My '82 Jeep DJ5 Postal Jeep (3 Viewers)

[PNWGERMAN]

Just wanted to share my Jeep build with you all. Haven't been doing much with my wife's '91 FJ80 besides keeping it going, because the Jeep isn't a runner yet and its a PITA to constantly be rolling it in and out of my garage. Plan is to finally get this Jeep running this year, and then the 80 can get some more in depth attention and a motor swap.

I started this build almost 4 years ago now. I don't make a tone of money and don't have a lot of free time, so the plan was always to take my time and do work when I had the money and time to do it right.

Basics of the build, build a utility Jeep that wont get stuck in most situations but is geared more towards camping/hunting and exploring rather then rock crawling or anything like that. Maybe also a bit of a SHTF build. The forest roads here in WA can get real tight, and I already banged up my '17 Tacoma twice bad enough to need body work to fix it, so I thought Id build a small 4x4 I wouldn't feel bad about rubbing trees with. I really wanted a FJ40 but they were to expensive for me at the time. I picked this DJ5 up for about $1,400.

This is the most in depth build I have ever done. Lots and lots of learning along the way, as well as doing things I had never done before like tube bending. Lots of the things I did on this Jeep I ended up redoing till I was happy with the outcome.

The day I picked it up.

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Build specs so fare

Front XJ D30 high pinion with weld in axle tubes, manual hub conversion, Spartan locker, 4.10 gears, and Yukon chromemoly shafts. HD steering links and a DIY high steer conversion I did my self.

Rear has a D44 from a XJ with the tow package with an ARB air locker, disk brake conversion, Yukon chromemoly shafts, and an anti wrap bar. Will get some sort of truss.

Engine is a LQ9 from a '05 Escalade paired up to an upgraded 4L65E and a NP241 transfer case with a JB Conversions super short SYE kit. Engine is basicaly stock besides some strength upgrades like a better oil pump and head studs. Lots of LCE parts. Running a Holley EFI set up and digital dash.

Suspension is a custom set up I did some "math" to set up running custom length Bilstien shocks and Rock Jock sway bars.

Brakes are hydroboost

I only have 33" tires on it now but I plan to eventualy change to gearing and put 35" on it.

The first thing I did when I got it was clean up all the rust on the frame and body. Only major rot was in the floor, and I rebuilt the entire floor. Later on I had the entire body sand blasted in my driveway by a moble blasting service.

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Untitled by Jeremy Nugent, on Flickr

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Fitting the engine in place.

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Im also trying electric steering asist from a Prius. Spliced it into the original steering column.

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Rear swing out

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I also ordered an aluminum fuel tank off Ebay and modified it to fit. The original tank was super tiny. I first made a foam mock up. Its got a Holley pump in it.

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Untitled by Jeremy Nugent, on Flickr

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[PNWGERMAN]

Here is the trans mount I fabricated and a shot of the drive line set up.

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Untitled by Jeremy Nugent, on Flickr

Fun center consul project. Got a bit creative with this one.

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Untitled by Jeremy Nugent, on Flickr

High pinion steering set up. I used some PVC pipe to mock up the steering link so I wouldnt waist DOM.

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Here is some suspension

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Some of the basic cage work, nothing fancy or super hardcore.

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Random pics. I ended up giving up on these hinged doors, I couldnt get them to work right after three rebuild atempts. The original sliding doors wont clear the rear tires. For now Im going to have a local shop make me some snap on soft doors that zip open.

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Untitled by Jeremy Nugent, on Flickr

Right now I'm working on finishing up the body, getting it painted so I can move on to getting drive shafts made and doing all the plumbing, wiring, and exhaust work. This Dec. I got the interior finished up and painted. Im curently working on getting the Jeep set back down on its ass end with my sealing hoist so I can paint the bottom side. Then Ill move on to painting the exterior.

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Thats it for now. Kind of a very quick version of the build progress so fare. Lots of details I didnt cover. I have a more detialed build thread on Pirate 4x4, But i havent updated it in a long time.

My '82 Jeep DJ5 Build

Howdy, I want to start a build thread here hoping to get some more interaction and input. I have had a build thread going on The Jeep Forum, and Im just not getting any interaction at all. Not even negative. So here goes. I'm relatively new to the off road world. Most of my experience in...

www.pirate4x4.com

 

[PNWGERMAN]

Not sure why some of these pics aren't working. Ill come back and edit later.

 

[PNWGERMAN]

Got the underside painted with Raptor Liner today. Turned out nice.

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[ducktapeguy]

That looks awesome. I have a 75 DJ5D that looks a lot like your "before" picture. They're fun little cars, more like a large toy than a real vehicle. I lifted it a couple inches with some jeep YJ springs and done a couple Gambler 500's in it, but haven't driven it for a few years.

 

[PNWGERMAN]

That looks awesome. I have a 75 DJ5D that looks a lot like your "before" picture. They're fun little cars, more like a large toy than a real vehicle. I lifted it a couple inches with some jeep YJ springs and done a couple Gambler 500's in it, but haven't driven it for a few years.

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Super cool! They are tiny inside. Its hard to gauge the size looking at it in my garage. Will be interesting to see it next to out 80 ones its rolling around out doors.

 

[clrussell]

This is rad

 

[PNWGERMAN]

Finished up the paint on the Jeep last weekend, and regained half my shop space back by moving it outside. I used a bunch of tint-able Raptor Liner and tint from Veloci-Tint. If you want to Raptor Liner anything and have lots of color choices, Veloci-Tint has over 200 colors and you can order sample cards to help make up your mind. I went with Cavalry Blue and Bone White. Keep the USPS look, but make it kind of retro looking. I'm super happy with it.
Now that I have shop space back, I'm going to get the exhaust figured out and built, and do some plumbing.

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[PNWGERMAN]

I've been slowly working on the exhaust for the Jeep. Hookers LS headers, Summit 409 SS 2.5" tube, Vibrant Ultra Quiet resonators, and a Flowmaster Flow FX transverse muffler. Its been real tricky finding a good rout for the exhaust, Its really tight inboard with all the linkages, and drive shafts and stuff. So I had to go outboard and notch the frame a bit after the headers. But I got it all figured out. Excited to hear what it sounds like in a few months.

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[aztoyman]

Man. Super nice work and very cool! I'm sure my mail lady would LOVE to trade you for her Jeep without question. She HATES it.

 

[PNWGERMAN]

Man. Super nice work and very cool! I'm sure my mail lady would LOVE to trade you for her Jeep without question. She HATES it.

Thanks