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A little project update on Chug A Lug

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Mark W. View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 02 Dec. 2019 at 12:34am
So a little non visual up date:

I managed to drill the 16) #29 holes in the edge of the 1/4" thick Micarta and get them all threaded 3/4" deep that I am using to hold the Fuse Box open side to the backside of the Firewall. I made the 3/16" thick Aluminum Frame that will reinforce the Engine side of the Firewall. And those holes counter sunk so a 3/4" L 8-32 stainless steel flat head bolt will hold it to the Fuse box. I then got the Opening in the Firewall roughed out to the new larger opening required.

What a mess this is something that would have been so much easier while doing Body work. I got chipped paint and extra holes half cut through (from the other type of Fuse Box mounting).  Not my prettiest work. Granted once I have the hole filed smooth and straight as possible. Then with the Neoprene Foam gasket that will go between both the Fuse box and the Firewall and the Reinforcing frame and the Firewall all the Goober looking stuff will be hidden. BUT still what a PITA.

The outer surface of the Fuse box lid will now be approx. 3/8" from the surface of the Firewall so interference with the Air Cleaner will no longer be a problem.

It does look like I will loose the Fuse Box and a place to have an engine compartment Power port mounted. I'm sure something will present itself on the Right Inner Fender with all the electrical stuff in that area. I also need to find a place to bring the Dimmer Switch pigtail through the Firewall as well. A simple hole and a rubber grommet will handle that.

Nothing like a couple dozen more hours of work on the scrap pile of failed ideas to make one happy.

Pretty sure this one is going to work. So there's at least the consolation that I was headed in the direction that would end up with success.

I was able to save my work on the Door and the Knob as well as everything within the Fuse Box. I also have a good way now to mount my RPM switch that will control my little Steering column mounted RED LINE warning light.

Photos hopefully Monday night.
Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 03 Dec. 2019 at 12:03am
So a couple photos of the new Engine side of the Fuse Panel box mounting. The Neoprene foam gasket is a little askew which makes the door look bowed but its actually very flat.


I made the Supporting frame a little wider and used flat head bolts to secure it to the Micarta Box.

This gives you a look at how much less it protrudes into the engine compartment now.


As you can see its now all under the lip of the rain gutter and should be even more weather proof then the last version. I will make a better fitting gasket once I install all this for the last time.

It is how ever much harder to make all the connections having to work from under the dash rather then through the hole in the firewall. But all and all I think its much improved this way.





Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 04 Dec. 2019 at 12:19am
Wow started testing circuits today what a night mare I made a couple mistakes in the Lockers relay trigger circuit been chasing it all day. Looks like the fancy new fuse box has to come back out so I can get a few things straightened out. OH well I wanted to upgrade my Headlight Switch to an AC Delco unit anyway the repop ones I had from my Chevelle Project have a crappy feel to the detents.


Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Mark W. View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 06 Dec. 2019 at 4:55pm
The New Headlight switch showed up and WHAT A DIFFERENCE solid positive detentes The Stem doesn't wiggle around once installed and I can easily remove the stem. The Repop switches I had bought you couldn't really tell when it was in the Park position and it was almost impossible to get the stem out. OH well its only money. I have been working on more wiring stuff and should be ready to put the Fuse box back in place today. Hopefully for the last time.

 
Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Post Options Post Options   Thanks (0) Thanks(0)   Quote LuzonRed47 Quote  Post ReplyReply Direct Link To This Post Posted: 06 Dec. 2019 at 7:06pm
Mark, have you test-fired Chug's engine yet, or did I miss that chapter of the development story?
CJ2A #140275 "Ziggie" (purchased new by my dad in 1947)
ACM #124334
CJ3A windshield, Warn Overdrive
1953 Strick M100 trailer
Serial #18253
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 06 Dec. 2019 at 8:05pm
Oh no firing up the engine is a ways off. I still need to finish the Header (can't until the steering is set in place) I still have no working Distributor (I need to rebuild mine and get the Petronix unit installed) And theres still a little work to do to the carb as far as Jetting and such. SO a while yet.

Next thing after I finish checking out as much of this electrical birds nest I have created is to get some touch up painting done on the frame finish assembling the front brakes and install the Prop shafts. Then a bunch of reorganizing of the shop to get ready to drop the tub on the chassis. Which I hope to do before Christmas.
Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Mark W. View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 08 Dec. 2019 at 10:38pm
OK I think I am done with this silly Fuse Box thingy. Least I am going to move on to testing all the circuits and figuring out exactly how I am going to do the Stop/4way/Turn/Tail/Park/Indicator lights stuff.

So just to show how it ended up:


Inside view showing various Fuses


Looking at this for a while it appears I could have worked it out better so that I could have made the Box smaller. But for two things 1. I already made the Micarta Box which was no small feat in itself) 2. The back side of this thing is crowded enough if the Fuse blocks and Relay blocks were closer together it would have been an even bigger nightmare to get everything hooked up.

Oh under the two Nylon Acorn Nuts you see in the middle are Brass posts connected to the Positive and Ground that come from the Battery into the Box (not relying on the sheet metal as a conductor everything has its own ground wire) This way I can connect something in the future if I want to add something. Plenty of room in the box for a couple inline fuse holders or it makes a place to connect anything needing 12V.

This is the same View with the little Slash Proof Covers on the Fuse Blocks


I printed the little labels on Photo Paper that I know will hold up well at least 15 years as I have photos printed on it with this same Canon Ink older then that. I also have a page in my manual that shows all this stuff.

And the lid in place:


I have the 3/16" thick Aluminum mounting flange gasketed to the firewall with .090" T Neoprene Foam as well as having a small piece wedged above the Top lip. Pretty sure I have this pretty rain and splash proof. The lid itself also has a layer of the Neoprene Foam on its underside to seal it.

I want to do something on the lid some sort of art work something. I might do Dads Whiskey Jug, I might do a Black background with some sort of electric blue lightning bolt Or I might get lazy and clear coat it.


Edited by Mark W. - 08 Dec. 2019 at 10:43pm
Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Flatfender Ben Quote  Post ReplyReply Direct Link To This Post Posted: 09 Dec. 2019 at 1:37am
Awesome fuse box Clap
1946 cj2a desert dog
1946 cj2a bulldog
1948 cj2a blue jeep
1953 cj3b yard dog
1955 willys wagon
1955 willys pickup
1956 willys pickup boomer
1960 fc 170
1968 jeepster commando
1990 Grand wagoneer
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Post Options Post Options   Thanks (0) Thanks(0)   Quote LuzonRed47 Quote  Post ReplyReply Direct Link To This Post Posted: 09 Dec. 2019 at 3:06am
I reckon your NASA-grade fuse box will pass the garden-hose-at-close-range test, Mark. Beautifully designed and built.
CJ2A #140275 "Ziggie" (purchased new by my dad in 1947)
ACM #124334
CJ3A windshield, Warn Overdrive
1953 Strick M100 trailer
Serial #18253
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Mark W. View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 14 Dec. 2019 at 7:56am
Well the winter budget is all set. I got my paid time off and my vacation time cashed in. Slid a little towards the House cause I won't get any unemployment this week because of it. And today got my Christmas bonus so I can run around and buy stuff for the wife kids and grandkids.

In any case funds won't slow me down from getting CHUG finished this winter/spring.

Now as soon as my left arm can move again (shingles Vaccine WOW DOES THAT HURT) I'll be back at it.

Next step is to touch up Frame paint that has bee scratched up while working on the chassis or was damaged when the Tub basically fell on it when I trial fit it. OH and the really nice big grinder looking marks on the Rear Cross Member that happened when my light stand fell on it.


Edited by Mark W. - 14 Dec. 2019 at 8:25am
Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Mark W. View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 17 Dec. 2019 at 6:49pm
OK so painting the Rear Cross Member (so nice it un bolts from the Frame and Receiver etc. I also managed to get the Micarta Plugs that go into the ends of the Tube that is now the rear cross member made. These do two things 1. they help keep crap out of the tube and 2" they give me a way to mount a pair of 3/4" D LED Clearance lights that will hopefully work as clearance lights as well as turn signals and 4 way flashers if I can figure out how to wire them up the same as the front park lights. Might not be able to do that with the available wires I have in the bundle of wires going to the rear. I think I will need an extra set of Right and Left turn wires. OH well something to figure out later.


I been thinking hard on how to lower the tub on to the chassis and I think I am going to see if my Huge Cherry Picker has the reach. I already have 3 guys willing to help so that will be nice.
Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Mark W. View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 22 Dec. 2019 at 5:09am
WOW got the spare Holley Red electric fuel pump I bought off eBay the other day. The description had said NOS but only showed the pump itself. Well yahoo it showed up complete with the box and everything that would have come with it. Its an older box then the Pump on CHUG which was bought in the late 90's (for my abandoned 66 Chevelle Project) So I am very happy. SO I am pretty sure its a Made in the USA pump Going to be good insurance for $52.00 all in.
Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 22 Dec. 2019 at 9:17pm
OH WOW big purchase just ordered my Tom Woods Drive shafts the fancy ones with lone splines and the upgraded boots. With a pair of extra U-Joints that will go in my parts stash $538.00 shipped.

HOPE THEY FIT LOL.

Pretty sure I will never break one, kind of like the DANA 44 30 spline flanged. I figure two less things to worry about when I am a couple hundred miles from parts.
Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Mark W. View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 23 Dec. 2019 at 7:07pm
Very pumped this morning received confirmation that my fancy Drive Shafts are being assembled and should be headed to me very soon.

The local Drive train shop I was going to have rebuild my M-38 shaft (new tube as the original was quite pitted) Wanted over $300 to do the work as they said the Splines were worn and would have to be replaced. So I got new shafts from one of the Top shops in the country for Offroad drivelines even went with the longer splines and fancy rubber boots and they were only $238 each. Money well spent especially when I plan on being so far from anywhere on a number of my planned trips.

Here is a shot of the Rear shaft from Tom Woods page:


And mine will be coming with the X Splines and XB type Yoke and Boot




Edited by Mark W. - 23 Dec. 2019 at 7:20pm
Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 23 Dec. 2019 at 10:09pm
Decided to throw some money at a simple problem. Having a Ceramic resistor mounted somewhere on my carefully planned Firewall was just not something I wanted. So I ordered a proper Ohm resistance Petronix Coil to go with my Petronix Trigger. I will miss the neat Yellow of the Accel Super coil but I'll get over it. I'll pickup a 1.5ohm resistor and pack it away with the Accel coil in my spare parts locker for long trips.

Anyway to get Free Shipping I added a 3 pack of 5qt. Jugs of Lucas Hot Rod and Classic oil 10-40wt So including the Break in Oil I have my first 5) Oil changes on hand. I already have 11 Oil Filters having bought them on one of NAPA's Filter case sales.
Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Mark W. View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 28 Dec. 2019 at 2:58am
I got the MC bench bled and remounted in the Chassis. Hopefully the Banjo fittings will seal. I also received from Summit my new Petronix Flame thrower 40K 300ohm Coil to work with the Petronix trigger I will be fitting into my IAT-4405 vac advance distributor.

And of course the thin is about .060" larger in diameter then the Accel Super Coil I made my aluminum coil bracket for. SO I figured out how to put the bracket in the lathe and carefully working 1/2 way from each side reamed it out to fit. Got it a tiny bit to big but a little card stock shim made a nice fit. I'll miss that vivid Yellow Coil but this one is much better suited to the Ignitor not requiring a Resistor to have the right ohms. Also it came with real nice 1/4" Brass tabs on the posts so easy to connect the wires coming in and going out to the Trigger.

In order to get free shipping on the Coil I added 3) 5qt. Jugs of Lucas Hot Rod and Classic 10-40wt oil. SO my first 6 oil changes are now on hand LOL I had forgot about the jug of Break in oil I already had.


Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Mark W. View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 29 Dec. 2019 at 3:47am
Front Brakes all assembled now. Man do I hate doing that job on the floor. My knees do not like being used as support units. But its done. SO now to scare up a helper and get to beeding the brakes. 
Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Mark W. View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 30 Dec. 2019 at 7:40pm
WOW OH WOW drive shafts from Tom Woods came in Great packaging almost too good LOL.

Going to collect up some new Straps from NAPA and get the Yoke for the transfer case painted and will take some photos these things are outrageously nice.


Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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