It's been a while since i've given an update; but, have made quite a bit progress; Also have been working on putting together a Build Thread; assembling the independent threads into one (never thought i'd need a Build Thread when we got the GW); but, feel like we've done enough work to warrant one - watch for that. In the meantime, am excited to show how far we've come in the 18 months since finding the leather interior in a local Junkyard.
Most of the work over the last 18 months has been mechanical: EFI wiring, cooling, A/C refresh, etc., with no apparent visible cosmetic progress the wife can see. Have had the seats sitting around the shop under sheets in the way; stepping over them for over a year... It's time to dive into cosmetics & clean out the woodshop.
For reference, here's what we started with:
Have been daily driving it, with only front seats, floormats & seat belts for the last 7-8 months... Wife hated it.
Last summer, in August 90+ degree heat, we stripped the interior, and installed Dynamat for sound/heat proofing. Make sure you mark the screw & bolt holes - blue painter's tape marks them here. Can say, it made a huge difference heat-wise - especially with trans tunnel & roof - having no headliner.
Next up, we need to build the cargo area underlayment that goes under the carpet. Kudos to MysticRob on ifsja.org for posting pix of what he had, to give others an idea of what should be there.
Link here - Post #24:
https://forums.ifsja.org/forum/tire-kic ... estoration
Using the pictures as a reference, i made up a reversible pattern that could be used to lay out the cuts on 3/16" plywood. While i started out with the full curve of the raised platform, i cut it down to match how the factory underlayment is shaped, which allows the carpet to laydown on the sides.
Laid out the measurements on paper to figure out how much plywood to buy, it came down to one 4x8 sheet of 3/16" plywood; there was very little scrap left over once everything was cut. To make the plywood easier to deal with, i had the 4x8 sheet cut in three pieces, 1 @ 35"x44", 1 @ 30"x51", and the rest based on measurements i'd captured on the patterns. The rest is cut into ribs & installed underneath for support.
Sidebar: the arm rest mounting brackets needed cleaning up & painting.
All underlayment fitted & test fit:
Ribs cut, installed & stapled:
Backside of piece 1:
Backside of piece 2:
With holes drilled for seat belt attachment - am thinking i used a 2 1/4" holesaw:
4wd hi/lo shifter: I disconnected the linkage underneath to allow pulling the shifter from up top. If replacing factory carpet with new with Mass-Backing, go ahead & find longer bolts (1/4-20x1) - or you'll fight short bolts unsuccessfully. At carpet install time, i fought short bolts for an hour or so before, giving up & hitting the hardware store for hex-heads. Also, the white grommet in the center, along with 2 layers of carpet is sandwiched between 2 identical triangle shaped plates - is a bear to work with - be patient. Multiple picks are a lifesaver to ensure screw hole alignment.
The carpet comes in 3 large sections: front, mid, & cargo. The middle section goes in first; then the front & cargo lays over it. After finding a hot/sunny day to work, i disconnected the battery & opened up all doors to lay out the carpet & let it soak up the sun for 1/2-day; then dove in. Used a small pick to locate the holes (thankful i'd marked all of them with blue tape).
First hole is the scariest...
Both back seat mounting brackets in: The carpet has slight humps in it behind the brackets, but it'll lay down once the cargo carpet & back seat are installed. Also, i've not yet cut the middle piece around the wheel wells, which will also help it lay down.
Working one section at a time, from trans tunnel toward doors, then one side then the other, i went about locating & punching holes, and placing bolts as i went to ensure alignment. Note there wasn't much scrap to trim from the front section of carpet -both sides had similar trimming.
Roasting marshmallows: Saw a YouTube where someone recommended using sockets to melt holes in carpet that perfectly fit the bolts going in. Worked well! Got this set at Harbor Freight for $6.99!
Front carpet is in: Time for front seats!
Junkyard front seats are in! Back to a drivable car.
Is still hard to believe these seats came from this car:
In celebration of being able to drive, I ran over to a couple local car shows; One held downtown by the Kingsport Antique & Rod Club, and the other the Gate City Jeep Jamboree, just over the state line in VA. Was more interested in getting to the Jeep Jamboree to see what FSJ's were there. I didn't think to take pictures, but i did see Scotty54 & his
Gorgeous 10 Footer Cherokee, along with a silver Wagoneer - no wood; a couple of Willys-era trucks: a 1955 Green pickup truck - restored to original; a 1947 Maroon panel delivery, along with a restored 1981 Red Scrambler, a few CJ-5's, & a WWII-era military restored Jeep. Other than that, it was an sea of Wranglers. Hopefully, i can make the Jamboree next year with ours.
Now for the hard part: wheel wells & managing the merge where 3 sections of carpet come together. Today it's raining, so there'll be no carpet progress; though i'm planning on pulling the seat belts and cleaning them with an upholstery cleaner & swapping the steering wheel to finish things up front.