Judy- this repair is a bit of a stretch
Build began a couple years ago to resurrect my pops old cj5. Problem is, I didn't have much to start with, and I wanted to get a little more out of it than a stock cj5 could offer. So I built a new frame, then I built or modified 85 percent of a new body, designed a suspension and full roll cage, swapped in a 6.0LS2 and 6 speed (6L80E) auto, and have had my hands on every piece of this thing. Choosing to design and build every part that was either no longer available or not available to begin with for a build of this undertaking.
Step 1
It all started with what was left of a rusted out cj5 body tub. I then built a frame table, so that I could design and build the frame. Once the frame was built, I began the tedious process of building the body, panel by panel, because I wanted to stretch the body to cj6 dimensions, with a twist, an extra 6 inches in the door frames for more legroom. Once the body was complete, I designed and formed the rollcage and welded everything up. Grafted a later model front end with custom fenders and cut the hood line up 3 inches to allow for more cooling capacity and suspension travel. Then I began laying out and designing the trophy truck (trailing arm) style rear suspension and long travel (3 link) front suspension. For the inside, the dash was hand built from stainless sheet, including the gauge panel and ignition panel. This helps hide and house the custom heat and ac system from vintage air, with custom fabricated aluminum ducting, that is also routed through a hand built center console so the rear passengers also have heat and air. Axles were gusseted and rebuilt in my garage as well, with lockers and 4.88 gear sets, and ride on 37 inch rubber. Rear armor was added to each side with hand formed 3/16 aluminum sheeting. Front and rear bumpers were designed, cut and welded in house as well. It's not quite done and I took the repairs a little to the extreme to resurrect my pops jeep (a few cans of wd40 definitely came to the rescue a time or two) but it's getting there. Thought it would just be fun to share as I'm almost ready to paint (yes, I'll be doing that too) thought you all may enjoy as well.
