Gone Postal : Mail Jeep Build

[95yjjeep]

I got back to work today.

I picked up a fsj dana 44 off of nc4x4 and here is the box of parts it came with. I got 6-lug hubs & rotors (new), small bearing spindles, flattop driver & passenger knuckles, caliper brackets and the housing too. I only really needed the caliper brackets and spindles but it was such a good deal I couldn't pass it up. I might use the axle for my next jeep project.

axle.

completely stripped.

dash stripped out too.

dash.

some really creative wiring done by someone. what a friggin' mess! luckily I won't be using any of this.

I plan on tying the shock hoops to the grill hoop. what cha think?

I also cut out the air door vents because I'm going to cut out the whole piece in front of the doors because it's bondo covered rust.

 

[95yjjeep]

couple more.

 

[95yjjeep]

not much progress. I did get the stub shafts stripped apart and greased the axle u-joints. I also cleaned up the spindles and caliper brackets I picked up last weekend.

 

[02dmax]

Love this build. Looking great.

 

[95yjjeep]

Love this build. Looking great.

Thanks man!

 

[Rayf-Daddy]

I am not a big Jeep fan at all, but this thing rocks! If I ever build a Jeep I'm going to have to find one of these and use Toyota motor/trans/axles

There used to one of these in Hickory with a 1800 in it. Met mailman (PERSON) as I was leaving work one day. I was walking out as he was walking in. Heard it running outside the door and just had to ask. (Something distinct about the sound of sound of those timing chains!)BTW been following this build from the getgo.SAAWWEEET! Nice work!

 

[95yjjeep]

There used to one of these in Hickory with a 1800 in it. Met mailman (PERSON) as I was leaving work one day. I was walking out as he was walking in. Heard it running outside the door and just had to ask. (Something distinct about the sound of sound of those timing chains!)BTW been following this build from the getgo.SAAWWEEET! Nice work!

Thanks! I'll be back at it this weekend so hopefully I'll have some more progress up tomorrow and/or sunday.

 

[95yjjeep]

didn't get much done today but I'll post up what I did.

I filled in the old side turn signal holes since I'm getting rid of those.

I added a few more supports to the floor too.

I'll be back at it tomorrow so HOPEFULLY I'll get much more done.

 

[95yjjeep]

I started cutting the rusty firewall out today and I had to go alot higher than I wanted to because I couldn't get to good metal.

I cut out the side panels too. Now I'll weld in all new metal for the sides and firewall. Anyone recommend a certain thickness of sheet metal? I'm thinking 14ga but I'm no body work expert.

I also started rebuilding the front axle. Chevy/FSJ knuckle, small bearing spindle, stub shaft and caliper brackets. The rest of the parts are from the Ford axle.

I was pretty happy with this idea. When I took the Ford lockout hubs apart and cleaned them up and painted them old ford blue. I thought it made them look way better than faded ass red.

with the wheel and tire back on.

 

[paradisePWoffrd]

Figured you'd machine the knuckles before putting them in...

I would set the drivetrain in before finishing the firewall. You might even BD able to move it slightly to get better angles/placement.

 

[95yjjeep]

Figured you'd machine the knuckles before putting them in...

I would set the drivetrain in before finishing the firewall. You might even BD able to move it slightly to get better angles/placement.

You're good! I actually did get the knuckles machined this week. Chris at Marsfab knocked it out for me. I forgot to post up about that.

Good idea on the firewall. I think I'm going to get the sides and supports of the firewall back in before I put the motor in and I'll leave alot of room in the middle that I'll weld in after the motor is in place.

I've also got a ballistic fab battery box, high steer studs and some random tabs and brackets coming to the house this week. I'm going to order a bunch of sheet metal this week so I can weld the new side plates in next weekend.

 

[95yjjeep]

my ballistic fab battery box and a few other parts came in today. Very high quality parts!

 

[freaknajeep]

awesome build bro..im picking up one of these this weekend for 500$ got the link settup out of my last cherokee to put under it with a 60 rear and hp44 front...i found you build thread after i found my dj sitting all alone and neglected beside a warehouse..im still not sure exactly what year it is but the back door says jeep instead of am general...i hope you wont mind if o copy some of your ideas like the body armor and door mods

 

[95yjjeep]

awesome build bro..im picking up one of these this weekend for 500$ got the link settup out of my last cherokee to put under it with a 60 rear and hp44 front...i found you build thread after i found my dj sitting all alone and neglected beside a warehouse..im still not sure exactly what year it is but the back door says jeep instead of am general...i hope you wont mind if o copy some of your ideas like the body armor and door mods

Thanks! Good luck with your build. no problem about borrowing the ideas. If it says jeep, it is probably a 70s vintage. Mine is an '82 and has am general on the door.

 

[95yjjeep]

I ordered most of my sheet metal this week and some aluminum for the dash and some other stuff but most of it didn't come in before the weekend so i'll make some substantial progress on the body next weekend. i drilled out the 1/8" aluminum and installed it. I also mounted my high steer arm to my left side knuckle. i'm planning on finishing rebuilding the front axle tomorrow.

I drilled out the rivets on this dash panel, refurbished it and reinstalled it on the new aluminum dash. I just liked what the dash plate said. I thought it was pretty cool.

 

[bigblueyj]

Man its coming along. This is one of the best and most detailed builds I've seen in some time. Thanks for keeping it so detailed for all of us to see. Keep up the good work man.

 

[95yjjeep]

Man its coming along. This is one of the best and most detailed builds I've seen in some time. Thanks for keeping it so detailed for all of us to see. Keep up the good work man.

Thanks man I really appreciate it. I'm definitely putting everything into it that I can. I hope everything falls into place with this thing in the coming months. We shall see I guess!

 

[95yjjeep]

I finished rebuilding the front axle today. I still have to regear the axle when I get it running but that will be one of the final things to do up front. You can see my oddball poison spyder customs high steer arm. Since my steering is backwards, it's perfect! :smokin':

fyi. i painted that shiny ass diff cover with the semiflat paint after these pics. gloss black makes me want to puke! and yes, that is a waggy narrowtrac axle shaft that is being used as my hood prop. It's for sale btw! It just happened to be the perfect length and I cut out so much of the tub, the hood was trying to fold all the way down to the bumper/frame. maybe I should start putting the tub back together?! haha!

no cro-mo shafts yet. I'm a poor ass so I'll wait until these 40yr old shafts decide to retire.

I added this little Ballistic Fab skull to my dash underneath the Safety Decal I reused from the old dash. If it's gay, let me know and I will take it off. I painted it old ford blue to match the hubs. The jeep body color will be really similar to old ford blue and/or cosmo blue from the new jk's.

 

[88 BII]

cool build man, i read the whole thing at work on friday. very nice work you've done. my next build is gonna be some sort of jeep build (off road vehicle only)

 

[95yjjeep]

I went by Carpenter's Auto Service in Charlotte, NC tonight after work and the owner (my gf's dad) TIG'd up the 1.5" .250 wall DOM for my tie rod. He's one hell of a welder. Good TIG welding is so sexy looking!

 

[95yjjeep]

cool build man, i read the whole thing at work on friday. very nice work you've done. my next build is gonna be some sort of jeep build (off road vehicle only)

Thanks man I really appreciate it. I'm liking your BroncoII build too. There was a really nice BroncoII in the Ultimate adventure last year you should check out.

 

[baby hulk]

This is def the coolest jeep build ive seen... great work

 

[95yjjeep]

This is def the coolest jeep build ive seen... great work

Wow! Thanks man!

 

[88 BII]

Thanks man I really appreciate it. I'm liking your BroncoII build too. There was a really nice BroncoII in the Ultimate adventure last year you should check out.

yeah, shay step. he's a member on a broncoII/ranger/explorer forum that i also post on. FW 8.8/D44, 4.0, doubler. it's pretty sweet. i dont want to copy his, but that's almost what i want mine to end up looking like.

 

[95yjjeep]

yeah, shay step. he's a member on a broncoII/ranger/explorer forum that i also post on. FW 8.8/D44, 4.0, doubler. it's pretty sweet. i dont want to copy his, but that's almost what i want mine to end up looking like.

Yeah it's a super nice little bronco. That's why I like lighter weight rigs...you can build them with half ton axles and they still hold up. Don't get me wrong, the monster rigs with rockwells and 49s or 42s, 60s and v8s are badass! They're just not in my budget. I do plan to build a tube chassis willys next; hopefully on links and 39s.

I would LOVE to do the Ultimate Adventure with this thing when it's done. It's definitely on my bucket list! You guys gotta vote for me if I ever get to the point I could do the UA! The fact that those guys can wheel the toughest trails, fix them on the trail and then drive their rigs to the next place is very impressive.