Thread: Project Hugs Version 4.0

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  1. #51 Re: Project Hugs Version 4.0 
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    Thanks. Even though this thing is a bit crusty around the edges I still want to do things right. It still progressing slowly, but I should get some more time to work on it next weekend.

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  2. #52 Re: Project Hugs Version 4.0 
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    Made some progress on the swap today. Decided to focus on that and if I need to drive it can throw a fender and bumpers back on quickly. This post and those following will be picture heavy as I really want to document the process I'm using really well for future reference.

    Auto shifter, cable, and shift interlock are all out. After drilling the 4 spot welds there is still a weld at the front of the lower portion of the shifter bracket. I just worked it back and forth until it broke, it didn't take much. This is definitely somewhere it would be nice to have the correct part from a donor 5 speed. It looks like I will need to cut the plate out at the top of the recess, meaning the bigger circle, for the shifter to clear right.




    Next the brake pedal came out and got lined up next to the XJ pedal cluster. There was a small bracket bolted to the clutch side of the XJ cluster, but more on that later. Once I had the XJ cluster marked I cut off the excess and welded on a new piece of 3/16" plate to make a new top. With some careful eyeballing with a straight edge I even nailed the top mounting hole.







    And here is that extra little bracket. It actually runs to the firewall and backs up the clutch master cylinder. Definitely a piece I will want to be using. Sadly, as I've read, the XJ cluster doesn't line up with the ZJ's existing holes. Clever Chrysler used the clutch master mounting hole to mount the TCM to the firewall, though! Looks like I'll be bolting the block off back in.


    The ZJ brake light switch does not fit the XJ cluster. However, I found an extra harness tucked up under the dash that the XJ one plugs right into. Not sure if it will work right, but I'll figure it out. Battery is disconnected right now.


    And finally a pic of the pedals installed.


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    Last edited by Yjsaabman717; 08-24-2019 at 05:28 PM.
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  3. #53 Re: Project Hugs Version 4.0 
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    Finally got to make some more progress today.

    My goal was to get the master cylinder mounting squared away today. The support plate has a stud pressed into it, so I made a small partial of the bracket out of some tin to locate the top hole. Then I made a card template of the master cylinder and marked it all out on the firewall. I pulled the pedal cluster back out to make some more room, but my cordless drill is just a hair too big to fit up in there right. My right angle drill is at work, so maybe next weekend. I do have a 1-1/2" hole saw that's going to be great for the hole for the body of the MC. You can see the overlap with the hole for the factory ZJ clutch hydraulics, I hope that doesn't cause too much issue.


    Next up was to pull the trans shifter and dry fit the trans to confirm the shifter location. Auto flex plate is now gone, and I pulled the trans cooler lines and the TV cable while I was at it. Trans fits as it should and the shifter should fall right where I thought it would.



    So back to working on the wheel openings. I did some final shaping of the flat insert panel at the rear door opening and worked on finishing up some of the welding back there.





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    Last edited by Yjsaabman717; 09-08-2019 at 11:25 PM.
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  4. #54 Re: Project Hugs Version 4.0 
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    Another weekend lacking in time. And this month is busy overall. I hope I can get this thing put together before I need it. Got the holes mostly drilled for the MC today. The hole saw I have has a fixed pilot bit for wood. I tried using another bit the same size, but the damned thing walked and I didn't realize it in the tight space under the dash. So I opened it up as large as I could with a step bit and will have to finish it up with a carbide burr, it looks like.

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  5. #55 Re: Project Hugs Version 4.0 
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    Got the clutch master center hole opened up to the final size today. Test fit the master and the reinforcement plate and all is well. Looks like the pedal cluster has gone in for the final time. I'll make a plate that goes behind the clutch MC mounting and covers the pre-punched holes in the early body. I think I can remove the mounting plate from the TCM and use it to help secure the new block off plate. I'll use some bulk gasket material I have around to help seal it all.

    Nest steps include cutting the plate for the shifter, grabbing the pilot bearing and CPS, and getting the flywheel surfaced so I can install the trans. I'm anticipating a shifter modification to keep it out of the dash, but until the trans is in I can't be sure.

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  6. #56 Re: Project Hugs Version 4.0 
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    Got back on the rocker replacement and wheel arches today. I didn't open up the front as big as the rear, I just don't think the front lends itself as well with all that's going on. I did still roll the edge to keep some structure and give it a finished look. I'm definitely wishing I had 2x6 vs the 2x4 I have. There's a slight gap to the floor when the 2x4 is where I want it with the doors. Fortunately i have some 1/8" angle lying around that I think will work well to fill the gap and the difference between the thinner metal of the body and the 3/16" wall of the new rocker. I plan to put the vertical edge against the inner rocker/floor to help distribute the load better. It's not attached, yet, but I have it cut to length, test fit, and the ends cut @ a 45 and ready to be capped.

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  7. #57 Re: Project Hugs Version 4.0 
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    Got the ends of the rocker capped last weekend. Heading to the junkyard Saturday to source a t-case and to check out some driveshaft options.

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  8. #58 Re: Project Hugs Version 4.0 
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    Well, I went to the junkyard under-tooled for the first time in a while. I also noticed there are two different output shaft styles. My 94 ZJ has the same style my 95 YJ had with the long tail housing and shrouded output shaft.

    https://images.app.goo.gl/xGjgiW8CuViR9GL4A

    All the ones in the junkyard were 96 or newer and had an exposed output shaft with a boot on the slip yoke. I may have to go with the newer style (though it appears to be an inch or so longer) and the rear shaft to match it.

    https://images.app.goo.gl/mRtt1yi77fhGXPZ47

    There was one XJ with an AX15 there, though. I briught home the front driveshaft from that as it's almost 2" shorter than the original front driveshaft. Between the shorter length, the low vs high pinion axle housing, and the budget boost I think it will work well.

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    Last edited by Yjsaabman717; 10-26-2019 at 04:46 PM.
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  9. #59 Re: Project Hugs Version 4.0 
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    Got some rocker work done today. The gap filler/reinforcement section has been prepped and is partially welded in. As usual it took at least three times as long as I had wanted, but it feels good to make progress. I was ignoring the waning light and pushing forward until I ran out of welding wire! D'oh! I had really hoped to have the rocker at least tacked in place today. I need to finish the reinforcement angle welding first before it gets covered up. The rest I'll finish inside at work once it drives.

    (Ok, I'm trying to use the smaller pic size as an upload to help the desk/laptop users, but it really kills the quality. Last pic @ medium upload size.)

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    Last edited by Yjsaabman717; 11-09-2019 at 06:07 PM.
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  10. #60 Re: Project Hugs Version 4.0 
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    awesome detail. Keep the pics flowing.
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  11. #61 Re: Project Hugs Version 4.0 
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    Today saw no actual work but many accomplishments. Flywheel has been resurfaced, welding wire has been ordered for delivery tomorrow, and a transfer case has been lined up for pickup Saturday afternoon. Found one with 104K miles, already pulled, walk up and plunk down the same cash as the junkyard only 30 miles away. Sold! Especially with less than half the mileage of most of the stuff at the u-pull-it yards.

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