88 YJ-CJ Front Clip Part 2

Distraction - Fast Orange Shelf 

I added a shop sink in my garage a few years ago (2016).  It was fairly easy, as the water heater and water softener hookups are both adjacent to the sink.  Since I am by the water heater, I also have hot water, which is nice.  I stupidly added the sink AFTER I did a major, dirty engine swap on my 95 YJ.  I should have done it earlier.  Better late than never.

The sink has been a great addition to my shop, but I never added a soap dispenser.  The soap has mostly been perched on the edge of the sink, but has also lived on the floor and also actually in the sink from time to time.  

Fast Orange in sink in 2016:

(the electrical outlet for the water softener was removed, since I don't use a water softener)

Another common Fast Orange location - also in 2016:

I prefer Fast Orange with pumice, but off-the-shelf wall hangers for Fast Orange are nearly impossible to find.  So, of course, I made one.  I started with some scrap steel pieces - very rusty, unfortunately.  I would have preferred to make it out of aluminum for corrosion protection, but I can't weld aluminum.

Bent, cleaned and welded:

The one gallon Fast Orange is a perfect fit:

Test Fit:

Primed and Painted:

Installed:

I also hung a new, better, paper towel holder.  

Front Clip

Back to the front clip!

Support Rods

Several months ago, I cleaned up and painted (black) the fender support rods.  They are original CJ7 parts and were in my parts stash.  The test fit was successful:

Driver's Side:

Another angle of the driver's side:

Passenger Side...there's a 2nd support rod mostly hidden under the evap cannister.  I need to drill a hole in the firewall to support the long rod on the left:

I also cleaned and painted the cover on the passenger side that goes between the bottom of the fender and the firewall.  I believe it's purpose is to keep the evap cannister clean.  It also fits nicely:

Battery Tray

I am using the stock 88 YJ battery tray.  It's different than the CJ7 battery tray, so it will be another clue that this is a YJ and not a CJ7.  The battery box fits nicely to the firewall, but the fender bracket had to be removed and repositioned to fit the CJ7 fender:

Battery box and loose fender bracket:

Fender bracket held in approximate position - I'll have to weld the bracket back to the battery tray, and also drill 2 holes in the fender:

The battery box is also supposed to have a bracket that goes down to the firewall - I'm missing this bracket.  It's fairly simple - here's a picture from eBay.  I didn't want to pay $45 for this bracket, so I'll make one.

I started with a piece of 3/4" EMT conduit and a cardboard template.

The ends were flattened with a vise and hammer and bent to 45 degrees in the vise.

Finished - the ends were slightly radiused with the belt sander

Here's the final test fit:

Primed:

Painted:

Fender bracket tacked into place:

Front Fenders

You can't tell it in the pictures, but I spent a lot of time straightening out the fenders.  And I filled all the extra holes on the passenger fender.  The fenders are very thin sheet metal.  I'm about 90% to smooth.  That last 10% will either be lots of time or a little bondo.  Or a combination of both.  

The driver's fender is the one that had a huge dent.  It is basically gone.  I still need to weld the extra holes on the driver's fender:

Front Frame Shackles and Bushings

I replaced the old front shackles, bolts and frame bushings with brand new bushings, brand new shackles and repainted factory screws from my 95 YJ.  

(I'll replace the leaf spring bushings later when the new springs get installed.)

Old, removed parts.  The old bushings were trashed.  Everything else will be cleaned up and used on the rear.  

The bolts and shackles were fully cleaned.

Primed:

Painted - ready for installation on the rear soon:

Distractions - 95 YJ Radio Connector

Of course, distractions pop up.  The radio in my 95 YJ has been acting up, so I pulled it out.  It was in the Jeep when I bought it, so I got a good 10 years out of it.  

The wiring I found behind the radio wasn't horrible, but the old factory connector had been cut off.  I bought a replacement and spliced it on in preparation for the new radio.  It wasn't really necessary, but it makes for a much cleaner installation.  And it makes all future radio installations much, much easier.  

I had just enough room to solder and heat shrink the wires.  

New factory YJ Radio Connector.  Wires wrapped in Tesa tape: