New2Me FSJ 1977 Cherokee Chief

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Topic author
1977ChiefLS3
Posts: 179
Joined: Fri Sep 11, 2015 6:40 am

Re: New2Me FSJ 1977 Cherokee Chief

Post by 1977ChiefLS3 »

I used the winch from the baby Jeep to pull out the frame from under the body.

ImageIMG_1494 by Max Bouthillette, on Flickr
Last edited by 1977ChiefLS3 on Tue Nov 12, 2019 3:34 pm, edited 2 times in total.
1983 CJ7 Renegade "Stella"
1977 Cherokee Chief WT "Moytoy" (current project: engine start next step)
1967 Super Wag (next up)
1969 J3600 "El Presidente"
1983 Wagoneer "Hulu"
1979 and 1980 Wags ... for parts
2014 JKUR "Ruby"

Topic author
1977ChiefLS3
Posts: 179
Joined: Fri Sep 11, 2015 6:40 am

Re: New2Me FSJ 1977 Cherokee Chief

Post by 1977ChiefLS3 »

Next project is to work up the frame. After pressure wash, set up inside to remove any surface rust and prepare for primer.

ImageIMG_1519 by Max Bouthillette, on Flickr
Last edited by 1977ChiefLS3 on Tue Nov 12, 2019 3:35 pm, edited 2 times in total.
1983 CJ7 Renegade "Stella"
1977 Cherokee Chief WT "Moytoy" (current project: engine start next step)
1967 Super Wag (next up)
1969 J3600 "El Presidente"
1983 Wagoneer "Hulu"
1979 and 1980 Wags ... for parts
2014 JKUR "Ruby"

Topic author
1977ChiefLS3
Posts: 179
Joined: Fri Sep 11, 2015 6:40 am

Re: New2Me FSJ 1977 Cherokee Chief

Post by 1977ChiefLS3 »

My front bumper is a Crawler model from BJ's Offroad. The bumper comes with solid brackets that mount via the 1977's original dual through frame bolts that held the OEM 3-piece bumper brackets. The BJ brackets are also designed to bolt through the frame horns on later models for additional support. The 1977 frame however does not have 'frame horns' up front and these needed to be fab'd to get the strength of all 4 mounting bolts per side.

I used a 6" C-channel to make up some frame horns.

ImageIMG_1672 by Max Bouthillette, on Flickr

ImageIMG_1673 by Max Bouthillette, on Flickr


I ground the weld smooth on the outside of the horns as the BJ brackets mount flush to the new horns and frame rail. Everything then got sprayed with the Eastwood Extreme Chassis Primer and Extreme Chassis Black in Satin.

ImageIMG_1691 by Max Bouthillette, on Flickr
Last edited by 1977ChiefLS3 on Tue Nov 12, 2019 3:37 pm, edited 2 times in total.
1983 CJ7 Renegade "Stella"
1977 Cherokee Chief WT "Moytoy" (current project: engine start next step)
1967 Super Wag (next up)
1969 J3600 "El Presidente"
1983 Wagoneer "Hulu"
1979 and 1980 Wags ... for parts
2014 JKUR "Ruby"

Topic author
1977ChiefLS3
Posts: 179
Joined: Fri Sep 11, 2015 6:40 am

Re: New2Me FSJ 1977 Cherokee Chief

Post by 1977ChiefLS3 »

For the rear Crawler bumper, I made a pattern of the mounting plates and transferred to the rear crossmember. You end up with 4 bolts in a square pattern on each side and 3 bolts in the middle section. I welded up the OEM mounting locations to strengthen the crossmember. BJ's also provides you two steel plates bent 90 deg. which you weld in to the outside of the frame rail / inside of the crossmember for additional strength.

ImageIMG_1669 by Max Bouthillette, on Flickr
Last edited by 1977ChiefLS3 on Tue Nov 12, 2019 3:38 pm, edited 2 times in total.
1983 CJ7 Renegade "Stella"
1977 Cherokee Chief WT "Moytoy" (current project: engine start next step)
1967 Super Wag (next up)
1969 J3600 "El Presidente"
1983 Wagoneer "Hulu"
1979 and 1980 Wags ... for parts
2014 JKUR "Ruby"

Topic author
1977ChiefLS3
Posts: 179
Joined: Fri Sep 11, 2015 6:40 am

Re: New2Me FSJ 1977 Cherokee Chief

Post by 1977ChiefLS3 »

I will be using a fuel tank mounted at the rear between the frame rail (ex-spare tire location). With the coffin tank out of the plans, I remove the mounting brackets for the tank and skid plate.

ImageIMG_1657 by Max Bouthillette, on Flickr

Used a cut off disc, welded up any defects and ground smooth. As I go I have been grinding off any OEM weld pimples (everywhere).
Last edited by 1977ChiefLS3 on Tue Nov 12, 2019 3:38 pm, edited 2 times in total.
1983 CJ7 Renegade "Stella"
1977 Cherokee Chief WT "Moytoy" (current project: engine start next step)
1967 Super Wag (next up)
1969 J3600 "El Presidente"
1983 Wagoneer "Hulu"
1979 and 1980 Wags ... for parts
2014 JKUR "Ruby"

Topic author
1977ChiefLS3
Posts: 179
Joined: Fri Sep 11, 2015 6:40 am

Re: New2Me FSJ 1977 Cherokee Chief

Post by 1977ChiefLS3 »

Last edited by 1977ChiefLS3 on Tue Nov 12, 2019 3:39 pm, edited 2 times in total.
1983 CJ7 Renegade "Stella"
1977 Cherokee Chief WT "Moytoy" (current project: engine start next step)
1967 Super Wag (next up)
1969 J3600 "El Presidente"
1983 Wagoneer "Hulu"
1979 and 1980 Wags ... for parts
2014 JKUR "Ruby"

Topic author
1977ChiefLS3
Posts: 179
Joined: Fri Sep 11, 2015 6:40 am

Re: New2Me FSJ 1977 Cherokee Chief

Post by 1977ChiefLS3 »

Harbor Freight ran a sale and I had an additional coupon that made their large blast cabinet worth a try. All of the expected features are there, just not very 'tight' - could be remedied. I opted to push it outside and save the clean up. Second issue is you do need a high CFM / PSI compressor to run it without constant starts and stops. There's a Sunbelt Rental near me that is closed on Sundays. If you rent 7am on Saturday you can return by 8am on Monday and charged just one day. I rented a large gas powered compressor, they loaded it in back of truck and I left it there all weekend (chained/locked to back of truck). I basically just blasted small parts all weekend.

Just a sample bundle:

ImageIMG_1374 by Max Bouthillette, on Flickr
Last edited by 1977ChiefLS3 on Tue Nov 12, 2019 3:41 pm, edited 2 times in total.
1983 CJ7 Renegade "Stella"
1977 Cherokee Chief WT "Moytoy" (current project: engine start next step)
1967 Super Wag (next up)
1969 J3600 "El Presidente"
1983 Wagoneer "Hulu"
1979 and 1980 Wags ... for parts
2014 JKUR "Ruby"

Topic author
1977ChiefLS3
Posts: 179
Joined: Fri Sep 11, 2015 6:40 am

Re: New2Me FSJ 1977 Cherokee Chief

Post by 1977ChiefLS3 »

BJ's provided NOVAK LS engine mounts were perfect fit. They install using factory frame holes and the strongly suggested weld at top of frame.

ImageIMG_1665 by Max Bouthillette, on Flickr
Last edited by 1977ChiefLS3 on Sun Jan 14, 2018 1:29 pm, edited 1 time in total.
1983 CJ7 Renegade "Stella"
1977 Cherokee Chief WT "Moytoy" (current project: engine start next step)
1967 Super Wag (next up)
1969 J3600 "El Presidente"
1983 Wagoneer "Hulu"
1979 and 1980 Wags ... for parts
2014 JKUR "Ruby"

Topic author
1977ChiefLS3
Posts: 179
Joined: Fri Sep 11, 2015 6:40 am

Re: New2Me FSJ 1977 Cherokee Chief

Post by 1977ChiefLS3 »

BJ's also provided the BDS 4" lift kit. Install is straightforward with no body and working at floor level.

ImageIMG_1645 by Max Bouthillette, on Flickr

ImageIMG_1647 by Max Bouthillette, on Flickr


Kit was complete with all hardware and had no issues except getting one U-bolt installed on the front axle (closest to center pumpkin). It's actually a bigger U-bolt as it goes over part of the pumpkin instead of the axle tube. Getting the U-bolt through the various plates underneath was the challenge and I ended up having to use a dye to redo threads.
Last edited by 1977ChiefLS3 on Sun Jan 14, 2018 1:32 pm, edited 2 times in total.
1983 CJ7 Renegade "Stella"
1977 Cherokee Chief WT "Moytoy" (current project: engine start next step)
1967 Super Wag (next up)
1969 J3600 "El Presidente"
1983 Wagoneer "Hulu"
1979 and 1980 Wags ... for parts
2014 JKUR "Ruby"

Topic author
1977ChiefLS3
Posts: 179
Joined: Fri Sep 11, 2015 6:40 am

Re: New2Me FSJ 1977 Cherokee Chief

Post by 1977ChiefLS3 »

With the lift installed, I started to detail out the various components and final chassis assembly. Here's the rear axle before detailing and installing the disc brakes.


ImageIMG_1661 by Max Bouthillette, on Flickr

Post-photo

ImageIMG_1659 by Max Bouthillette, on Flickr
Last edited by 1977ChiefLS3 on Sun Jan 14, 2018 1:39 pm, edited 3 times in total.
1983 CJ7 Renegade "Stella"
1977 Cherokee Chief WT "Moytoy" (current project: engine start next step)
1967 Super Wag (next up)
1969 J3600 "El Presidente"
1983 Wagoneer "Hulu"
1979 and 1980 Wags ... for parts
2014 JKUR "Ruby"

Topic author
1977ChiefLS3
Posts: 179
Joined: Fri Sep 11, 2015 6:40 am

Re: New2Me FSJ 1977 Cherokee Chief

Post by 1977ChiefLS3 »

The rear center cover on the '77 Dana 44 is steel with a rubber plug, instead of a threaded plug. I ordered a Dana OEM style steel cover but with threaded plug, so this has to wait a bit.

ImageIMG_1662 by Max Bouthillette, on Flickr
Last edited by 1977ChiefLS3 on Sun Jan 14, 2018 1:36 pm, edited 1 time in total.
1983 CJ7 Renegade "Stella"
1977 Cherokee Chief WT "Moytoy" (current project: engine start next step)
1967 Super Wag (next up)
1969 J3600 "El Presidente"
1983 Wagoneer "Hulu"
1979 and 1980 Wags ... for parts
2014 JKUR "Ruby"

Topic author
1977ChiefLS3
Posts: 179
Joined: Fri Sep 11, 2015 6:40 am

Re: New2Me FSJ 1977 Cherokee Chief

Post by 1977ChiefLS3 »

Way too early to tell whether the BDS kit will sit level ...

ImageIMG_1651 by Max Bouthillette, on Flickr
Last edited by 1977ChiefLS3 on Sun Jan 14, 2018 1:37 pm, edited 1 time in total.
1983 CJ7 Renegade "Stella"
1977 Cherokee Chief WT "Moytoy" (current project: engine start next step)
1967 Super Wag (next up)
1969 J3600 "El Presidente"
1983 Wagoneer "Hulu"
1979 and 1980 Wags ... for parts
2014 JKUR "Ruby"

Topic author
1977ChiefLS3
Posts: 179
Joined: Fri Sep 11, 2015 6:40 am

Re: New2Me FSJ 1977 Cherokee Chief

Post by 1977ChiefLS3 »

Detailing the front hubs and brakes. I installed the Warn Premium locking hubs.

ImageIMG_1655 by Max Bouthillette, on Flickr
Last edited by 1977ChiefLS3 on Sun Jan 14, 2018 1:41 pm, edited 1 time in total.
1983 CJ7 Renegade "Stella"
1977 Cherokee Chief WT "Moytoy" (current project: engine start next step)
1967 Super Wag (next up)
1969 J3600 "El Presidente"
1983 Wagoneer "Hulu"
1979 and 1980 Wags ... for parts
2014 JKUR "Ruby"

Topic author
1977ChiefLS3
Posts: 179
Joined: Fri Sep 11, 2015 6:40 am

Re: New2Me FSJ 1977 Cherokee Chief

Post by 1977ChiefLS3 »

Sway bar back in, used same POR-14 stainless paint on it. BJ's provided the tie rods and steering linkage kit, including new ball joints. New bushings throughout.

ImageIMG_1656 by Max Bouthillette, on Flickr
Last edited by 1977ChiefLS3 on Sun Jan 14, 2018 1:42 pm, edited 1 time in total.
1983 CJ7 Renegade "Stella"
1977 Cherokee Chief WT "Moytoy" (current project: engine start next step)
1967 Super Wag (next up)
1969 J3600 "El Presidente"
1983 Wagoneer "Hulu"
1979 and 1980 Wags ... for parts
2014 JKUR "Ruby"

motcat
Posts: 186
Joined: Tue Oct 06, 2015 4:07 pm
Location: Chandler AZ

Re: New2Me FSJ 1977 Cherokee Chief

Post by motcat »

Very nice work!
- John (aka JR)
78 Chief Dad bought new in Kenosha WI, 401, RV cam, Part time kit, Edelbrock+Holly 600, DUI, 3" Rancho, Skyjackers, Crossflow rad, Rust, rust, rust
78 J10 Bob's (Becca's) old J-Truck, Tired 360, Tired TH400, Tired QT, Just really tired, but keeps on runnin

Topic author
1977ChiefLS3
Posts: 179
Joined: Fri Sep 11, 2015 6:40 am

Re: New2Me FSJ 1977 Cherokee Chief

Post by 1977ChiefLS3 »

BJ's also offers a steering box support arm, which you can see running from left to right just behind the front crossmember (steering box is missing).


ImageIMG_1707 by Max Bouthillette, on Flickr

The stainless steel brake lines are also from BJ's Offroad.

Note that if you go with the poly body mount bushing kits, some do not differentiate the two mounts for the radiator support up front and you will have to modify the poly or use OEM style.
Last edited by 1977ChiefLS3 on Sun Jan 14, 2018 1:50 pm, edited 1 time in total.
1983 CJ7 Renegade "Stella"
1977 Cherokee Chief WT "Moytoy" (current project: engine start next step)
1967 Super Wag (next up)
1969 J3600 "El Presidente"
1983 Wagoneer "Hulu"
1979 and 1980 Wags ... for parts
2014 JKUR "Ruby"

Topic author
1977ChiefLS3
Posts: 179
Joined: Fri Sep 11, 2015 6:40 am

Re: New2Me FSJ 1977 Cherokee Chief

Post by 1977ChiefLS3 »

To finish up the OEM wheels, I ran two lines of vinyl pin-stripping tape based on measuring the OEM. Fact is, the original stipe on the wheels was hand painted and had a lot of width variances ... much easier to replicated :oops:

ImageIMG_1674 by Max Bouthillette, on Flickr

I used automotive red pin-stripping paint and brush:

ImageIMG_1677 by Max Bouthillette, on Flickr

If you do this, recommend you do it before mounting tire - the tire valve presents a problem for a good tape layout.

Note that's the original rear center cap polished up, looked mint.
Last edited by 1977ChiefLS3 on Sun Jan 14, 2018 1:52 pm, edited 1 time in total.
1983 CJ7 Renegade "Stella"
1977 Cherokee Chief WT "Moytoy" (current project: engine start next step)
1967 Super Wag (next up)
1969 J3600 "El Presidente"
1983 Wagoneer "Hulu"
1979 and 1980 Wags ... for parts
2014 JKUR "Ruby"

Topic author
1977ChiefLS3
Posts: 179
Joined: Fri Sep 11, 2015 6:40 am

Re: New2Me FSJ 1977 Cherokee Chief

Post by 1977ChiefLS3 »

motcat wrote:Very nice work!
Thanks! Working on the road a lot and only way to stay attached is threading. Can't wait to get back to it.
1983 CJ7 Renegade "Stella"
1977 Cherokee Chief WT "Moytoy" (current project: engine start next step)
1967 Super Wag (next up)
1969 J3600 "El Presidente"
1983 Wagoneer "Hulu"
1979 and 1980 Wags ... for parts
2014 JKUR "Ruby"

GaJeep94YJ
Posts: 313
Joined: Fri Dec 18, 2015 12:00 pm

Re: New2Me FSJ 1977 Cherokee Chief

Post by GaJeep94YJ »

Are you doing an ls swap with those mounts?

If so, unless novak just created new ones, these mounts will push the engine too far to the passenger side and interfear with the pass drop differential.

I just went through this

Sent from my Nexus 5 using Tapatalk

Topic author
1977ChiefLS3
Posts: 179
Joined: Fri Sep 11, 2015 6:40 am

Re: New2Me FSJ 1977 Cherokee Chief

Post by 1977ChiefLS3 »

GaJeep94YJ wrote:Are you doing an ls swap with those mounts?

If so, unless novak just created new ones, these mounts will push the engine too far to the passenger side and interfear with the pass drop differential.

I just went through this

Sent from my Nexus 5 using Tapatalk
Interesting ... in a FSJ or YJ? What lift? Thanks for the heads up.


Sent from my iPhone using Tapatalk
1983 CJ7 Renegade "Stella"
1977 Cherokee Chief WT "Moytoy" (current project: engine start next step)
1967 Super Wag (next up)
1969 J3600 "El Presidente"
1983 Wagoneer "Hulu"
1979 and 1980 Wags ... for parts
2014 JKUR "Ruby"
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