Gone Postal : Mail Jeep Build

[95yjjeep]

Another small project knocked out today. I cut 3 circular holes in each side of the frame rails and then welded in nuts on each side so I can bolt the transfer case skid plate to the bottom side of the frame rails like typical jeeps. This thing never had any skid plates so this had to be done before I could bolt on the barnes 4wd CJ skid I bought and then chopped up.

Onto a few pics. The nuts are welded in place, ground smooth so the skid will fit exactly flat against the underside of the frame on both sides. Glad that project is done, that was a PITA!

I'm going to add some additional metal to the skid to protect the bottom side of the transmission as well. I also have to finish welding and modifying the Barnes 4wd skid. Just haven't gotten that far yet.

 

[95yjjeep]

A buddy of mine brought over a new tool for my garage. I added some sticker swag to my new frig. If youre company isn't on my frig, just send me a sticker and I'll add it.

I helped that same buddy build some spring plate / shock tab mounts for his ECORS XJ. They are not done yet, but they should be pretty tough when they're done.

I worked on the skid plate a little more today. No major progress on my hoopty though.

 

[TJcrawler97]

thanks again for the help! Its going to be nice not having to leave the garage for a frosty beverage!

 

[95yjjeep]

I got some 7am fab time in this morning. Loved it! I got the skid plate finished up. I wanted to finish it this weekend so I can mark one more thing off of my to-do list.

Inside of skid. You can see where I butchered the original and then had to re-weld and fab in corner pieces along all 4 sides. I about should have just started from scratch but o well. It's done now!

I added a big piece to the front of the skid plate to protect the tranny.

Wide shot of the bottom. It's nice and smooth.

Bolted in place.

Another.

 

[UncleWillie]

That is a sexy looking skid plate. Will be a shame to beat it up.

 

[95yjjeep]

Thanks Warbeast!! Much appreciated.

 

[95yjjeep]

I had a pretty productive day today.

First off, I cut off the old threads on the SM465 shifter and found a random bolt that fit my new-to-me shift knob that my brother gave me. Everyone has to have a little bling in their rig somewhere.

After that I installed the junkyard brakes I bought a good while back for this build. My redneck engineering seems that it might actually work. I used the whole braking system from a ford explorer. The mounting flange is the same size with same threaded holes so it made for a super easy swap.

from the backside.

I also added the 1" stretch Barnes 4wd leaf spring perches. I went ahead and prepped the surface on the axle so all I have to do is weld them on.

That little 1" change did help.

I also messed with my plasma cutter too. I wanted to add a gusset to the rear bumper hoop because this is my only rear tow point.

 

[gmentavlos]

I think if you can mass-produce this jeep you could sell a ton of them to the Alaskan Postal Service or any where lacking paved roads and bad weather, just sayin....

 

[95yjjeep]

I think if you can mass-produce this jeep you could sell a ton of them to the Alaskan Postal Service or any where lacking paved roads and bad weather, just sayin....

I like it! I can't wait to go through drive thru's in reverse.

 

[95yjjeep]

A little update. Not postal related but I did finish up the spring plates for my buddy's XJ tonight. His name is TJkrawler97 on the board. I did go by MarsFab to pick up some tubing tonight to make my tube bender stand. Hanging around his shop motivated me to come home and weld anything.

 

[bigblueyj]

Build is coming along man. Still amazes me how far this thing has come since you first bought it. One question about the skid plate. Have you considered adding a brace to the front of it to tie it to the frame? I ask this because if you were to hit the front on a rock would it fold it up to the transmission? Maybe a small piece of angle iron or tube to the frame? Just a thought. I'm always one to over-build things anyways. Not trying to hijack it though. Still loving the build.

 

[95yjjeep]

Build is coming along man. Still amazes me how far this thing has come since you first bought it. One question about the skid plate. Have you considered adding a brace to the front of it to tie it to the frame? I ask this because if you were to hit the front on a rock would it fold it up to the transmission? Maybe a small piece of angle iron or tube to the frame? Just a thought. I'm always one to over-build things anyways. Not trying to hijack it though. Still loving the build.

Thanks. I'm definitely looking into adding a front support. I just need to route all the fuel lines and exhaust before I add anything because the framerails are so tight that there isn't much spare room.

 

[95yjjeep]

I have been working hard but I don't feel it shows. I am on vacation all this week so I'm hoping to get some more stuff done.

I started building a welding table. My dad gave me his old weight set to chop up and do something with so I built a table out of it. I just need to get a sheet of 3/16 for the top.

Upclose. I hacked up the table and made sure I could use the old bench adjusters as an axle stand.

I also started on my tube bender stand. Nothing fancy, just using the weight bench pieces.

I also built the upper radiator mount for my postal.

In place. I will drill holes and mount it to the grill.

I also got a new hood for my project.

 

[95yjjeep]

Back at it today. Vacation day #2.

I started by re-mounting the brake pedal in a new position so I could fit the clutch pedal also. I drilled some holes in the brake pedal to make it look better. I thought it would look like crap next to the wilwood pedal if I didn't do anything to it.

Then I got the brake master and clutch master installed along with the heim firewall mount for the steering shaft. It was a tight squeeze to fit everything. If I ever change that huge steering u-joint, I'll go to a smaller one which will help make more room.

Side note: the brake master cylinder is a 60s vintage corvette manual brake master cylinder from a 'vette with 4-wheel discs. I have seen some people have success with this master cylinder so I hope it works well for me too.

I made a spacer to fit between the heim firewall mount and the steering u-joint so the steering wheel doesn't move in or out. It seems like it should work well.

Then I started working on the 2nd tube fender. Now that I have a straight hood, I was able to get this knocked out fairly quick. I think making the 2nd one was the hardest one. Sucks having to make things match from side to side. I think it turned out okay. I just need to add the angled piece and then the body protection.

Front shot.

another.

 

[18_JKU]

Cant wait to see this thing finished!

 

[95yjjeep]

Cant wait to see this thing finished!

Me too! I'm trying to get it running this week.

 

[95yjjeep]

Back at it. Vacation Day #4.

I got my welding table finished up. I will add some shelves along the bottom but that isn't important right now.

My fuel system arrived from Summit Racing. Some assembly may be required.

I made a mount for the fuel pump.

Bolted in place. I'm running a Walbro GSL392 pump in case anyone was curious.

Fuel lines ran. I got 20ft of AN8 stainless braided lines and all the fittings needed. It was a pretty simple install.

Another shot.

In cab lines.

I haven't gotten any line for the rollover vent tube. I'll do that eventually too.

I also got the quick disconnect fuel line GM line adapters for LS engines. It made for a super easy install.

 

[95yjjeep]

Another weekend in the garage. The weather was awesome. A buddy came over to help me with my wiring nightmare. He was a huge help. He actually took my harness to work on it at his house. I had removed most of the unneeded wires but he finalized everything and set it up so it's ready for the external fuse connection.

He turned this...

Into this.

He removed these additional wires.

Today I started knocking out the interior wiring. I re-installed the gauges and added a check engine light since my buddy told me to add it.

Then started on wiring up the lights and gauge senders.

Still to do. Sucks!

Rear wiring is done. See the wiring above the window. I ran all the wiring up really high. It was done like this in the original wiring harness I removed. I also mounted some speakers. I got them out of another postal jeep. I did hit them with a coat of paint.

Finished front lights wiring. I still need to add some wire loom to protect the wires from damage.

 

[95yjjeep]

Another garage day. My buddy Michael came over again last night and today and helped out. He's definitely the man when it comes to wiring.

Here is the fuseblock I'm using for powering the injectors and obd2, etc, etc.

Driver side wiring after all the wires were ran to their proper locations.

Driver side all buttoned up. FYI. The place I bought the engine from sent me the wrong plastic intake cover. It's the old vortec cover. I'll run that one until I find the right 5300 cover.

Passenger side ready for the battery.

You can see in this pic where the fuse panel, relays and PCM are locations. I made a mount that I welded to the bottom of the battery box to mount the PCM.

 

[95yjjeep]

I got back to it last sunday and then again tonight after work.

Upclose of the battery PCM bracket I welded to my ballastic fab battery box bracket.

This was my seat for the day yesterday.

More wires buttoned up.

Gauges wired up.

Gauges and Check engine light lit up.

I also got the ignition wired up...then re-wired it since I needed to change a few things to make it run. HOPEFULLY it will run by this weekend.

 

[49erRider]

Never been more pumped to see a build finish!

 

[95yjjeep]

Never been more pumped to see a build finish!

Thanks guys! I really appreciate it. I've been working on this thing every night after work trying to get the wiring knocked out so I can try to get it running this weekend. Wiring definitely tests your brain power and patience. I've been scratching my head over quirky wiring issues for days.

 

[95yjjeep]

Got the tail lights / brake lights / turn signals working. I also got the wipers and horn power ran. I just need a horn now. haha! Now just have to figure out why the front lights are not working. Once I get the headlights finished up I HOPE that they'll work properly. I've waited a loooong time to see these lights light up.

Another. Pardon my messy garage. I've been busy.

 

[02dmax]

Man I cant get enough of this build. Your fab work is amazing and the Jeep is going to be sick! I love it. Next time Im in Charlotte I would love to see this in person. My favorite build on here for sure!

 

[95yjjeep]

Man I cant get enough of this build. Your fab work is amazing and the Jeep is going to be sick! I love it. Next time Im in Charlotte I would love to see this in person. My favorite build on here for sure!

Thanks man! I really really appreciate it. Your comments and opinions are definitely helping me stay motivated to finish this thing. I've been working on it every second of every weekend and every night after work to get it running. Thanks for the kind words and I'm hoping to have a start up video on here in the not too far off future. Whenever you're in Charlotte give me a heads up and we can hang out in my garage and have a few beers. maybe even start it up with open manifolds. My neighbors are going to LOVE me.