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~ The Barnacle ~ [CJ-7]

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  • I was worried about the cracking issue.

    From what I have read, it was only on the earlier model years.
    'Tall' Peter -- Former NJ Resident
    1962 CJ-5 ~ 1984 CJ-7 ~ 2008 JKUR ~ R/C Toys

    Comment


    • The smaller exhaust ports could be a bonus if they improve spool times with the velocity improvement. I doubt they would have any negative affects on the motor since its not a high RPM screamer and turbos like smaller port sizes before the turbo on street driven motors.

      I like the freeze plug idea, that seems like a much more permanent fix than the epoxy method.
      Pete
      CJ 5.75

      Comment


      • There was indeed an issue with defective head castings in 2001. Mine cracked at around 60k. DC made good on it and the $1100 repair only cost me $100.

        I also am liking the freeze plugs!
        Chris Barnes - Former NJJC President, Wannabe Fabricator, Errant Mechanic
        I fix stuff by a little bit of trial, a lot of error, and a TON of bad words!
        2001 TJ, upgraded as broken

        Comment


        • got sick of posting with the phone and finally got all the pics off of it and onto the laptop.


          The head came out great-- here's the rest of the story~

          Using my jewelers drill and some carbide burrs, the head ports were cleaned up.

          before & afters








          valve collection-- the re-builders didn't lap the valves into the seats, so that got done as well



          It quickly became clear that the freeze plugs were not going to work. The casting was too thing to support them adequately, and they would have protruded into the combustion chamber significantly and prevented the head gasket form sealing (BAD). I ended up using pipe plugs and milling them close to flat and then cleaning them up with a hand file.




          Then I tuned my attention to the exhaust manifold-

          Due to my inexperience, I had the tune with too little (retarded) spark. This causes the fuel to combust late in the cycle and sends a lot of the heat out the exhaust. The stainless doesn't mind the high temps too much, but the carbon steel turbo flange was not happy--

          The cracked welds had alot to do with the different heat expansion characteristics between 304 stainless and carbon steel. The carbon steel was also burning up-- literally flaking & chipping away. THe stainless looked no worse for the wear.






          Last edited by Jeep-Power; 11-30-2015, 09:42 PM.
          'Tall' Peter -- Former NJ Resident
          1962 CJ-5 ~ 1984 CJ-7 ~ 2008 JKUR ~ R/C Toys

          Comment


          • The first thing to do was to make a jig that would allow the replacement flange to be welded back in place exactly where this one was. If this didn't happen, then the turbo & entire exhaust system would ahve to be redone. I needed this thing to go back together exactly as it had came apart.

            After some meditating on the subject, I came up with this.




            When I was happy that the jig was going to work, I cut off the old flange. You can see how it had actually shrunken on the left side




            I was not able to find a 3/4" thick stainless turbo flange, so I got 1/2" think 304 Stainless from Specialty Metals (just around the corner from work) and made my own.







            I also had to add some material to the head flange, so that the gasket had metal supporting it. Some quick welds and some file work and it was all ready to go back together



            All that heat also did a number on the turbine side bearing, in the turbo. There was significant play in the bearing on that side. A little bit of Amazon Prime had me the bearings in a day or two



            Then it was off to Motion Lab for some load-dyno tuning.
            'Tall' Peter -- Former NJ Resident
            1962 CJ-5 ~ 1984 CJ-7 ~ 2008 JKUR ~ R/C Toys

            Comment


            • But before they could squeeze me in-- it was time to drive 6 hours north to The Cove Crawl!














              The whole way home...




              THEN it was time to tune. They are right next door to work, so drop off was easy.

              Motion Labs has a load dyno, that allows the engine to be held under any load at any RPM range-- this allows the tuner to find the optimum timing curve. It was worth every penny, as the Jeep has much more power between 1K-2K , starts up alot easier, has a smoother idle, and runs ALOT cooler.



              'Tall' Peter -- Former NJ Resident
              1962 CJ-5 ~ 1984 CJ-7 ~ 2008 JKUR ~ R/C Toys

              Comment


              • That's awesome!! How did the numbers look on the dyno? Horsepower, torque, and AFR? Load cell dynos are hard to find but they are the absolute best for EFI tuning!
                Pete
                CJ 5.75

                Comment


                • Nice to see the Rest of the story!

                  Surprised that turbo mount was still attached.

                  Looks good.
                  Dan M.
                  Former President, Secretary, Treasurer
                  48 days on trail in 2012!
                  '85 CJ7 - 4.0L,T-18,4.10s,Locked F&R,35s,Caged,Winch
                  '68 Kaiser Jeep M715 body transplant on '90 Dodge W350 in progress

                  Comment


                  • Pete- yes, they are hard to find! I literally stumbled over these guys. The nunbers were about the same overall, just alot more torque down low.

                    Dan, yeah, it wasn't on by much.
                    'Tall' Peter -- Former NJ Resident
                    1962 CJ-5 ~ 1984 CJ-7 ~ 2008 JKUR ~ R/C Toys

                    Comment


                    • Nice Work!
                      Rich Volpi - 2000 XJ, 1989 MJ

                      Comment


                      • Thanks Rich

                        Was out at Bearwallow in WV this last week. 300 miles eaxh way - got 16 mpg doing 65-70. Wheeled it hard. No issues to report. Love this thing!
                        'Tall' Peter -- Former NJ Resident
                        1962 CJ-5 ~ 1984 CJ-7 ~ 2008 JKUR ~ R/C Toys

                        Comment


                        • The Barnacle was featured in this month's issue #60 of Crawl Magazine. Starting on page 56 you will see Peter's Jeep CJ. Very cool!
                          Mike S.
                          NJJC President
                          '94 YJ Buggy "BlackRhinoYJ"
                          https://www.northjerseyjeepclub.org/...black-rhino-yj
                          www.youtube.com/c/BlackRhinoOffRoad

                          Comment


                          • Thanks for the props! That was a great time-- extra cool to have it in Crawl.

                            I gotta update some tech-- just harder than ever for me to get photos off my phone and onto the internet.
                            'Tall' Peter -- Former NJ Resident
                            1962 CJ-5 ~ 1984 CJ-7 ~ 2008 JKUR ~ R/C Toys

                            Comment


                            • Some much needed updates-

                              Jan, 2016-- Holley Hydramat! Freakin' expensive, but worth EVERY penny! It will literally run standing on the tailgate, with 3 gallons in the tank.


                              The new SS flange worked great, but I still had issues-- the manifold cracked. THis was in part doe to the turbo being unsupported and the head flange of the hedder not allowing the stainless to expand and contract. I cut the #1 & #6 exhaust flanges free of the rest of the flange. Sorry, no pics of the cool turbo brace. That was over a year and a half ago-- no new issues so far!






                              Seems like the catalyst wore out-- got a new one of those in over the winter. I think it was $70 from NAPA. Jeeps smells alot better now!



                              'Tall' Peter -- Former NJ Resident
                              1962 CJ-5 ~ 1984 CJ-7 ~ 2008 JKUR ~ R/C Toys

                              Comment


                              • The Fall of 2016 I started accruing parts for a 1350 rear driveshaft. The 1310's would literally last a day of wheeling or a few hard turbo pulls on the street ( I would hear the roller bearings popping) This shaft has been in since May, 2017, and haven't touched it since. The CV donor shaft is a '97-98 Ford Expedition. The slip yoke was a junkyard shelf find out of MIllers in Fort Mill

                                #jereel




                                'Tall' Peter -- Former NJ Resident
                                1962 CJ-5 ~ 1984 CJ-7 ~ 2008 JKUR ~ R/C Toys

                                Comment

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