Dan will do what he can to post daily progress reports and photos for website. This vehicle is currently at being work at C.A.R.inc and AutoFashions locations
Previous process of restoration or customizing pictures are not shown because we have limited web space for pictures online for each project, Also a lot of the other pictures have not been transferred from a windows 98 computer that we could no longer use on the web. The following already has been done as follows:
When Jeep arrived at shop the body was already removed. Daniel Removed engine & Transmission for Inspection from vehicle. He Removed cooling system, Rebuilt Carburetor, Rebuilt Fuel Pump, All Front & Rear brake systems Including all new brake lines, Replaced both front & rear inner axle seals, Front 4WD steering knuckles have been removed, inspected,added new seals,cleaned & lubricated, New tie rod ends, steering bell crank bushings & bearings, knuckle bearings replaced, all wheel bearings cleaned & repacked, Both rear leaf springs were rebuilt, all new shackle bushings installed, All 4 wheel rims sand-blasted & prime bonded. Rims where painted by owner. Steering gear & column were replaced. 5/29/
06-15--Dan Brought in the vehicle back into shop from storage
06-23--Rolled Jeep in the original spot where restoration took before moving into storage.
09-14--Clearing area around jeep, so it can be worked on.
09-28- Remove rear wheels, rear bearings & remove entire rear axle housing out of vehicle to set up for adjusting Ring gear, Pinion back lash.
10-16--The pinion bearings look good. My help Ken moves the ring gear back lash was adjusted by help to .005". Lots of shims were added here since all were missing. Both of us carried the entire unit back in jeep. Install rear axle housing, U-boats & rear shocks back in vehicle.
10-17--sorted out engine parts & set up engine where it can be cleaned from storage. All engine parts are set up on a new table to continue rebuilding engine. My help then Cleaned engine from storage. Install lifters, valves, valve springs & valve keepers. Remove remaining engine seals from timing cover & bead blast cover. Check new .060 pistons to bores. They will fit, but extra honing will be required.
10-23--Then he Remove & Install new cam bearing & camshaft. Honing out piston bores to fit pistons. Measured piston gaps & pistons to bore clearances. Lubricate & Set up the valve train valve clearances. Install crankshaft and the new main bearings. Plastic gauge test to make sure there is enough clearance between bearing & crankshaft. torque main bearing caps.
There was a problem found. The new timing chain does not fit. It is one link too small. New timing chain is required to continue in this particular area. The timing cover will be installed at a later date.
10-24--Install three pistons on rods and insert them into engine. Torque rod bearings. One piston & rod installation to go.
11-09--Finished installing the remaining piston. After cleaning, Installed all the cylinder head studs, new head gasket & attached the cylinder head. Torque down all the head nuts to specification. Part number below in parts list shows in incorrect timing change. Another chain is needed.
11-14-Invoice #39.
11-15--Invoice 39 & 40
12-20-I Repaired rear axle differential cover with torch, hammer & grinding. This area was previously welded by someone else. It had a twist in the metal and would have made the gasket leak if cover was installed. From the inside it looks like a hole was created by a bullet.
12-22--Install axle covers front & Rear. Install new yoke front seal & Nut.
01-17-- I took apart transmission to inspect gears & bearings and remove transmission from transfer case. So far the transmission looks good except for the dirty sludge down at the bottom of housing. The Counter shaft is the only thing that has not been removed, then further cleaning can be done as well as replacing gaskets. The transfer case is a different story. The gears do show signs of pitting from rust, though all teeth on gears are still intact. The rust will make slight noise when in use. Further disassembly is required here. Only took one picture looking over table since working room is limited in space. I will take close up photos soon.
01-18-I Removed countershaft remaining in transmission. then cleaned the transmission housing have been cleaned.
01-19--looking in inventory to see if all seals & gaskets are available for transmission. Found the gasket set, though found two gaskets in set that have are torn. New gaskets will have to be made. The transmission is currently being assembled along with the new gaskets & seals.
01-22--Fabricate two new transmission trans axle gaskets. The originals were broken
02-05--Found out today that the gaskets that were made on the 22nd were in fact for the transfer case and not for the transmission. The transmission gasket set does not have any gaskets for the transmission only for the transfer case. Today was spent continuing to assemble the transmission and fabricate new gaskets. The Transmission body was installed on the clutch bell housing.
03-26-- trans axle was taken apart further today. Old gaskets were scraped off. Found one seal that is different than what came into your transmission kit. So a seal may need to be ordered. No news on the Timing chain. I called they told me it was ordered and should arrive soon.
03-28--Correct Timing chain arrived
03-29--Office work
04-06--Paid-Thank you
05-16--My help Installed new timing chain & gears. Install timing cover. Cleaning engine oil pan. Install new gaskets on valve cover & breather on valve cover.
07-11-I researched the transfer case seals. Looking a little bit closer at the new seals & the original that remain in transfer case. The original seal that is in the transfer case was of different design by a different manufacturer. The seals that came in the transfer case gasket set may work. My help installs the oil pan along with bead of sealant. The original gasket were too old & brittle to use. The water pump has been installed.
10-25--Please prepare the body of your Jeep to arrive at AutoFashions after the Porsche body is finish, so ~my help is planning on starting the painting process. ~I will try to finish transmission and install both engine & transmission back into chassis.
03-06--Emailed the owner about bringing body parts in on 3/28/08 as the Porsche will be moved from it current location.
03-31--My help manufactured a special stand to hold up future body parts to be painted. Email was sent to owner, we are waiting to receive all body parts to start the painting process. Daniel is currently moving shop equipment to other locations, so that Jeep chassis can once again be brought indoors.
04-04--The owner brings back the body parts to be painted and we all move pieces back inside the shop. My help removes the paper on the remaining parts that were brought in today to inspect for body damage.
04-07--We all take hold of the body and flip it upside down to do the underside first. When my help sends me a written report before 11:00pm tonight I will update this report if more work was done to the body that I don't know about yet. From what I can tell Newman- started preparing the main body to be primed.
04-08--Newman-continues to prepare the underside of body and later my help gives me an update. The underside of the body has been sealed & primed. The exterior sides have been epoxy primed.
04-10--Ken- prepares the jeep body, then paints the under side of the body.
04-14--We all flip the body on the stand and then Newman starts to sand the inside of the Jeep body to be primed by my help.
04-16--More sanding was done by Newman inside the jeep.
04-22--Newman finishes sanding the interior of the Jeep, so now my help will prepare the area for priming. Later at night I continue to move equipment and positions the jeep chassis back in shop to have the main body attached to the chassis.
04-23--My help prepares the body to be painted, masked areas of Jeep body and paints it.
04-29--The first coats of paint burned through while buffing, so the body was sanded again on the exterior and the instrument panel area. My help masked the areas again and repainted the jeep body, but this time added three additional coats of clear. The job turned out alot better this time. There is no charge for all this additional work for today.
04-29- I remove the steering column that was previous temporally attach to the Jeep chassis so vehicle could be steered. Since I have limited space in my shop for storage the freshly painted Jeep body will be temporally placed on the chassis, so other areas of jeep can be worked on.
05-29- I'm evaluating and setting up again to continue working on the transmission, replace the -There is no charge to do this
06-18- I removed both the front & rear Trans axle output shaft bearing caps seals, and the under drive shifter shaft seals. Then dissembles the clutch gear and release fork from the bearing cap housing. There is some end play and roughness on the output shaft bearing, so further removal is needed.
06-19- I remove the output shaft and bearing out of the casing.
06-24-My help shows me how to mix the paint for the Jeep engine, then I mixed the paint which by the way takes some time to measure the grams of paint. Also new bearing was picked up locally.
06-25--one more part will be picked up later
09-09--The engine has been moved to the body shop and will be painted tomorrow after BMW drives off to new location at CAR,Inc.
09-10- I roll out of the mechanical shop and into the paint booth the engine and chemically cleans the engine to be painted. Then my help masks the areas off that will later be painted black and covers all the flanges and other screw holes that are exposed. I then starts to spray the Navy blue-grey paint , followed by some clear coat paint.
09-15-I removed the masking off engine that covered the oil pan, water pump pulley and bracket behind timing cover.These areas were painted today and the rest of the engine was masked off from overspray. Later in the evening I moved the entire jeep engine back over to the mechanical side. The transmission when finished will be painted next.
09-16--Newman sanded down parts to be painted in the near future. When I was there N was working on the front windshield bracket.
10-08--I pressed off the old output shaft bearing and installed a new one, followed installing additional seals. Preparing parts of the transmission to reassemble.
10-15--When I was at our new shop Carolina Auto Restorers today Ken had applied etching liquid on the fenders to lock out small traces of rust. Has I was leaving today Ken mention that he will be priming the parts
11-28--We Lifted the recently painted body that was temporarily on chassis, so Dan can continue work on chassis~~~~
12-02--We move the chassis outside to be cleaned with steam Jenny, so the entire chassis will be painted a glossy black.
12-03--This Evening I started steam washing the chassis
12-05--Working on finishing the steam cleaning process
12-11--Dan finishes steam washing the chassis. The new guy named J and I rolled the vehicle back into body shop and flipped the entire assembly upside down to prepare the frame to be painted chassis glossy black.
12-14--On Friday I bought in Cary two more wheel jacks with wheels to raise tires off the ground. Sunday afternoon was spent placing these new jacks under two front wheels since we already had at the others on the rear. The Jeep Chassis can now be moved around with ease within the shop.
12-15--Bonding agent was ordered today and should arrive tomorrow.
12-17--I worked on preparing the frame for the bonding agent, so a lot of scuffing was involved today.
12-18-I applied sprayed rust prevention as best as possible to the rusty areas of the frame as best as possible on the bottom side of the chassis, bonding agent will be applied next
01-15--John primes front end body parts along with fenders & hood on one side.
01-16--Owner stops by an makes a payment for assembly at AutoFashions for future assembly, not for the painting work that will be done at the new shop Carolina Auto Restorers, Inc
01-24--Photo update on hood as I found that it had be worked on for priming while moving 73-sj hood out of view.
02-6-2009-Disolving at C.A.R.inc begins
03-05--I Collected more body parts to be painted from, Gas Tank, Head lamp housing and turn signal light housings so Ken can paint them too.
03-11-I started to take apart both of the tail lamp assemblies and one of the fog turn signal housings so they can be media blasted. I will look tomorrow if I can find the other missing turn signal housing assembly in one of the enclosed storage boxes. Not sure if Ken has made progress or not at C.A.R., but when I am there tomorrow picking up Mazda parts I will check
03-12--When I arrived at C.A.R. they haven't painted the jeep parts, though John told me the hood was primed on both sides. The frame is in the process of having the chassis painted.
04-14--I Stopped by at C.A.R again and asked-J said no progress on primed parts
05-05-2009-Owner stopped by Auto Fashions to pick up Gas tank, I recommended that he head over to where K can listen to owner and K told owner that parts will be painted in a week
06-01-2009-Move things in shop and set up jeep chassis in paint booth to continue on Friday
06-05-2009-Elisabeth made some wonderful chocolate pastries for me-Thank-you:). Alex started on the project with scuffing pads and continued to scuff areas of Jeep that were missed, while I was setting up the tables and the bonding agent. Later we both hand painted the entire chassis with the bonding agent. The chassis is drying and later will be flipped over to touch up anything that was not painted.
06-16-2009-B*Move Body of Jeep into body shop-No charge for this
06-26-2009-B*Flip chassis again and temporally install wheels
06-28-2009-B*all Jeep parts from mechanic shop side to body shop side, no charge for doing this, and place on shelves. Currently researching in manual the proper bolt fasteners to mount body to chassis.
06-29-2009-Picked up the nuts & bolts this afternoon. I touched up the chassis tonight
06-30-2009-Alex, Elisabeth and I moved some equipment out of the way than we rolled the jeep chassis out in the main body shop, later we all took hold of the painted body and set it on the chassis. Alex got underneath the vehicle and help guide Elisabeth and I while shifting the body to fit the chassis properly. I found that the body did not have pre-drilled holes to line up with, so many will have to be made. The body portion is on hold until Ken can do his redo work on the fenders, so the body can be mocked up correctly for future reassembly. We all did a lot of research today and learned a lot more about the Jeep. Alex took several new pieces along with some pieces to be painted for Ken as well as for himself at home. Elisabeth made more goodies for me-WOW-thank you for the cookies I'm currently eating the last one now..lol piggy me :).
07-06-2009-Alex brings by both front fenders
07-09-2009-A*-Alex brings more parts for the Jeep, also we both were talking about the parts and where they fit, Alex helped me find parts I had in storage for resale that he like to purchase,more office research later.
07-10-2009-ABC*we worked on drilling & mocking up the body, steering column & fenders to chassis. The body had to be removed so some areas could be cut out for proper adjustment
07-14-2009-ABC*-We Installed body back on, mark and drill out body mount holes, file holes square for carraige bolts, Temporarly install bolts. Mock up fenders to body . New rubber gaskest were fabricated. Hood and grille were picked up from owners house. Clean up area
07-16-2009-Photo update
07-18-2009-Move Jeep parts to one shelf instead of two. Needed room for 71 Fiat parts, no charge for this
07-28-2009-I Cut and remove the old pedal counter shaft and housing from chassis and grinded smooth.Than welded new housing back on to frame. Alex and I took turns honing out the bushings so that the new counter shaft would fit smoothly after packing it with grease. A new Brake arm was installed to counter shaft. Alex over the week had fabricated some aluminum spacers to fit between the body and the frame. We than started mounting the body with the new aluminum and rubber spacers. The body and fenders are now set in place. Some mocking up of the old steering column was passed through the body to make sure it will fit later. Alex has the new steering Column painted at home and it is currently drying.
Alex fabricated and welded two new custom wheel bearing covers that work as good as the originals would have if we had them
Parts List:
locking washer tabs for axle shafts (rear).
This is used for a guide to understand what symbols we use:
= one icon per person where we are located in progress reports
~ = Planning to work on. area
^= Currently working on.
+= required work on a daily basis.
*^= some progress areas finish for that day, will be working on the following day.
~^= Planning about working in the last area of repair for the following day.
* = Finish a particular area for that day.
XX = Canceled Plans.
!!!= Unexpected problem that took us away from project for that day.
## waiting for customers reply.
/= slot between two days.
(HOLD) = The project has stopped by owners request or there is lack of funds for project to continue.
<>= Conflicting issues and could not finished a particular area for that day.
Image:
Auto Restoration, Auto Parts Auto Sales. Home Decor & Gifts
Founder of the Chatham Socials, C.A.R.Club, and organizer of The Chapel Hill Dining Group
Website design, website editing, photography work, written reports, video work.
by: Daniel at AutoFashions.com
Volunteer work -Debbie when available.
Autofashions.com has been established online Since 2000 Offline since 1979. Copyrights° 2009
= one icon per person where we are located in progress reports 
