88 YJ-CJ Front Clip, Part 1

Front Clip

With my goal to run the Chevy 350 soon, I need to get the cooling system ready to go.  That means that the front clip needs to be test-fit again.  

All of the following will be touched/checked:
  • Fender clearance and fit
  • Grill Clearance and fit
  • Radiator Clearance and fit
  • Cooling Fan Clearance
  • Power Steering Lines - clearance to grill and radiator
  • Upper and Lower Radiator Hoses
  • Radiator Overflow tank and hose
  • Windshield Washer Tank
  • Horns
None of this stuff is easy or trivial because these parts were never intended to fit together.  Mods will be made...curse words will be spoken!

Front Fenders:

Neither front fender is in great shape, but original CJ fenders are tough to find.  So, I'm trying to save them.  The driver's fender has a massive dent.  There are also various stress cracks, extra holes, etc, that needs to be fixed.  There's not any serious rust-thru, so no patching is needed.  


First, I evicted the interlopers!




I did some quick work and got the majority of the big dent out.  There's still a pretty massive low spot in the flange that is very noticeable with the hood installed.  I'll address the flange later.  I also welded shut some stress cracks and other flaws.  Much more work is needed.  


Then, I re-installed both the fenders.  Unfortunately, the change in body lift changed the front fender fit, and I was getting interference with the frame on both fenders.  I took care of some of the interference, but need to do more. 


Front Clip and Grill

 

For clearance, I cut away big chunks of the grill in the corners, as shown.  And also on the back side around the power steering lines.  Luckily, both of the power steering lines fit okay after some trimming.  I will now be able to do a final installation on the power steering lines, and then fill and bleed the power steering system.   



Overflow Tank

I have been looking for a good, reasonably-priced, aftermarket overflow tank, but wasn't happy with anything that I found.  After struggling with this for a couple of weeks, I ended up just using the stock YJ overflow tank, but I moved it to the passenger fender.  I had to make a custom sheet metal bracket for it.  I'm not in love with it, but I love that it is finished.  


Cardboard template of bracket

Template transferred to steel

Bent

Holes drilled and installed

Overflow tube - I need a reducer from 3/8" to 5/16", so I'm holding the two hoses together in this picture.  The radiator is a 3/8" port, but the tank will only accept a 5/16" hose.  The reducer has been ordered and will be here soon.  

As a side note, I looked at using an old brass fire extinguisher as an overflow tank, as many hotrodders have done in the past.  I love this idea, but decided that I didn't want to spend the extra time on a custom tank.  This could be a future upgrade! 😀   


 

Lower Radiator Hose

This was a pretty easy task.  I had found a recommendation for a hose (Gates 23227) from some other engine swap posts.  I just had to shorten it, and it fit great. 

Unmodified lower hose

Shortened Lower Hose - fits perfectly

Upper Radiator Hose

The upper radiator hose was much more difficult.  The serpentine belt drive that I am using puts the alternator right in line with the upper radiator port.  I went through the Gates Hose catalog line by line searching for a hose that might work.  I eventually just decided to route the hose behind the alternator using two hoses and an elbow.  

As above, I'm not in love with it, but I love that it's done.  This would be easy to re-work later if I think of a better solution.  



Cooling Fan

I wanted to use a thermally-controlled, factory-type fan, but there just wasn't room.  I'm stuck with the flex fan.


I have good 1" of clearance between the fan and radiator.  I ordered the 2" fan spacer after carefully measuring during the first radiator installation.  

Windshield Washer Tank

I bought a CJ7 washer tank, and it fit into the factory location using the factory holes. 






Horns

This is minor, but I wanted to get the horns mounted now.  (So I didn't have to drill holes in a freshly painted fender!)




Fan Shroud

Still to do...the fan shroud.  I have a YJ shroud that doesn't fit too poorly - it could be modded to fit.  But I will probably just make an aluminum shroud.  I may address the shroud immediately or in a few weeks - I haven't decided yet.  


Next step...do more work on the fenders and grill.  Get them all ready for paint.