Gone Postal : Mail Jeep Build

Back at it again.

Finished up the transmission crossmember and removed the old original jumbo one that hung down so low.
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I picked up some Barnes 4wd 4" shackles this week and add some beef to them. I had to make some new shackles because the other ones were too long. :shaking:
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The cross piece is .25 wall. :D
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I also got a Barnes 4wd CJ skid plate. it's BADASS! Too bad it doesn't fit and I'll have to cut it all up and reweld it. :shaking:
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New shackle angle is much better. I have got to fix that hood angle.
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Upclose.
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One more of the new crossmember.
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Back at it today. Got a big project done.

I worked on the pitman arm. I built my own pitman arm using the splined portion of the original pitman arm only.

This is what went bye bye. :D
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Full lock one side.
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Full lock the other side.
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Different position. Full lock one side.
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Full lock other side. You can see where I twisted the pitman arm so it doesn't mind at full lock.
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Added some speed holes in the gussets...'cause it's what all the "cool" kids do.
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Another.
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Pitman arm mocked up. What do you guys think? Will this be strong enough?
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My CJ Barnes Skid went on a diet too. It was meant for late model CJs and my frame is the same width as early CJs so I had to shave off about 5-6" in the width and square it up since the framerails are parallel in my model vs angles framerails on later models. It wasn't too bad of a job with the use of my plasma cutter.
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Partially welded.
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Still loving this build man. That pitman arm should work pretty good and those speed holes should help it turn a little quicker too. :D Keep it up.
 
amajeepman said:
Pitman arm looks bad ass.
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bigblueyj said:
Still loving this build man. That pitman arm should work pretty good and those speed holes should help it turn a little quicker too. :D Keep it up.
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Thanks guys! I really appreciate it. I'm going to have the pitman TIG'd by my fiance's dad. He TIG'd the other stuff for me and he can make it look good. I'm hoping to have that done this week. I'm going to have him TIG the steering wheel quick disconnect too. I'm really glad you guys like it. With it sticking outside the framerail a custom part might make that ugly steering box look a little better. :D
 
I don't think you could really do anything that we wouldn't like on this build. You've already made it a killer rig just with everything you have already done. Looking forward to seeing it out and about man.
 
bigblueyj said:
I don't think you could really do anything that we wouldn't like on this build. You've already made it a killer rig just with everything you have already done. Looking forward to seeing it out and about man.
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Thanks man! Much appreciated. I can't wait to get it on the trail.
 
A buddy of mine came over and helped out in the garage today. I got the pitman arm, draglink and steering shaft welded up at my fiance's dad's shop the other night so that is done.

Crappy pic of the welded up pitman. You can see that I had him weld the washers on the bottom and top of the mounting holes.
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We also started on the front fenders too. You're probably thinking...WTF?! He bought rectangle tube instead of DOM. Well, I decided to change it up. I have had the idea of doing square tube fenders in my head forever but Poison Spyder took it right out of my head. I might be a little crazy but I just hope I can pull it off. :D
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This is my sketch of the fender design so you can get an idea of what it's going to look like when it's done. They have a long way to go but I'll have them done in a few weeks.
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That pitman arm is badass, and I'm waiting to see those fenders. Sketches are just as equally badass as the pitman arm.
 
Sick work man, freakin awesome!
 
Redneck92 said:
That pitman arm is badass, and I'm waiting to see those fenders. Sketches are just as equally badass as the pitman arm.
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49erRider said:
Man every time I check this thread I'm hoping to see a video of it fired up and pulling out of the garage.
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02dmax said:
Sick work man, freakin awesome!
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ORV design and fab said:
Very original man!!!!! Sick work
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Thanks guys! I really appreciate the positive feedback and responses. It's definitely motivational! Trust me, I look forward to the day I drive it out of the garage too. Soon enough I guess!
 
More garage time today. I worked on the passenger front fender some more.

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You can see that I went ahead and welded in some tabs for when I add inner fenders.
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You can see more tabs for the rearward area as well.
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My high-tech armor template. :D
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1/8" armor mocked up in place. The only thing I lack is cutting out the speed holes I'm planning for.
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Another angle.
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A buddy of mine came over and hung out in the garage for a bit so I got a little bit of work done.

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I think the middle hole needs to be a little bigger.
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Looks killer.
 
I helped a buddy of mine work on his XJ today so not much progress. I did get the "new to me" harnesses mounted in place.
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I love the Pitman arm, but I myself might worry if it would be too flexible under high loads on the trail. There is a reason there all made of solid cast. Keep up the great work though, I love seeing your updates!
 
dasbulliwagen said:
I love the Pitman arm, but I myself might worry if it would be too flexible under high loads on the trail. There is a reason there all made of solid cast. Keep up the great work though, I love seeing your updates!
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Thanks for the input! I'm not too worried about the pitman. It's much much more beefy in person than it appears in the pics. It is made with 3/16" plate as the top and bottom pieces and is welded all the way around on both sides of the factory splined piece of the pitman and the gussets are welded all the way around and plug welded along the splined shaft also. If it breaks, it will surprise me. Crazier things have happened though! haha!
 
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