1963 M38a1 Build

[DanStew]

I got this M38a1 from a friend in December.
It was in pieces to say the least.
This is how i got it home, in the box truck

When I got it, it was missing some pieces and I knew I was going to do things a bit differnt than my last CJ5 build. I am not gonig to go crazy with this. I wanted to keep spring under suspension and keep the tires size at 33s, maybe 35s. First thing I did was mount XJ rear leaf springs front and rear.
I made the mounts for the springs, and added about 1 inch to them to give a little more lift.

The springs on the frame

After that I put on a saginaw steering gear for the steering

I wasnt going to use the original motor and transmission. I wanted fuel injection and I wanted a 5 speed. Problem was I wanted to keep the original stance of the early CJ. So i had only a few options. I wanted a Samurai motor and tranny/tcase cause the samurai wheelbase is the same as the early CJ5. So after looking around I got a 1.6L 16V Suzuki motor, and a tracker 5 speed and samurai Tcase.

I trimmed the heck out of the grill to get everything as far forward so i can get as long as a rear driveshaft as possible. I made the motor mounts and got the motor mounted.

I got the transmission crossmember made up

I got the body put on it today to see the fitment of it all.

I got alot of room in the engine bay for it, I can even access to everything behind the motor with little issue.

Here is the inside tub shots

Transmission fits pretty much perfect, I will have to cut out some of the tool box and reweld it to make it smaller so i can cut into the cnter of the tub to get the Tcase to fit. I will have to make a firewall cover, but it shouldnt be that hard. Next on the agenda is to modify the grill better to drop radiator down and make it fit better.

 

[Black Bear]

So why not go with a toyota driveline?

 

[DanStew]

I jsut couldnt fit it in there with a usuable rear driveshaft. The wheelbase is 81 inches and the Toyota 22re/5speed and tcase came in at about 76 inches long. I measured my yotas to see, and just too long. I would have liked a 22re in it, but the suzuki motor will do good. It is about 200 lbs lighter and 50HP more than the stock Fhead, plus fuel injection THe axles are already geared to 5.38.

 

[raven mad]

cj5

Nice ... Ive always been a huge CJ5 fan, keep the pics comin, it will be cool to see you finish this thing, I almost ran a 4cyl... As a matter of fact I would have run a 4 banger except I found the 4ltr. doner vehicle first... Perhaps youll be finished by MAY 21st !!! just in time for a CJ5 only run at URE

 

[DanStew]

Probably not done by then, but I will be there with the earlycj5.com guys, I will be in my Land Cruiser this trip.

 

[raven mad]

trip

Probably not done by then, but I will be there with the earlycj5.com guys, I will be in my Land Cruiser this trip.

right on ...

 

[Black Bear]

Makes sense.. Cant wait to see the final product.

 

[cj5walt]

Probably not done by then, but I will be there with the earlycj5.com guys, I will be in my Land Cruiser this trip.

earlycj5.com has a ride going on the same day?

 

[DanStew]

It doesnt look to be a huge ride but some guys from the site will be there I would say abotu 5-8 families.

 

[cj5walt]

It doesnt look to be a huge ride but some guys from the site will be there I would say abotu 5-8 families.

oh okay. im not a member over there, tried to register but it has been deavtiveted for the lonest time, maybe you could metion to those guys about meeting up the the guys fron nc4x4 we got about 8-10 rigs going so far. so for hijacking your thread.

looks like it is coming along good, will you be running the hard top i saw hiding in the truck?

 

[mmcj7]

Thats how I like buy them except it would be piled on a trailer, pick-up bed and anywhere in the cab of the truck we could set parts. Good lookin work, keep the pics coming

 

[Smokeater]

maybe you could metion to those guys about meeting up the the guys fron nc4x4 we got about 8-10 rigs going so far.

Allready taken care of!
Looks like your movin right along Dan! This things lookin good, great job.

 

[cj5walt]

I got this M38a1 from a friend in December.
It was in pieces to say the least.
This is how i got it home, in the box truck

will you be runnin the hard top i see hidin underneath there?

 

[DanStew]

I will probably have it on in te winter. Or until i get tired of it haning in the garage and decide i need the sell it to get $$ for the jeep build.

 

[cj5walt]

I will probably have it on in te winter. Or until i get tired of it haning in the garage and decide i need the sell it to get $$ for the jeep build.

well if you decide to part with it, put me first in line for it. i kinda have a soft spot for em

 

[DanStew]

I got to working on the jeep. I got the pedals mounted, and have aquired an XJ booster and MC to install later. Since I have to modify the floors and the original tank would not fit, i decided to make a new one. Much cheaper than paying $500 for a new tank and only to have to cut into it. I bent it up and welded it together. I used a gas neck from a rotted M38a1 tank to finsih it off. I still have to weld on the bungs for the fuel inlets and cut the top hole for the sending unit but that will wait a bit. I am gonig to epoxy seal it after that is all done. After this i can work on mounting the seats, then i can get at my Steering column setup. It is a slow build, but it is getting there.

IT FITS!!!

 

[ord.sgt.26NC]

what are your plans for braking and the axles?

 

[DanStew]

Got my driver seat mounted today. Now I get to work on the steering column position an the pedals and work on the brake setup.

 

[DanStew]

Got some more done. I got the XJ power brake setup mounted, and the sidekick clutch cable mounted. I still need to get my dang drill back from my father in law so i can drill and bolt the plate down completely. The pedals are ready to accept the brake pushrod and the clutch cable.

I made a simple spacer out of a piece of tube and made a flange on the MC side for the brakes to bolt on, and then welded the other end to the plate.

 

[ncgamedog]

Updates??? I really like where this thing is headed, might steal a few ideas for my intermediate 5.

 

[DanStew]

Not much right now. I am slowly working on the Firewall and tranny cover. I was missing the original pan and have to make one.

 

[technologyteacher]

Looks Good!

 

[DanStew]

Got the tunnels done and they fit great. I still need to cut out a hole for the Tcase, but i need to mount it first.

Tunnels with gas tank fitment.

Tunnels with seat and gas tank.

 

[raven mad]

Nice sheetmetal work... I need to get a brake... ill start my own fuel tank in a couple of weeks...

 

[DanStew]

Boy I have been on a roll lately. Tranny tunnel, gas pedal install, radiator installed. Now I got my Crossmember cradle for my Tcase almost done. I copied the Kong cradle for a Suzuki Samurai.

Next step is to get the body off the frame and order some spring bushings to make my mounts to the frame, and add a gusset to secure the Tcase front output to the cradle and make a skid plate for the bottom.