,cage

  9. #19
    Member warthog_cj7's Avatar
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    Needed to start on the frame to get it ready.

    Dropped the fuel tank to access behind it.



    disconnected everything off the frame and went to town with needle scaler for 5hrs bustin all the loose crap off. Feel like I'm throwing away my project one dust pan at a time....



    Did AquaKlean and Rust blast to the whole rear o frame. This was waiting for it to dry. Forgot to take pic of the Rust Seal coating, but it sure made it look pretty.



    This past Sunday we flipped the bed back on the frame. I grabbed a box of just the 3" nylon body mounts for a F250 a buddy was selling and have been cutting them up to make my custom setup. Have to get the rear bumper completed for the rear body mounts for the end of the bed. Here's where I'm up.

    Dan M.

    '85 CJ-7, 4.0L,T18,4.10s,35s,Fully locked,winch,cage

  10. #20
    Senior Member HillBillE's Avatar
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    looking good! Thanks for the updates!!


    As long as the people remain armed,
    government knows that it cannot rule over the people by force.
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    do so out of duty, honor, oath and love of country.


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