Gone Postal : Mail Jeep Build

[95yjjeep]

I can do it Chad. Hit me up when you're ready.

Thanks Chris I'll hit you up.

 

[95yjjeep]

No major updates or anything but I think everyone can appreciate this.

sSats unpacked and sitting in my den. All black vinyl corbeau baja ss suspension seats. Now I just need to finish up those damn floorboards so I can start on the rollcage and seat mounts.

 

[bigblueyj]

Awesome build man. Makes me want an old DJ for sure. I like the look of it. Keep it up and keep posting up the pics.

 

[95yjjeep]

Awesome build man. Makes me want an old DJ for sure. I like the look of it. Keep it up and keep posting up the pics.

Thanks man!

 

[95yjjeep]

I picked up an RCI 2161 aluminum 15 gallon fuel cell off NC4x4 today. I haven't gotten much done lately because I've been traveling a good deal with work. Luckily I just got back from my last work trip of the year. Now I should be able to get some work done.

This was one dirty ass fuel cell when I got it. It was used but it was never run or hooked up so it's basically new, just really dirty.

then i hit it with some aluminum polish for about 2hrs and put it in the jeep about where I'll be mounting it. I know polishing it is overkill but I think it looks so much better than it did before.

 

[95yjjeep]

got a little more done today. I finished up the other floor subframe. I sanded the top side of the sub floor smooth so I can plug weld sheet metal on top and it will fit perfectly to the tub. Now I need to weld the subframes to the tub and make a tranny tunnel.

 

[dasbulliwagen]

Dont you think you should wait to build your trans tunnel until you have a drivetrain in mind, in case you need to build around transfer case clocking or engine and trans mounting height? Just asking. Love the build. Keep up the great work!

 

[95yjjeep]

Dont you think you should wait to build your trans tunnel until you have a drivetrain in mind, in case you need to build around transfer case clocking or engine and trans mounting height? Just asking. Love the build. Keep up the great work!

Thanks for the input! I'm only building part of the trans tunnel at this point in time. I will explain with the pics I'm about to post up.

 

[95yjjeep]

I went back out into the garage and messed around tonight. I wanted to build part of the tranny tunnel because I want the full piece to be welded together so I can get everything squared up nicely when I put the subfloor into the jeep tub. Then once I have it fully welded I'll drill the holes for the body mounts and then weld the full piece to the tub.

another pic. the tunnel I'm building is at the farthest point of the floor from the transmission. I guess this is kind of a driveshaft tunnel?!

 

[95yjjeep]

I put the tacked up subfloor in tonight to make sure all was good with it before I fully welded it. The cross braces in the frame I made will be sitting on top of the body mounts that they're behind.

 

[95yjjeep]

I worked on the bracing today. It doesn't seem like I got much done but trying to weld 5ft of sheet metal takes FOREVER!!!!!

I welded in a cross support that connects to two braces I've already welded in. It really really stiffened up the tub. Once I welded the rear floorboards to the cross brace, I hit everything with a flap disc and hit it with some primer.

Tomorrow I'll weld in the subframe assembly I've built. Next weekend I'm probably going to add sheet metal and weld in some plating on the inner framerails where the rear spring perches are.

 

[95yjjeep]

I got quite a bit done today. I first drilled the holes for the body mounts and then painted the underside of the subframe I built.

then installed and some of the pieces welded in. I'm still adding a lot more support but you can get the idea. I had to stop working on the floors because it started raining. sucks not having a big garage.

another.

When it started raining I went into the garage and started building a my fuel cell hold down mount. I used 1/8" cold rolled steel sheet for the frame. It's just a design I thought up. I was pretty happy how it turned out.

 

[95yjjeep]

Side 2. I made the mount bigger on this side to make it look more unique and to also cover up some imperfections in the used fuel cell I bought. The previous owner spilt something on the cell and discolored the aluminum. Best fix....cover it up!

Side 2. I made the mount bigger on this side to make it look more unique and to also cover up some imperfections in the used fuel cell I bought. The previous owner spilt something on the cell and discolored the aluminum. Best fix....cover it up!

A buddy of mine came over and lended a hand tonight. it helped me get more done.

Side 1 again.

Side 1 again.

 

[whitneyj]

very cool mount design.

 

[MarsFab]

Dang man! You outdid my cell mount!

 

[95yjjeep]

very cool mount design.

Thanks! It still needs another coat of paint and I have to drill the mounting holes but it should be rough mounted in the turd this weekend hopefully. Gota long weekend coming my way.

Dang man! You outdid my cell mount!

Shooot! You must be huffin' spray paint if you think mine is better. I appreciate the compliment though!!! I've been drooling over your new Bronco buggy build.

 

[bigblueyj]

Saw that it made it into JP magazine. Congrats on that man. Any progress made lately?

 

[95yjjeep]

Saw that it made it into JP magazine. Congrats on that man. Any progress made lately?

Thanks man! I was so excited about making JP magazine that i went to wal-mart the other day and bought 4 issues. i'm a dork i know! haha.

no progress today. i'll get out there tomorrow and get to work. i'll post up what i get done.

 

[95yjjeep]

I finished welding in the cross braces for the floor today. now it just needs sheet metal. I'm planning on adding another piece of rectangular tubing on the front of the subfloor that will be welded onto the bottom of the sheet metal that I'll be replacing that is below the little door passenger vents. That would be done on the far right of this image.

The a-pillar structure was rotten so I cut it off at the brace I added in and then added in two more of those short braces so strengthen things up. It should be very strong now.

another.

Upclose of the braces that are welded to the tub. The top brace they're welded to is one I welded in a few weeks ago.

Wide view of the whole jeep after I hit it with some primer.

 

[95yjjeep]

I also drilled holes in the fuel cell mount and floor and went ahead and bolted it in. I used some spare cj-5 urethane body bushings that I had left over and put them between the cell and the floor. I thought it would help prevent noise and vibration.

back.

Wide shot...driver side.

 

[upnover]

Lookin good man! Congrats on the JP shoot. I dig it!

 

[95yjjeep]

Lookin good man! Congrats on the JP shoot. I dig it!

Thanks! I really appreciate it.

 

[95yjjeep]

nothing really productive today. I did start thinking about the roll cage so I sat the seats in the jeep and took my first ride. hahah! I wish!

I'm about 6'2" and I pushed the seats back as far as possible. It's still not as much room as my YJ but it's better than a CJ-5. If I had not cut out the floors where I did, I wouldn't be able to fit in the front seats since it would be so tight up front.

another of just the seats and not my ugly mug sitting in them.

 

[Nissanwheeler]

Looks good man, Exo-cage or inside cage? I have a nieghbor that has one of these mail jeeps but its just sitting there rusting and everytime i go by it i see the potiental and it makes me mad that they dont even give it the time of day

 

[95yjjeep]

Looks good man, Exo-cage or inside cage? I have a nieghbor that has one of these mail jeeps but its just sitting there rusting and everytime i go by it i see the potiental and it makes me mad that they dont even give it the time of day

Interior cage for sure. it'll be a simple 8 point cage. I'm going to start accumulating tubing in the next few days. The seats will be mounted directly to the cage and I will tie in the cage to the frame at 6 of the 8 points. I want to build the cage before I add the sheet metal to the floor so I can drop the cage down through the floor to weld the top of the cage bars. I thought that would make it easier and cleaner than drilling a bunch of 1.75" holes in the floor to drop the cage down to weld them up.