Axle swap in "The Big Cheese"

[randyscycle]

All right. Before Grantshire comes after me with a sharp pointy stick wanting his truck finished, I figured I'd better get crackin'

So we'reon the downhill side of things now, and have a few more things complete. The steering column was a tilt column from a Super Wagoneer, and needed a bit of attention, but overall was in good shape:



With a some work to get a bearing installed in the bottom, instead of a plastic bushing, we have a good repair that is serviceable in the future. Also used a Borgeson joint:



To adapt the Waggy column to the M715, I had to cut the old mount flange from the bottom of the original 715 column and weld it onto the Wagoneer column. I think I heard faint weeping from the Jeep purist set as I did the welding:



And finally, the finished product:

[randyscycle]

In between the column install, I worked on dropping the fuel tank to replace the old 24V mil sender that wasn't working anymore, with a 12 volt unit. The inside of the tank was pretty clean overall, so that got a quick flush and new lines before going back in. No pics of that right now, but they will follow.

Next, the gauge panel will get installed, along with a diesel tach, and new wire harness. Finally, the batteries will be moved out to the right side of the bed, and the truck will be back on the road again!

More pics to follow as it happens.

[Grantshire]

Looking good Randy! Column looks like it belongs there. Can't wait to drop the top and cruise down the road with it. Wait until I pull up behind a MiniCooper!

[Roy]

That Randy guy does awesome work.....

[randyscycle]

Well, I am closing in on this one it seems now. After the last couple of days, I now have electricity and gauges, relocated batteries, and a running truck that I'd trust for a drive down the road.

Removing the old electrics, I ran across this scary gem. An unisulated 4 gauge battery cable supplying everything in the cab with no fuse to boot:



All of the old wiring was run through the firewall and floor in various places just like this with no grommets or other protection:



The batteries were originally stowed in the cab behind the seat. Not my idea of a safe or good thing, so they got moved to the right side of the bed. I do have a cover made for them as well:



No more sealed beams with their questionable output. 55/100W Halogens are now installed:



That's better:

[randyscycle]

Fuses and a real wiring harness will round out the package with both good connections, and peace of mind. Plus a relay for the fuel pump can't be a bad thing either. I did the same as I did on my truck, by locating it in the glovebox:



And finally the cool instrument panel. It uses a CJ speedo, and 4 other gauges. I also installed a diesel tachometer on the left side of the dash, but not pictured. This allows for turn signal indicators, the original Jeep fuel gauge, and temp gauge, and high beam indicator too:

[glenn]

It looked to me like the battery voltage cable in the cab had a fuse, it was a 200 amp slow blow fuse that let you know it was blowing by dripping molten metal on your feet and letting all the smoke out of the wiring. There are a couple of ideas I think I am going to steal from you, the battery mounting and the CJ speedo. Got any pictures of the battery cover installed?

[Ronner]

As usual Randy, stellar work. The only think I'm not crazy about is the battery mounting. Yours is very safe and convenient but I don't think it will look that good even with a cover. Whenever I finally get mine cleaned up (will still look like e comparatively) I plan on a slide out under the bed tray holding 2 Optima s because they can be laid on their side.

[randyscycle]

I'll get the cover on in a couple days once I am done with the finer points and post a pic of it. It actually doesn't look too bad and balances out the jerry can on the opposite side. It only sticks out about a 1/2" past the fender well, and with the 42's, they are out further.

Glenn, that's funny! Welding and fuses all combined in one.

[Grantshire]

As usual Randy, stellar work. The only think I'm not crazy about is the battery mounting. Yours is very safe and convenient but I don't think it will look that good even with a cover. Whenever I finally get mine cleaned up (will still look like e comparatively) I plan on a slide out under the bed tray holding 2 Optima s because they can be laid on their side.

The side saddle batteries are my idea, I just did not like the batteries in the cab, whether between or behind the seats. Besides, there is not much room in the cab and a pair of batteries take up a lot of space. I considered the tray concept but decided I did not want them slung under the bed and exposed to mud, water, salt, etc. I also rejected putting them in the bed as I have future plans there, too. Often there is a Jerry can mounted on the side and it would have been cool to modify one into a battery box but I could not make the size work with regular batteries and decided against specialty batteries due to their expense. I think when it is all finished it will look good and not out of place.

To me the CJ cluster should have been used in the gauge panel. The large speedometer is easier to see/read and with the fuel and water temperature gauges in the cluster you can get seven gauges in the space of five.

The poor/unsafe wiring was an unpleasant surprise. This was Tom Lawlor's truck and his other work/fabrication on the truck has been outstanding. I had never been under the dash so I had no idea it was this bad. When finished, Big Cheese will have a completely new wiring system so there should be no worries in the future.

Randy has done a fantastic job on everything and I can't wait to drive it!