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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.
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.
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.
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.
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.
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"
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.
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.
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.
- 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
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"
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
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.
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
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Interesting ... in a FSJ or YJ? What lift? Thanks for the heads up.
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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"