Full Size Jeep Network

Greetings FSJ friends:

Finally have a bit of time to start a build thread. First time 'threader' but I have enjoyed reading the work and threads done by so many of you, it seems only right to do my part to keep the FSJ legacy moving forward.

First Question ... why a FSJ? Well, why not? In the family we have a 'modern' Jeep (2014 JKUR) and a 'baby' Jeep (1983 CJ-7 Renegade), so it was time to bring in a 'big' Jeep.

Second Question ... what are you going to do it with? Enjoy it! More specifically, I've seen on this site, very useful authentic drivers, crawlers and all in between. For me, I want to be able to drive it daily if need be, drive it over long distances reliably, deal with Colorado mountains, weather and trails, and user friendly. I want to trust it with wife and kids in it or driving it!

Third Question ... what' the big picture for the build? A classic looking FSJ on the outside, well upgraded underneath with a turn-key reliable power plant and some 'comfort' features on the interior.

Fourth Question ... why not buy another JK or 4Runner or crew cab? I enjoy the work from start to finish.

Finally ... timeframe? depends on work ... industry taken a beating past years and well that affects how much I have left over to spend on projects.

I'll probably get photo posting all wrong at first, so apologies.

Starting point ... solid frame and body with exception of 3 of the 4 WT flares, and the right fender is pushed back by way of front bumper. Solid California foundation to work on.

IMG_0058 by Max Bouthillette, on Flickr, on Flickr

IMG_0067 by Max Bouthillette, on Flickr

IMG_0059 by Max Bouthillette, on Flickr

IMG_0060 by Max Bouthillette, on Flickr

IMG_0063 by Max Bouthillette, on Flickr

IMG_0070 by Max Bouthillette, on Flickr

Always liked that grey on a Cherokee.

Welcome to the forum!

Now that I understand how to directly post the photo, here's a full view of my starting point.

That's a good looking start.
Long live the Chiefs!

As purchased, it matched up with the VIN tag and the 'build sheet' found under the seat cushion.

Original Pewter Gray paint and decals
360 4V 195HP
Hydramatic
QuadraTrac with Low Range
Dana 44s front and back with 3.54s

All black interior
Cruise control
Power Steering
Power Brakes
But no power locks or door windows, but a power rear window. Go figure how they decided to save on the manual locks and door windows.
All 5 OEM wagon wheels; rear center caps are in good shape and are original. The front center caps are pitted are look like replacement due to the part-time conversion.
Tow Bar

Original Tracker AT tire was the spare under the Jeep.

It did have a part-time conversion done, down to the revised instruction sticker in the glove box.
The part-time conversion was the only modificaiton I could find.

Radio, speakers were original, no window tint had been added, and every bit of those magical vacuum lines were under the hood, down to original air cleaner set up.

IMG_0108 by Max Bouthillette, on Flickr

IMG_0109 by Max Bouthillette, on Flickr

IMG_0110 by Max Bouthillette, on Flickr

This Chief had set for a long while ... but actually ran and drove.

Rear window was inoperative in the down position. Later investigation found wires frayed / cut where they pass through bottom of tailgate / body.

Below is the Low Range coming off the back of the QuadraTrac

IMG_0086 by Max Bouthillette, on Flickr

I will not be using the engine, transmission, transfer case & low range. This was a hard decision as on my previous builds, originality was a key for me. But since I figured each component would be rebuilt to match up with the objectives in my first post, I was open to a new approach. Here I offend the purist.

Blasphemer!

It hurts me down low to read of your plans to eviscerate such a fine specimen.
I understand, but the PAIN!

Good luck with your project you heathen!

You have '77 Chief ... might have a few parts for you! It has the full A/C factory set-up as well. I know, I myself cringe at my plans from a purist view. Still, I has made it much easier to start with a good FSJ. Hey, it was on eBay for anyone to grab

Mentioned the tailgate window was 'stuck' in down position. This is where the wires were frayed, not too bad but enough:

IMG_0609 by Max Bouthillette, on Flickr

Suspension was all stock, no lift etc. Tires were smaller than stock at 30s. I can't stand the sight of a FSJ this way and plan for the wheels and tires to be first on the list just to give it back some of its attitude.

IMG_0061 by Max Bouthillette, on Flickr

IMG_0121 by Max Bouthillette, on Flickr

Wheels off, debated whether to paint or powder coat. Only issue I have with powder coat is if you do get a chip, the repair is what?

Took measurements of the pinstripe as plan to replicate on finished wheels.

IMG_0136 by Max Bouthillette, on Flickr

IMG_0140 by Max Bouthillette, on Flickr

1977ChiefLS3 wrote:Wheels off, debated whether to paint or powder coat. Only issue I have with powder coat is if you do get a chip, the repair is what?

Took measurements of the pinstripe as plan to replicate on finished wheels.

I have always just used some touch up paint on my bumpers and such. Typically the chips are very small.

Decided to powder coat wheels to original color.

Tires will be BFG KO2 33x10.5 ... with the white letters out ala the original Tracker ATs

I won't be crawling (intentionally any way), so not worried about the white letters rubbing off etc. And I love the look of the classic wheels and white letters.

So for the purist, I promised to keep the outside classic FSJ. I cheated on the tires a bit, really less than an inch from the OEM Chief.

The only other item I will cheat on is the bumpers. I love the factory 3-piece and am keeping them for later use / project. But I did want upgrades on protection front and back and want to add a winch up front. I also plan to remove the factory coffin tank for a rear center mounted unit, which means the need for a rear tire carrier.

My first shout out has to be to BJ's Offroad for their help and great parts. First on the list is their Crawler Bumpers.

The bumpers came with some cutout initials ... presumably the builder. I welded over them and ground back to smooth. Hey I paid for them, I can do what I want

IMG_1681 by Max Bouthillette, on Flickr

IMG_1685 by Max Bouthillette, on Flickr

Bit more work needed on last photo ...

lost photo with photobucket conversion to Flickr.

Removing the emblems, measuring for later re-install.
IMG_0658 by Max Bouthillette, on Flickr

IMG_0657 by Max Bouthillette, on Flickr

IMG_0654 by Max Bouthillette, on Flickr

nothing to see here; lost photo