Well gang, I worked late into the evening yesterday....and I am writing this post from my office at the labs....first day driving the junker without any mechanical issues!
It was really surreal for me to drive a vehicle that doesn't reek of gasoline and old engine oil that sounds like a cartoon lawnmower and threatens to collapse in on itself to become a flaming a singularity of old german steel. Campus safety was all over me as the new plates haven't shown up yet and the parking permit was removed since it wasn't mine. They couldn't believe this is the same sap and rust soaked junker I gingerly drove off the campus back to my Fortress of Squalitude a few weeks ago! (That really felt good- the previous owner was another staff member's child, hence why they were confused. We are a pretty small Uni and everyone knows everyone and their vehicles) It was also nice to drive the jeep without it sounding like I had a few cheerleaders in the back trying to kick their way free...
Now that the bulk of the gross mechanical issues are repaired, I can finally focus on quality of life fixes and fully outfitting the beast for what is shaping up to be a truly epic 19 day excursion into the Great Basin and West Desert in July. By the time I get home today, new front wheel bearings, the repair parts for the window regulators, OEM steel wheels refurbished in black, rear window struts, stereo adapter, rear wiper motor, OEM jack set, new driver side seatbelt assemblies, wheel center caps (which I have to paint black), black lug nuts, power mirror switch, and a "mall rated" style stick figure family being dismembered by xenomorphs from the movie Aliens will have arrived for a long weekend of wrenching and cussing.
By Next Tuesday, I'll have only to get the tires I want and get the dang suspension lift in. The stock suspension is in surprisingly good shape, found out it is only 3 years old, however with the planned modifications, I have opted to replace the front suspension in it's entirety- Moog and Mopar where it belongs. I noticed a few things last night done by previous "mechanics" that don't sit well with me. I will spend more time going over the rear suspension this weekend. I noticed a few things I am completely unsure of and will post photos and more newbie questions, even though the rear suspension strangely enough reminds me of super beetle front suspension for some reason.
Hopefully I can spend my wrenching time fabricating the front bumper. I have the 1:1 scale cardboard and MDF mock up complete and ready to install and tweak before I tear the whole thing apart to use as templates to cut the steel and aluminum pieces. I have also started designs for a rear bumper. I discovered the free tail hitch jerry can rack I got has some design issues and it will have to be modified to fit properly. It doesn't clear the spare tire, so have to extend things a bit. I have decided I'm not going to bother fabbing a rear bumper at this time.
I looked at fabbing my own cross rails and roof basket (even though I really didn't want them), however I found some on Amazon that meet my needs and are better than what I could fab and cheaper than what my materials of choice would cost. Why the sudden flip-flop on roof racks? Well, math vs. life... With the back seats out and my nearly finished flatfloor in, I am around 2.5 inches too tall to lay down back there even at an angle. This is an issue as I had planned to use the Jeep as a backup shelter for inclement weather while in the field (high winds/hail/ ground to hard to properly pitch a tent, etc....
I hate rooftop and SUV tents- they look stupid to me, are all poorly designed and overpriced, and really screw you if you have to bug out in a hurry say due to a wildfire or flooding both of which are a very real hazards in the places I go (Some day I'll share the story of how I escaped a severe thunderstorm induced wildfire in a rental 2WD in the sandhills).
Soooooo....I have to re-think things a bit...however bits of origami involving sliding rails and repurposed rubber garage door weather stripping is banging around in my skull...combination camp kitchen/lab workspace and mini-camper that slides and unfolds to extend out when parked...hmmmmm
I also learned that the rear lower control arm recall (U38 / 18V-278 ) was never taken care of, so scheduled that with the local Jeep dealership. This being the main reason I am holding off on the lift kit yet again- I want them free LCAs since this is definitely a Salt Belt vehicle and they will often refuse to do recall work if it has been modified from what I read here and on other forums.
Ok...so I have had my morning pot of coffee and once again used this thread to get my plans laid out before I forget them. Time to get ready to yell at undergraduates, feed the critters, threaten the cantankerous GCMS with a very large "Universal Adjustment Tool", and hopefully get out of here early to do Jeep and VW stuff....gotta get that Bug ready to sell as my wife suddenly wants a KK instead of an Outback after driving the KJ and seeing how affordable they are to fix...