31-OCT-2012
Pile of Bullnose parts
After finishing the bodywork, priming, and block sanding of the doors I was finally able to turn the Jeep around and start to tear apart the front clip. Since I am not too fond of the Bullnose front end (plus mine is not in very good condition) I am removing it and replacing it with a more traditional type early "Jeepster" front end.
I am replacing it with a CJ7 grille with some custom made Jeepster ears, YJ fenders, and a lengthened Jeepster hood made by combining two Jeepster hoods together.
31-OCT-2012
Naked front end!
No more Bullnose!
Everything came off pretty easy. I left the wiring intact for now just in case I need to move the Commando around.
31-OCT-2012
Front end gone
It's pretty amazing how easy everything on the front end comes apart. Now I'm hoping that fitting all the new parts goes just as easy!
31-OCT-2012
Goodbye old radiator
This will be the last time this radiator will be in this vehicle as it will be replaced by a new updated, more efficient radiator. For cooling the radiator it will also utilize a Spal electric fan with a heavy duty aluminum shroud fitted up to the back of the new CJ grille.
03-NOV-2012
Old wiring harness out
The old wiring harness needed to go so here it is!
I had no idea what any of the glass fuses fed power to because nothing was labeled and I found more fuses spliced in under the dash. There were also wire splices everywhere which I didn't want to deal with fixing or figuring out while out on the trail. The wiring will be replaced with a 21 circuit EZ wiring harnes.
03-NOV-2012
No more rats nest of wiring
With all the wiring removed from the vehicle it made a clean palate for an updated wiring install.
03-NOV-2012
Hacked up dashboard
I have a good idea of how this dash will look when it's done and it will look nothing like this!
03-NOV-2012
Test fit of new front clip
I had to re-drill a couple holes on the fenders to utilize the existing mounting studs. I bolted the grille in place which will need to be drilled out also and threw the hood on top.
03-NOV-2012
All the pieces in place
After test fitting all of the pieces for the front clip, I now have a good idea of how much work it will take to make everything fit.
Since the CJ grille has blinkers mounted in it already I'm going to make some custom "Jeepster" grille ears that will house some very bright LED off-road lights instead of the standard front blinkers.
03-NOV-2012
Hood is just a little short!
I need to lengthen the hood by about 7 inches or so. I have a second hood that I picked up to fill the gap.
Looks like a lot of welding is in my near future!
07-NOV-2012
Grille to fender spacers
I used so 1/4" thick flat bar to make some spacers because I needed to move the fenders out slightly to make the hood fit right where the grille meets the fenders.
07-NOV-2012
Bent to fit
I bent the 1/4" flat bar to fit the contour of the grille perfectly without any wide gaps so I will be able to put a small TIG weld where the pieces meet.