Project: Pariah - CJ360T | Now with bad pics of even worse welds

Re: Project: Pariah - A '77 CJ360T goes cafe....

No worries. Something new developed today and I'll be going another route. I'll keep the stock headers as spares, but I'm not planning on running them as of right now. I'll be selling the stock CJ360 exhaust.
 
Re: Project: Pariah - A '77 CJ360T goes cafe....

Had some spare time at work today. If only I had Photoshop. All we have is Snag-It, which we use for screen captures. So, it's basically just a poor quality mock-up of seat position, a rough idea of how I'd like to reshape the seat foam and what the clip-ons might look like. I also moved the headlight down some, as that will be happening as well.

mockupq.jpg


It's rough, and missing most of the upgrades I'll be making during the rebuild, but I like it.
 
Re: Project: Pariah - A '77 CJ360T goes cafe....

So, I'm really looking forward to getting the parts I ordered last week.

I ordered three items, from three different suppliers. Only one of them has communicated with me in any way since, and when I went to track the order, UPS said in big capitol letters "The shipper has requested an intercept and return to sender pending."

Never seen that one before, but it kinda bums me out. I'm sure everything will be fine and arrive soon, but that message was a new one to me.

I wonder if the guy accidentally sent me a kilo of Columbia's finest and realized it at the last second.

Man, I could have made some cash with that.
 
Re: Project: Pariah - A '77 CJ360T goes cafe....

I like it too. I even really like the 70s pain scheme!
 
Re: Project: Pariah - A '77 CJ360T goes cafe....

Thanks for the kind words, guys. Here's "Rough Mockup v2.0"



I like the paint scheme too. Not the colors, per se, but the lines. I think I'll somehow incorporate that look.

I was having a problem getting the old swingarm bushings out. Here is what worked for me.

I used a "micro" hack saw to cut two relief lines down the length of the bushings. You'd want to be careful not to saw into the swingarm, but you can more or less feel when you're through the bushing. There were a couple times I thought I was all the way through, but I ran the end of a paper clip down the lines and could feel sections that were raised and not cut all the way through. Once you're through the bushing all the way down both lines, just remove the section in the middle. You should then be able to pinch the bushing enough to compress it. Now just stick a punch or screwdriver down the opposite side of the tube and tap out the bushing.

cj36046.jpg


cj36047.jpg


The hardest part for me was making sure I wasn't cutting into the swingarm. After removing the old bushings, I stuck my finger into the tube and felt around the surface, but could not feel any indication that the swingarm was damaged at all.

I'm cutting the frame up tonight. Pretty stoked.

I have my rear sets now, which means I'm just waiting on my clip-ons for final fitment.
 
Re: Project: Pariah - A '77 CJ360T goes cafe....

Nice nice. Those things are a mongrel.

Did you take them out to PC your swingarm? If so you'll need your lower shock bushes out too.. same process just be careful not to cut the outer housing like I did (doh)
 
Re: Project: Pariah - A '77 CJ360T goes cafe....

BB - These are just working on what I've been told thus far, but <u>supposedly</u> those rear suspension bushings only really need to be replaced if they're damaged in the PC process. The powder coater I'm probably going to end up using has stated that he can avoid damaging them and still do a bang up job on the powder. We'll see on that one, I guess. If they end up damaged and needing to be replaced, then the swingarm may need to be powdered again as well, I'd imagine, but I'll just see how things go. My attempt to save $20 may cost me in the end, but that's all part of it, right?

Replacing those front swingarm bushings was important to be me because the stock ones just aren't great, and the bronze ones will probably not need to be replaced for a long long time.

Ian - The bushings were made available thanks to a member at another board that made an arrangement with a machine shop in his area. The thread with the info is here. The bushings, if I remember correctly, are about the same price as the OEM part after shipping. I was very pleased with my transaction with the seller.
 
Re: Project: Pariah - CJ360T

First time using an angle grinder. I dig it. It has allowed me to go past the point of no return....

cj36049.jpg

Obligatory grinding picture (Not OSHA approved)

cj36050.jpg

I've removed the tabs from the frame, including the center stand mounts, and got started on smoothing things out Haven't cut the tabs off the swingarm yet.

cj36048.jpg

I left a couple of tabs that I will try to utilize for a battery box I have yet to make (above the swingarm), and am planning to store the other electrics under the modified factory seat pan using the factory battery box mounts. I Also left the seat mounting bracket and lock mechanism in the hopes that I can keep the rear cowl as a functioning storage compartment.

That tab at the bottom left of the frame is coming off as well, I think. It used to host a bracket that connected to the exhaust collector, but since I'm using different exhaust, and I can't remember it having another reason for being there, I'm going to ditch it. Unless someone can confirm that it does indeed still have purpose, that is. I've actually seen another CJ use it for the kick stand.
 
Re: Project: Pariah - CJ360T

nice work man, just picked up a cj360t a month or so ago myself. watching with great anticipation.
dan
 
Re: Project: Pariah - CJ360T

Saw your bike, Dan. Looks clean as hell! I'm looking forward to seeing what you end up doing with it.

Thanks, Yinzer. The grinding is so loud I don't get to do it as much as I'd like, but it's getting done. Hope to finish smoothing things out this weekend so I can take the frame and some bits over to my wife's dad's.

cj36052.jpg


cj36053.jpg

I intentionally left the seat lock and mount/hinge. With any luck, at the end of all this, I'll still be able to flip up the seat and stow my tool kit in the cowl's storage compartment. That last touch of "Factory" to go along with the cowl and tank.

cj36054.jpg

Some grinding left to do.

cj36051.jpg


cj36055.jpg


Things going on at the Father-in-Law's:
  • Cut the factory seat pan down in length and move the rear cowl forward
  • Fabricate mounts for the rearsets and new position of rear cowl.
  • Weld new mounts to the frame
  • Make new battery box to mount above the swingarm
  • Make a tray for the electrics to mount under the seat.
 
Re: Project: Pariah - CJ360T

I've finished grinding the frame down. Some time in the next few days I'm going to take it over to my wife's dad's place for some fun stuff. A lot to be done over there. Cut the seat pan down in length, weld some mounts for the rearsets and rear cowl, make a battery box, a tray for the electrics and probably a few other custom bits. I actually need some input on that.

I plan on eliminating the tach, and mounting the speedo in a BCR headlight bucket. I'd like to move the ignition to the horn mounts, and have some ideas on how to do so. That leaves two unsightly tabs at the top front of the tree. It seems to me I've got two options; either grind off the tabs, or make some sort of plate that hides them. I was already planning on mounting the neutral and turn indicators in the holes for the risers, and a plate could easily be added into those plans.

cj36060.jpg


cj36061.jpg

Just a starting off point

cj36061a.jpg

A little better, but not the final draft.

cj36062.jpg

I was thinking I could use sections of rubber tubing as spacers.

Are there any concerns with grinding those tabs off completely? I don't want to compromise a perfectly good triple tree, especially since they're pretty hard to find. That in itself is almost reason enough to fashion a plate of some kind - to keep the tree factory. Opinions?

Also, what kind of material would be best for this sort of plate? Something like this? What about this? For the battery box and electrics tray, I intended to just use 18ga sheet metal.

I know I'll need to make more things like this during the build, and I also plan on rebuilding more bikes after this, so I don't mind buying the 3' x 3' section if it works for the application.

Cheers.
 
Re: Project: Pariah - CJ360T

There are a fair few builds getting around where those tabs have been ground off. Most also grind off the steering lock too...

I didn't, but I planned to use them for my headlight mount. Its kinda handy to have them, but if you don't use them, it can look well wonky.

Plus I'm lazy and grinding and shaping a triple sounded like work. :-\
 
Re: Project: Pariah - CJ360T

Well, I'm officially done waiting for my father-in-law to help me with my welding and fabrication. What this means is that I'll be experiencing more delays, as I'm now going to buy a welder and try and teach myself how to use it. I could go out and have a welder/fabricator do this, but then I'm not only out all that money, but I've gained nothing of any real value in the deal because I still won't know how to do the shit.

What I need to do:

Rearset mounts
Cut middle section out of seat pan and weld it back together
Mount for the new position of the rear cowl
Ignition relocation
Battery box above the swingarm
Electrics tray

I'll also need something to cut some 1/4" steel stock. All I have is a sawzall and a bench mounted vice.

What do you guys think? Will this $99 HF welder work? I'll need to have an electrician come in and set me up for 230 volt if I go much larger.

I should have taken shop in high school, but I was too busy with....um.....extra curricular activies to be bothered with going to classes.
 
Re: Project: Pariah - CJ360T

DO NOT USE A SAWZALL!!!!!!!!!!!!!!! There great for tubing and 2x4s but you dont want to use them for much else. Get a cheapy scroll saw with a metal blade. The cheap Harbor Freight welder will work, but you need to be real proficient with it. It tends to leave pretty ugly welds, which brings me to my next point... Has it been explained to you that there are two (basically) different discs for a grinder? Very thin "wafer wheels" for cutting, and thicker wheels for grinding. You DO NOT Want to use the thinner disc to grind. It can shatter and throw some serious shrapnel... Ive had it happen and almost lost my ear. Do yourself a favor and get some of each. Also, if you can see the threads (youll know what i mean) in the cutting disc, get a new one. It can/will shatter soon.
 
Re: Project: Pariah - CJ360T

Just watch some vids on you tube on how to weld... it takes a bit of playing around on scrap to get the hang of it but no real easy way to learn other than just giving it a burn!

Good luck, hey sometimes if you want things done, you've got to do them yourself!

And bragging rights are all yours once you've built your bike. ;) ;)
 
Re: Project: Pariah - CJ360T

Thanks for the tips and the compliment. I'll pick up a scroll saw at the same time along with a metal cutting blade. No one really explained the difference to me between the cutting and grinding wheels, but when I bought my angle grinder I also bought some of both. I have to admit I was a little puzzled when I first looked at the cutting wheels as they didn't really seem "sharp" but I understand why.

I'll probably end up taking some scrap metal and pipe and practicing for a while ( a few weeks maybe?) until I can at least get some decent looking welds with the HF unit, then I'll attack the bike. Then maybe later, when I get a proper welder, I'll be half way proficient with it.

I'll check out some vids on the youtubez and I also found this stick welding guide. I haven't looked at it much yet, but I imagine it's a start.
 
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