Project Jeep CJ-7 Specs & Mods | Offroaders.com
Offroaders.com

Project Jeep CJ-7 Specs & Mods

The budget Rebuild by Ralph Hassel
The complete build is documented
here on www.Offroaders.com

This 1978 Jeep CJ-7 never started life as a complete Jeep; rather it was built completely from parts. The goal was to build a Jeep CJ-7 that was as close to an original Jeep CJ-7 in appearance as possible while upgrading weaker components with stronger components. Parts were acquired from many vehicles including many Jeeps (CJ’s, Wagoneers, Jeep Grand Cherokee’s, etc), several Scouts (axles, T-18A transmission & transfercase) as well as parts of unknown origin. Plenty of new parts were acquired as well to put together this Jeep. The titled, street legal Jeep was built over several years under a limited budget and limited time. The Jeep is primarily used offroad in the mountains of PA such as at Rausch Creek and the former Paragon Adventure Park as well as other privately owned hunting lands.  The entire build project is documented on www.Offroaders.com as Project CJ-7. Specs and Mods below.

Specs & Mods:

Engine:

AMC 360 C.I. (5.9 Liter) Crate Motor from a Jeep Grand Cherokee, 14k miles on engine, HEI Ignition, True Dual Exhaust

Transmission:

Borg-Warner T-18A – Manual 4-speed, 6.32:1 1st gear, Rebuilt, Short Shaft Conversion, Centerforce II Clutch

Transfer Case:

Dana 20 – Rebuilt with Teralow Gears, 3.15:1 Low Range

Front Axle:

Dana 44 – Narrowed Wagoneer Wide Track, Scout axle shafts, CJ Dana 30 Outer Knuckles, Warn Hubs, PowerTrax No-Slip, Gear Ratio: 3.65

Rear Axle:

Dana 44 – 1976 Scout II, Detroit Locker, Gear Ratio: 3.65

Crawl Ratio:

61:1 (6.32 x 3.15 x 3.56 = 70:8)

Suspension:

BDS YJ Leaf Springs 3.5″ Lift, Double Military Wrap,Shackles 1.5” Lift
Custom Front Outboard Leaf Spring Hangers for Scout width Dana 44 axle

Body Lift:

1″ Polyurethane Body lift

Tires:

Interco Super Swamper SSR 33×12.50×15 Mud Tires, full size spare

Wheels:

Jeep CJ OEM Laredo, Renegade Chrome Wheels, 15×8

Steering Modifications:

AGR High Performance Pump
AGR Superbox 2 Saginaw Power Steering Gearbox
Heavy Duty Saginaw Steering Gearbox Mounting Bracket
Custom Saginaw Gearbox Brace
HEAVY DUTY Six States Tie Rods, Flipped Tie Rod and Drag link

Storage:

Tuffy Console Modifications Raised with additional Lockable Storage Below
Rear Seat Modifications, Raised and hinged with storage below & good place to mount 6×9 Speakers for Great Bass … In a Jeep!

Ammo Boxes for Storage Mounted with Quick Disconnects

Bumpers:

Custom Made Front Bumper / Winch Mount, Bumper is an Air Tank, Air Outlet

Custom Made Rear Bumper / Tire Carrier / HiLift Jack Mount / Storage Rack, Bumper is an Air Tank with Air Outlet, Reese Hitch accommodations

Combined bumper air capacity is about 2 gallons of air.

Onboard Air:

Onboard Air – York AC Compressor Conversion, Pressure switch, 3 Air connection points (each bumper and under the hood), 1972 MACK Truck Air Horns

Armor, Skid Plates, Protection:

Sun Rocker Panel Guards

Warrior Rear 1/4 Panel Guards

Differential Guards

1/4 inch Steel skid plating protecting transmission and transfer case

Custom Oil Pan Skid Plate Protection

Custom U-Bolt Plates with Skid Protection

Full Roll-Cage, attached to frame

Recovery:

Warn 9500i, D-ring attach points front and rear bumpers

Lighting:

Lightforce Offroad Lights with H.I.D. Conversion 23,000 Volt High-intensity discharge Upgrade, Custom Wind shield mounts

Electrical:

Custom 12 Volt Ground Wire Backbone – Body & frame not the ground circuit
Relays for high amp circuits (Headlights, Highbeams, Spotlights)

Communications:

Cobra 148 GTL 40 Channel CB Radio upper and lower sideband, power mic (original 1980’s unit, “tweaked”).  Also a backup Cobra 20 Plus CB

Mounted Garmin GMRS /FRS 

Other Modifications:     

Swaybar Modifications Scout Width 44 to CJ Frame

Bestop Softop and Bucket Seats

DIY Paint Job – ’77 Corvette Yellow

Rancho 9000 Adjustable Shocks

Rinoliner Interior

Hand Throttle from Bicycle Parts

MP3 Sound System

Rear Utility Lights

Jeep Project
Index of Articles

Project CJ-7 Article Index

Project CJ-7 Articles

Project Jeep CJ-7

Project Jeep CJ-7 Specs & Mods

August 6, 2017 0

The budget Rebuild by Ralph HasselThe complete build is documentedhere on www.Offroaders.comThis 1978 Jeep CJ-7 never started life as a complete Jeep; rather it was built completely from parts. The goal was to build a […]

Project Jeep CJ-7

Skid Plate Protection For the Oil Pan!

August 2, 2017 0

This relatively simply oil pan modification, though it’s being done on Project CJ-7, can be installed on almost ANY 4×4 with an exposed oil pan.  Though it may be a rare event to poke a […]

Project Jeep CJ-7

Fabricating an Armored Jeep Skid Plate

August 1, 2017 0

This Project CJ-7 article is about converting and armoring a Dana 300 skid plate to work with a Dana 20 transfer case.  An ounce of prevention is worth a few pounds of steel.  After hearing stories […]

Project Jeep CJ-7

T18A Clutch Fork Modifications

August 1, 2017 0

In swapping the T-18A onto this Jeep project, a good tip was passed onto me from Mike of www.Jeepfan.com.  This tip has to do with the stock clutch fork being used in the stock bell […]

Project Jeep CJ-7

Project CJ-7 gets Armored Custom U-Bolt Plates

June 23, 2017 0

Fabricating Custom U-Bolt Plates with Skid Protection for Project Jeep CJ-7   With the job of a Dana 44 axle swap to the project CJ-7 came the need for new u-bolt plates.  Two things made stock u-bolt […]

Project Jeep CJ-7

CJ Flipping the Tie Rod & Drag Link

June 21, 2017 0

A Simple yet very effective method of protecting your tie rod from impact with rocks and things, is to raise the tie rod up.  Raising the Drag link also reduces bump-steer, a side effect of […]

Project Jeep CJ-7

Project Jeep CJ-7 Radiator Protection

June 13, 2017 0

Using 6 bucks worth of material to protect a 300 dollar 3-core radiator and to cool the V8 Engine. When looking at the grill of my 78 CJ-7, the one thing that just stuck out like […]

Project Jeep CJ-7

Project CJ-7 gets a T-18A Borg-Warner Transmission

June 5, 2017 0

After doing some research I finally decided to look for a Borg-Warner T-18A manual transmission.  Manual because that is what I prefer.   The T-18A because of it’s 6.32:1 first gear and it’s heavy duty, cast […]

Project Jeep CJ-7

Jeep CJ-7 Swaybar Bracket Upgrade

May 17, 2017 0

Project Jeep CJ-7 Daystar Swaybar Bushings Tip.  When swapping out your stock CJ swaybar bushings with the Daystar Swaybar Bushings, here’s a Tip – Use the CJ bracket!  Here’s why…First off, upgrading your sway bar bushings […]

Project Jeep CJ-7

Jeep CJ Dana 44 Front Axle Swap

May 12, 2017 0

Project Jeep CJ-7 – Disassembling the Scout II  Dana 44 Front Axle.  After acquiring the Dana 44 axles I also picked up a Dana 30 narrow track front axle that was in great shape.  The […]

Project Jeep CJ-7

Dana 44 Rear Axle Swapped onto a CJ-7 Frame

May 12, 2017 0

Continuing on from the front axle prep, the rear axle’s spring pad angle recorded and spring pads were removed.  That was followed up by an inspection of differential and rear drum brakes to make sure […]

Project Jeep CJ-7

Front Spring Hangers

May 9, 2017 0

Project Jeep CJ-7   Scout II Dana 44 Axles Swap onto a CJ-7 FrameNew Custom Fabricated HangersFront Springs – Front HangersThe front hangers were a little easier to design than the rear hangers.  Mainly because they […]

Project Jeep CJ-7

Painting the Hangers

May 9, 2017 0

Project Jeep CJ-7   Scout II Dana 44 Axles Swap onto a CJ-7 FrameFabricated Leaf Spring HangersInstalling the Front Leaf Springs HangersBelow is the whole set of hangers.  Gussets have been welded in and all the holes […]

Project Jeep CJ-7

Custom U-Bolt Plates with Skid Protection

May 9, 2017 0

Project Jeep CJ-7   U-Bolt Skid PlatesFabricating Custom U-Bolt Plates with Skid ProtectionWith the job of a Dana 44 axle swap to the project CJ-7, came the need for new u-bolt plates.  Two things made stock […]