Full Size Jeep Network

The driver side of the 77 Chief has a different floor structure where the seats mount vs. the 89 GW. I used some extra steel from the tank support I cut off the frame previously. After some bending, shapin, cutting and welding, fit just right onto the original 77 Chief floor.

IMG_3667 by Max Bouthillette, on Flickr

IMG_3668 by Max Bouthillette, on Flickr

IMG_3669 by Max Bouthillette, on Flickr

IMG_4048 by Max Bouthillette, on Flickr

Here is the other side, it bolted right up to the floor

IMG_4046 by Max Bouthillette, on Flickr

I did start on cleaning up the body.

First step was to strip the bottom. Xylene worked well on the OEM underbody treatment. Here, getting ready to remove the heat shield under the passenger side:

IMG_3581 by Max Bouthillette, on Flickr

As suspected, raw steel was present under the heat shield; fortunately no rust issues

IMG_3584 by Max Bouthillette, on Flickr

IMG_3588 by Max Bouthillette, on Flickr

With the body on a rotisserie at 90 deg, made it easier to spray the Epoxy DTM primer.

IMG_3836 by Max Bouthillette, on Flickr

The rear wheel well extension will be repaired by the body shop who will paint the exterior.

Here are a few shots after the DTM went on:

IMG_3850 by Max Bouthillette, on Flickr

IMG_3848 by Max Bouthillette, on Flickr

IMG_3846 by Max Bouthillette, on Flickr

As part of the prep work, I stripped out all of the OEM seam sealer, so that will be redone in the next steps.

After applying new seam sealer (SEM 29382 Beige Seam Sealer), I opted to spray 3M 08964 No Cleanup High Coverage Body Schutz. This is a paintable medium textured rubberized underbody coating.

IMG_3852 by Max Bouthillette, on Flickr


IMG_3853 by Max Bouthillette, on Flickr

IMG_3854 by Max Bouthillette, on Flickr

In the last photo, you can see that I shot DTM on the whole of the wheel well, but held back the 3M Body Schutz to be spray once the body shop has made the metal repair to the fender flares.

Next applied the PPG base coat color, OEM Pewter Silver. I applied 3 coats of base, and 3 coats of PPG DCU2021 clear coat

IMG_3869 by Max Bouthillette, on Flickr

IMG_3865 by Max Bouthillette, on Flickr

IMG_3868 by Max Bouthillette, on Flickr

Same time, worked on clean-up firewall. This Chief had an OEM AC unit, but needed a full rebuilt and to save space in engine bay, under dash, going with a modern unit, so closed up the excess holes.

IMG_3616 by Max Bouthillette, on Flickr

IMG_3737 by Max Bouthillette, on Flickr

IMG_3739 by Max Bouthillette, on Flickr

Started to prep the inside for paint as well. Cleaned up the floor down to metal:

IMG_3736 by Max Bouthillette, on Flickr

Just before I sprayed the bottom, cut these access holes for the center mount fuel tank for the pump and sender units. I used 18 gauge sheet metal to fill in the low spots in the corrugated floor pattern and applied some temporary primer

IMG_3777 by Max Bouthillette, on Flickr

I have a little grinding and filler work to do on this still.

This is the access panels mocked-up

IMG_3710 by Max Bouthillette, on Flickr

I stripped the entire interior down to clean metal, and prepared for PPG DT 90 Epoxy DTM black primer.

IMG_3927 by Max Bouthillette, on Flickr

IMG_3926 by Max Bouthillette, on Flickr

IMG_3924 by Max Bouthillette, on Flickr

IMG_3920 by Max Bouthillette, on Flickr

IMG_3921 by Max Bouthillette, on Flickr

How have I missed this??? Awesome build!

Wow, you went all-in! This looks awesome.
Where did you source your fuel tank? What capacity is it, and how far does it hang below the frame?
Thanks

Sorry for being tardy; I've been tied up for a month. I sourced the tank from BJ's Offroad. Mine is 27 gallons. Tank is out right now, so cannot put a tape measure to it, but you get the idea from this photo (keep in mind no body weight). Body is on now, and I'll take some photos when I get tank back in:
IMG_3305 by Max Bouthillette, on Flickr

Catching up on posting. With the interior, door jams, and firewall sealed with PPG DT 90 Epoxy, it was time to shoot some color and clear coat. I'm using PPG base and clear coat. Most of this will be covered by sound and temp. insulation layers, headliner, carpet etc. but if I've gone this far, I might as well spray the color and clear on every inch of this Chief that I can reach.

IMG_4058 by Max Bouthillette, on Flickr

IMG_4057 by Max Bouthillette, on Flickr

Made sure to get this area very clean, metal treatment, DTM primer ahead of the base and clear coat.

IMG_4091 by Max Bouthillette, on Flickr

I've got some orange peel (too many cold days - for Texas anyway - in a row). I will cut and buff it but only where it will show like around the side windows and sail area. Not so much for the floor ... but I did put down new seam sealer everywhere prior to final DT 90 coat (OEM sealer was removed in the prep):

IMG_4081 by Max Bouthillette, on Flickr

Tearing down is dirty, but a lot cheaper. Building back up is clean, but expensive. I'm just thinking of all the stuff that has to be reworked, rebuilt or replaced from this point.

IMG_4076 by Max Bouthillette, on Flickr

The worst of the orange peel was up top; you would need to build a platform or have a way to reach in to do the full interior in one shoot. Maybe shoot the top first, mask it off and come back to do the rest. Just reaching in from the tailgate to get the full floor is a bear.

IMG_4059 by Max Bouthillette, on Flickr

IMG_4060 by Max Bouthillette, on Flickr