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rosco11

'91 Comanche H.O. Build

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With the Comanche front axle on the workbench, I'm starting with some easy stuff. Removed the brake calipers and did a simple rebuild kit and a fresh coat of paint! I'll have a series of brake system posts coming up.. lots of cool upgrades to stop better! 05351d2275a9ca77f23bd62f930c881a.jpgc67b6d21991b63dbc97045f425742271.jpg

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Upgrading the Comanche brake system my brother and I decided to swap out the brake booster and master cylinder with a newer and better dual diaphragm version. We went to a pull a part location and luckily they had 17 donor vehicles to choose from.. we searched around and found the best one. It came from a 2000 Jeep Grand Cherokee. I broke it down, cleaned it up and flushed the master cylinder with brake fluid into a drain pan. We got the booster installed.. next step is making the brake lines from the cyl to the proportion valve!01ed175c58b91bebff377ba1a0773df5.jpg4fb7c50f2aeba1b7cc22711b2b7876dd.jpg853f6f012aa404e4e06c88016017849f.jpg

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Finished up the entire Comanche brake line overhaul. I ended up creating 6 of the 7 hard lines on the Jeep. I rented brake flare kits from O'Reilly and Advanced Auto and used the best pieces from each kit. I did multiple practice flares, over and over and over again until they looked like factory. I used copper nickel lines for most and steel lines from the master cylinder. I bought a tubing bender and took my time shaping and fitting them just right. This was a heck of a project. I think it turned out really good!

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For the Comanche fuel and electrical system there is a ballast resistor. My original was crusty and broke as soon as I started removing it. I replaced with a different style that takes ring terminals. Easy 20 min project! a8df6ee007d6d921bbedd7bafcf49549.jpg73648df06645588a594ab9801f8e9d6e.jpg

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Can you post the part # and where you got the new ballast resistor? 
WahooSteeler, yes definitely! I want to make sure it works first before I put up any bad info. Truck hasn't started in 2 years but coming soon.. hopefully!

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Getting a new battery for the Comanche was definitely part of the plan. In the scope of the whole project we started with the rear axle and moved forward on the truck. Took out the old battery and noticed my battery tray bolts were disintegrated. Rrra Rrro! Upon further inspection check out the fender metal that holds the battery tray.. We found our next rust project! It stinks but ya know, we'll figure it out. Battery tray metal fix.. coming soon!b464fd85ab920305b9b9d5f3e8c014e5.jpg84dca4d5d4a5b53e9c928e16c2ad7978.jpg03337db0771d056657dacd5ced5d7b25.jpg

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For the badly rusted out battery tray on the Comanche we found this good looking donor Jeep Cherokee at a junkyard in Tomball. My brother and I used a battery powered die grinder with a cut off wheel and cut out the battery area. Man, it was hot but the piece we got was so solid. Can't wait to clean it up and finish the fabrication and replacement!667d57cab3f0985d386d7524719b6fb5.jpg39932ad4c5f01aaf7aa65f365ef002ef.jpgbf64d284cef84b9b1e7ddb6a8ecde398.jpge70889a9531b6148b012db0438bfaa35.jpge3d9ee00c03fcdf5cc3142781714286d.jpg72ba6809c1fe9f37685fa67745345847.jpg

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On the Comanche battery tray project, I carefully cut out the bad, started prepping the new peice to put in. We got it coated with Rusty Metal Primer. Next step is to prep for welding and get it done!6b0ffc4d2565ca76adf3ca1beabe4794.jpga4bd7113689be2fff8356baa83818943.jpgfe03df8e9312b92bf025b184783b39f7.jpg55db2646345d81df78cced4e3a54df45.jpg3b48f7bff99e900bb899dd7622846165.jpg

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Got the Comanche battery tray all welded in.   Recoated it with Rusty Metal primer and then with rust-oleum pro enamel and an added hardener. I had cut out the template for the new piece using the old and because the sides were crushed in, I was off a bit.  I had to weld fill some gaps around.  I was a little worried about some of the gaps but it actually turned out really great considering.  Battery tray project done!

Biggest news of all.. that is the last major rust project on the entire truck. We are done fighting rust and cutting metal and fabricating fixes! 

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battery powered grinders and sawzalls are just the best thing ever in a junkyard! 

 

"hey, look at that cool thing!  bbzzzzzzzzzzzrrrzzzzzzrzrrzrrrzrrrzzzz...  and now it's mine."  :D 

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battery powered grinders and sawzalls are just the best thing ever in a junkyard! 
 
"hey, look at that cool thing!  bbzzzzzzzzzzzrrrzzzzzzrzrrzrrrzrrrzzzz...  and now it's mine."   
Haha! That's the truth!

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With the Comanche rust-free (fingers crossed) it's time to move forward building it up. We have the front axle out and will take advantage of the extra room to add frame stiffeners to the unibody front frame section. This area receives quite a bit torque due to all the steering being connected here. I went with the JCR front section stiffeners and 3/16" steel. Used a wire wheel to work on all the very bad rubberized undercoating in the fender wells.  Got it cleaned up nice and now we are mocking up the stiffeners.  Clamped them down and beat them to shape with a dead blow hammer.  They came out pretty good and fit nice

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The Comanche unibody and frame stiffeners are prepped and final fit. To prep I used bare metal primer on the insides of the stiffeners and rusty metal primer on the unibody. Once we got it all mocked up I hit the edges with a wire wheel to clean up the weld areas. Started welding them in. It's so much nicer welding to the thicker unibody metal vs all the thin patches and rust resto I've been doing. Actually got to run a few good hot welds instead of stich welding or just spots. Can't wait to see this project finished up!e7047a072cc4ab6abe867b673436f483.jpg0f6df927948c82933080af6cbace8fba.jpg4d066ecc020b33577fbc40e35276bfe4.jpga3f90435fa35a67ba8370d8b179a970c.jpg

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The Comanche frame stiffeners (JCR Off-road) are done! They welded in very good. Then we hand brushed the stiffeners, unibody and fenders with Rusty Metal primer and finally.. an awesome topcoat of 3M rubberized undercoating. That stuff went on so good! However, you have to move quick.. it'll empty the whole can in just a minute. Once I got the coverage and speed down. It looks awesome 905fabb40dc4509f471b49aeab49ee91.jpg523ceef42d10dd9da2efd6bb825e2a3b.jpg82ce4b5c69cfc86f4159fb5665a95b51.jpg

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After the Comanche battery tray inner fender turned into a major restoration project, I decided I might as well get a new battery and a major cable upgrade.. these from Ksuspensionlifts are awesome and so we'll made. My terminals were not in good shape. I replaced them with the military style. I refreshed all the grounds. The ground from the back of the engine to the firewall was a beast to get in there, but lots of trying and finally got it done.. Good project!56ba0cb8c482ab5da603c064c740a372.jpge5cc2189f968cdfe5130caae083e5c79.jpg

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