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-   -   Jerry The '82 DJ-5M (https://www.jeepforum.com/forum/f22/jerry-82-dj-5m-4413541/)

PNWGERMAN 10-12-2020 07:59 PM

Jerry The '82 DJ-5M
 
This is my first Jeep build, and first domestic car. Iv owned and worked on mostly Germany and Japanese cars till now. I come from the dark side of Toyota, and my daily is a '17 Tacoma. I havent had a project car for about 6 years now because Iv been putting all my money and time into "adulting" and home buying. Got a sweet place with a work shop with the hopes of eventually putting a small 4x4 project in it that can wind its way through the trees here in the PNW.


So I saw the Gone Postal build, along with some other cool looking Postal Jeep at some Jeep meet ups on TV shows, and I liked the idea of doing something a bit weird that was cheep to get into and I didnt feel bad about hacking up. So I did some looking and had some fellow car nerds help out, and we found an '82 DJ-5M localy that I picked up.
https://live.staticflickr.com/65535/...077e7f23_z.jpgUntitled by Jeremy Nugent, on Flickr
https://live.staticflickr.com/65535/...1745243c_z.jpgUntitled by Jeremy Nugent, on Flickr



The plan is to build a fun mild trail rig I can take camping/fishing/hunting. Nothing to crazy. I want to use a lot of stock Jeep parts so that if I brake down some where it will be easy to find parts. So fare I'v been using a lot of XJ stuff. Id like to stick some sort of V8 from a Chevy truck in it like an LY2 or something with an auto trans and some sort of transfer case. Ill be running a D30 and D35.



As soon as I got it in my garage I started stripping it down. Pulled the body off and yanked the motor. The cabs not in bad shape. Ill have to throw in some floor pans up front and do some rust repair on the corners by the fire wall right under the A pillars where the fenders bolt up. Other wise its super solid. Frame is solid too.
https://live.staticflickr.com/65535/...8a249cd8_z.jpgUntitled by Jeremy Nugent, on Flickr
https://live.staticflickr.com/65535/...1d7f8136_z.jpgUntitled by Jeremy Nugent, on Flickr
https://live.staticflickr.com/65535/...303d3fa4_z.jpgUntitled by Jeremy Nugent, on Flickr

https://live.staticflickr.com/65535/...d21225c3_z.jpgUntitled by Jeremy Nugent, on Flickr


Iv started reinforcing the frame a bit and getting some bumpers welded on, as well as getting the XJ springs and axles mounted. Im going to wait to weld the spring purchases up till I can get all the weight on the chassis and I can set pinion angle.

Im spraying .035 flux core so things are a bit messy, but it allows me to burn a bit hotter with my Hobart 140 and I can run a fan when I get hot with out blowing my gas away. Now that its getting cold that shouldn't be an issue though. All the frame work is 3/16" stock, and the bumpers are 1/4".

I know the rear bumper looks a bit wide, but its the same width as the back of the cab, so if it comes down on any rocks it wont mush any sheet metal. Eventually it will get a swing out tire carrier too.
https://live.staticflickr.com/65535/...fa735a2a_z.jpgUntitled by Jeremy Nugent, on Flickr
https://live.staticflickr.com/65535/...821acd5a_z.jpgUntitled by Jeremy Nugent, on Flickr
https://live.staticflickr.com/65535/...189bef1b_z.jpgUntitled by Jeremy Nugent, on Flickr
https://live.staticflickr.com/65535/...e360b4e7_z.jpgUntitled by Jeremy Nugent, on Flickr
https://live.staticflickr.com/65535/...f4ba1109_z.jpgUntitled by Jeremy Nugent, on Flickr
https://live.staticflickr.com/65535/...1c191050_z.jpgUntitled by Jeremy Nugent, on Flickr
https://live.staticflickr.com/65535/...bdc7bd2d_z.jpgUntitled by Jeremy Nugent, on Flickr
https://live.staticflickr.com/65535/...f01fc72d_z.jpgUntitled by Jeremy Nugent, on Flickr
https://live.staticflickr.com/65535/...10242fed_z.jpgUntitled by Jeremy Nugent, on Flickr
https://live.staticflickr.com/65535/...01bdc576_z.jpgUntitled by Jeremy Nugent, on Flickr



Iv done a bit more work on the front bumper and axle but don't have pictures of that yet, as well as some caps and reinforcement tabs on the spring perch outrigger things. Ill get some updates later this weekend.

Progress is usually a bit slow because of work and life, plus COVID makes parts delivery slow. Waiting on a bunch of front axle parts for a rebuild.



Im hoping by the end of this year I can have the cab on the frame and get it all fixed up as well as getting both axles rebuilt. Next year find a motor and trans combo and do all the wiring, plumbing and so on.



Here are some of my inspiration pics.
https://live.staticflickr.com/65535/...1826ef73_z.jpgUntitled by Jeremy Nugent, on Flickr
https://live.staticflickr.com/65535/...2ca9e783_z.jpgUntitled by Jeremy Nugent, on Flickr



Thanks guys! If anyone has any input or ideas please throw them my way. Im new to Jeeps. Iv built a few track cars so Im not new to fab work, wiring, and so on, but setting up leaf spring suspension and all the other off road and USDM stuff is totally new to me.

4Low2G0 10-16-2020 11:33 AM

Looks like you have a good start on your project. I've always wanted a DJ

If you plan on running the stock DJ sliding doors make sure the
track width is kept narrow enough the doors can still open without
contacting the rear tires.

Are you planning on converting it to LHD or keeping the RHD?

My Idea was to build a stock looking 4X4 DJ that the USPS may have had,
but with some subtle upgrades.

Good luck on your build, subscribed.

PNWGERMAN 10-17-2020 11:11 AM

Quote:

Originally Posted by 4Low2G0 (Post 41099909)
Looks like you have a good start on your project. I've always wanted a DJ

If you plan on running the stock DJ sliding doors make sure the
track width is kept narrow enough the doors can still open without
contacting the rear tires.

Are you planning on converting it to LHD or keeping the RHD?

My Idea was to build a stock looking 4X4 DJ that the USPS may have had,
but with some subtle upgrades.

Good luck on your build, subscribed.

Thanks

Yeah I’d like to keep it close to stock, with a few modern touches. Nothing to aggressive. It will have a winch and some modern lighting upgrades but other then that I’d like to keep it close to stock looking.
It’s hard to tell yet if the doors will clear the rear tires. It’s been hard to find the time to wrap up the frame work and throw the cab back on to check.
I think I’m gona keep it RHD, and I have been doing some research on using Toyota parts to do an electric power steering upgrade. It’s something a few guys with older muscle cars have done, and Iv seen it done on some Suzuki 4x4s as well. It doesn’t look very hard. Basically it’s just chopping out a piece of the steering shaft and welding the Toyota section inline, and doing some very basic wiring.

4Low2G0 10-17-2020 12:19 PM

What wheels do you plan on using?

I like the electric PS idea.

measure the width between the inside of the doors and throw the wheels and tires on
measure the width outside of the tires and compare.

if you don't have wheels yes measure the axle flange to flange and see how much room you have.

It would really suck to have it not fit after all that work....

PNWGERMAN 10-18-2020 03:13 PM

Quote:

Originally Posted by 4Low2G0 (Post 41100683)
What wheels do you plan on using?

I like the electric PS idea.

measure the width between the inside of the doors and throw the wheels and tires on
measure the width outside of the tires and compare.

if you don't have wheels yes measure the axle flange to flange and see how much room you have.

It would really suck to have it not fit after all that work....


I remembered that I cut the rear bumper to the same width as the back of the cab. The tires and wheels I have on there now just temporarily poke out past the bumper a bit so I can already assume that when I put larger wheels and tires on the door wont clear. But I have some ideas to make them work and still slide. Otherwise Ill convert them to hinge out like a normal Jeep. But I am going to try hard to make them slide.

I like the wider track width of the XJ axles because of the high center of gravity. It will help it stay a bit more steady.

PNWGERMAN 10-18-2020 03:18 PM

I did a tiny bit of work today. Finished up the trailer hitch, and welded the D shackle/sling hooks on the front bumper. Also did some frame clean up and removed the last of the old brackets and stuff.

I have two small sections of frame I still want to box in but I have to grab a bit more metal to wrap that up. After I do that I can wire wheel the frame and get some paint on it. Im also hoping my front axle rebuild parts show up this week at 4WheelParts so I can get the temporary wheels on the front and roll the frame around. Then I can get the cab in the shop and start cleaning it up.



https://live.staticflickr.com/65535/...0f690ba9_z.jpgUntitled by Jeremy Nugent, on Flickr
https://live.staticflickr.com/65535/...2897ffe8_z.jpgUntitled by Jeremy Nugent, on Flickr

PNWGERMAN 11-28-2020 05:58 PM

Man I’m itching to keep progress going, but I’m waiting on some axle parts to show up so I can roll the frame out of my small shop, and get the body in for rust repair and modification. Every time I call 4 Wheel Parts to check on my parts, I’m told that because of Covid 😷 the factory is way behind on parts production and it will be another two weeks. I ordered early Oct and was originally told I’d have the parts Nov. Now it’s mid Dec. Hopefully they don’t get delayed again.
So I’m just collecting parts and supplies and day dreaming about the build.

4Low2G0 12-04-2020 12:24 PM

Any Progress?? :PopCorn:

PNWGERMAN 12-05-2020 12:38 PM

Quote:

Originally Posted by 4Low2G0 (Post 41140071)
Any Progress?? <img src="https://www.jeepforum.com/forum/images/smilies/popcorn.gif" border="0" alt="" title="PopCorn" class="inlineimg" />

Not yet. Still waiting on axle parts so I can roll the frame out of the shop and get the cab in for some body work.
I’m going to call 4 Wheel Parts again this upcoming week to see if I can get an ETA on the parts again. Should be here in a week or two according to their last estimate.

PNWGERMAN 12-17-2020 10:01 AM

Well I had to cancel the order for the front hub conversion and axles. They delayed it again for another 90 days and that was just an eta with no promise of delivery.
So I’m going to order parts from a different supplier.

Also does anyone have a recommendation for a mandrel tube bender for my home shop. Some affordable that won’t be used more then 4-5 times a year but is t a complete piece of ****.

PNWGERMAN 12-21-2020 05:51 AM

Placed a new order with Morris 4X4 for a Yukon Spin Free hub conversion kit plus both inner axles. Funny thing is the new order is delayed as well, even though the website said the parts were in stock. Ships 1/12/2021, crossing my fingers.

lovett86 12-24-2020 12:52 PM

I really like where this build is going.

PNWGERMAN 12-25-2020 09:19 AM

1 Attachment(s)
Quote:

Originally Posted by lovett86 (Post 41157863)
I really like where this build is going.

Thanks man &#x1f60a;

Good news. The shipping date for the hub kit moved to the 1st. And I got my inner axles and I joints already. Finally moving forward.

PNWGERMAN 12-26-2020 09:16 AM

Got a cool little Christmas present from my brother in law. Ill stick it on the dash when Im done with the project.

https://live.staticflickr.com/65535/...b8950681_z.jpgUntitled by Jeremy Nugent, on Flickr


I got my U joints installed on the inner axles yesterday after they showed up. Took all of 10 minutes, some times I wish it would take longer for the enjoyment of putting mechanical things together.

https://live.staticflickr.com/65535/...ee495b93_z.jpgUntitled by Jeremy Nugent, on Flickr


And a few weeks ago I fit my new 1" lift body mounts to the frame. I got board and just wanted to do something. Cant wait to get some work done on the body and drop it on the frame.

https://live.staticflickr.com/65535/...040ff6b5_z.jpgUntitled by Jeremy Nugent, on Flickr

4Low2G0 12-26-2020 01:05 PM

You should paint it white with the red and blue stripes LOL.

or at least some version of that.


The time now is 11:29 PM.

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