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Old September 1st, 2012, 10:06 PM   #1
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Default Postal CJ

I've browsed this forum a few times and really like it. Decided to share my wheeling rig with you guys, maybe get some tips and ideas along the way.

I'll keep this post shortish. I just built my postal last year, but after wheeling it a couple times its not good enough. Gearing isn't low enough and its too tippy. Thats why I'm tearing into it again. I got it as a Postal DJ body on a CJ frame. So I swapped the steering over to normal left hand drive in the body to match the frame. With the clutch linkage this was much easier and saved me money up front. Got it with no motor, t90, and d18. I put spacers on the stock axles and slapped my 33's on. Stock F head was installed, then power steering. Fuel cell cut into floor. There was a 3" body lift in it as well, helped it fit the frame. But after the first trip I cut it down to about 1/2" because it was too tall.

I've now picked up an AMC T18 with granny gear, d20, GM 4.3l Vortec, ford 8.8 rear end, scout 2 d44 front end, and I wanted to go spring over to get some flatter springs. I think I'll keep my RC 4" yj lift leafs though because it'll be much easier. And it'll likely get to see a trail again this year if I keep my spring under setup, since I haven't found any close to me stock yj leafs. Hopefully the wiring for the 4.3 isn't too much of a problem.


picking it up


body lift was stupid tall, was removed after first wheeling trip








Too narrow





picked up some more tubing to build the cage, I got scared a couple times of flipping it on the last trail. Was very close to it. Then someone flipped over right in front of me on the way out, it was a great excuse and motivator to build my cage.



then some spray paint



getting the 4.3l out, what a pain it is to pull these motors..
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Old September 1st, 2012, 10:09 PM   #2
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um, there is a 2002 in the mix?
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Old September 1st, 2012, 10:24 PM   #3
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So far on the rebuild I've gotten the front scout 2 dana 44 knuckles turned, bolted the front and rear axles up, finally got my Novak stuff figured out after incorrect shipments and studs breaking so the motor and trans are bolted together, twin sticked the dana 20 case, and I put the motor/trans/tcase in the jeep. I welded up the front motor mounts and got that done. The setup is up and back as far as possible, but afterwards I noticed that the stupid oil pan is like 5" below the frame rails… And I need to bend the levers back so that when they are in the forward positions they don't smack my knuckles into the dash. So tomorrow I think I'm going to chop my motor mounts out as well as the tunnel so I can get them back farther and up higher. I'm going to measure the drive shafts and see if this is a good idea first though, and maybe get a second opinion. I also installed a TJ rear bumper with tire carrier.

8.8 perches



outboarding front leafs




finished the knuckles with my new welder



tire carrier


two sticks!


spent about 2 hours trying to get these two things together


then put it in and made the mounts

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Old September 1st, 2012, 10:30 PM   #4
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Quote:
Originally Posted by High Center Hancho View Post
um, there is a 2002 in the mix?
Yes, glad to see someone that knows german cars too! It's my amazing little restomod. M42 swap, 5 speed, half cage, RS's that I built last winter, lsd, speedhut gauges, roundie tail light swap, rust…but I still like it.





Last edited by gli_ryan; September 1st, 2012 at 10:33 PM.
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Old September 1st, 2012, 10:46 PM   #5
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Wow, I wanna be ur friend. Both are sweet. I'd love to get my hands on a PJ one day.
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Old September 2nd, 2012, 08:21 AM   #6
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Cool Jeep, and nice welds.
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Old September 2nd, 2012, 09:36 AM   #7
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Good looking jeep
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Old September 7th, 2012, 12:43 AM   #8
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Quote:
Originally Posted by OttoMan View Post
Wow, I wanna be ur friend. Both are sweet. I'd love to get my hands on a PJ one day.
I want to be your friend! I've never been into Canada, but plan on buying a new muscle cruiser bike after I graduate to travel around up there and check it out.

Thanks for the compliments! Today a friend and I got most of the wiring done, just need to clean up old wiring pretty bad. I also noticed my rear axle isn't straight! Not sure where the issue is yet, but I seems like it is in the mounting spots on the leaf where the axle sits. Never noticed/had this issue with the last axle. But the shims aren't in the same location relative to the spring pads on the axle tube. I'm going to pull the shims anyways and I'll investigate further then. Hoping to start it up this weekend and replace my rear end gears.
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Old September 8th, 2012, 06:26 PM   #9
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Been working on this the past two days attempting to get it ready to start up. Attempting to start it now, but the starter isn't kicking in. I think that thing is fried. Fuel pump sounds good the first time it starts up, then after that when it kicks on it sounds like the battery is dead. It's still over 12v though.

everything in…had to move the shackle mounts forward and screwed up their placement. Going to have to build mounts into a front bumper


moved my wheel up so the tilt was useful.



and how it's sitting now.
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Old September 9th, 2012, 08:03 AM   #10
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Quote:
Originally Posted by gli_ryan View Post
Yes, glad to see someone that knows german cars too! It's my amazing little restomod. M42 swap, 5 speed, half cage, RS's that I built last winter, lsd, speedhut gauges, roundie tail light swap, rust…but I still like it.
very cool, I've always had a soft spot for the 2002
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Old September 12th, 2012, 10:16 PM   #11
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Finally got the damn thing started. The wiring got mixed up and the ecu was not getting power under cranking.

I'm waiting on gears for my dana 44 front and a new press. Then I'll finish my rear end and start my front.
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Old September 13th, 2012, 11:27 PM   #12
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8.8 drive gear teeth. Some look really good, some don't really look that good.


coating teeth


The gears are used. Based on the coasting pattern I think thats as good as it gets. The drive pattern is a little towards the inside of the gear. The paperwork I have says that the pinion depth is good in terms of the coast pattern. But based on a majority of the drive patterns it says add backlash. Backlash is already at .010 though, so I'm going to leave it as is I think.
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Old September 14th, 2012, 03:34 AM   #13
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Pattern looks great to me. Go with it. Cool build too !
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Old September 15th, 2012, 09:41 PM   #14
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After putting my new bearings on it was all dickered up. Got is as good as I thought I could. Got the d44 re-geared this morning too. Hoping tomorrow after I get off work that I can redo my front leaf mounts to move them back an inch or so. I'd love to have my jeep on tires and ready to go in that sense in a couple days. Getting tired of working on this in all my spare time though, really need to just get it done though.
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Old September 18th, 2012, 12:00 AM   #15
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Got the clutch linkage built today, need some adjustment so it fully disengages though. Put the front driveshaft in as well. Tomorrow I should be able to get quite a few more things checked off my list of things to-do.

Also looking at some 80% tread, 38.5x14.5 Swamper SX's. Seem to be a fair price, and there are 5 of them. I'd rather have 35-37's but this seems like they would be perfect. I don't have any experience, but it sounds like I should be alright with my axles and them if I'm just crawling around like I usually do.
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Old September 19th, 2012, 03:22 PM   #16
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Seems like I've got a working clutch linkage, it's not top notch by any means but works. Hopefully works without fussing too

Picked up some cool stuff last night! 38.5x14.5 swamper sx on wheels and a 1979 Rockwood drill press. Press is like new! I've also got a question concerning my suspension. The jeep leans to the drivers side pretty good. I double checked and all my perches are the same distance apart and I even swapped leafs from one side to the other. It still leans. There really isn't any weight thats more on one side or the other either. The shackles show the lean with an increased angle as well.




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Old September 19th, 2012, 04:08 PM   #17
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did you crank down the shackle bolts to tight?
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Old September 19th, 2012, 05:47 PM   #18
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They are all loose. I can double check the back, but the front isn't even tight. I'm fairly certain the back is in the same situation though, not even tight. I flipped the rear springs around first and didn't get a change. Then I switched the front springs around with no change either.
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Old September 19th, 2012, 09:02 PM   #19
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hmm. did by any chance you flip one of the springs around in the front causeing the arch to have a different position for the center pin?
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Old September 19th, 2012, 09:09 PM   #20
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jackstands and floor level?
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