'78 AM General DJ5

[altec]

I know, opening another candy bar before I finished the first one. :facepalm:

The Vehicle: 1979 AM General DJ5D 232ci I6/904 Torqueflite

The Condition: Apparent problems included rusted front fenders, single rust hole in frame, gas tank straps, slight transmission oil pan leak, and bad tires. The good is decent frame besides a single spot, good sheet metal everywhere else, starts right up, tight-ish steering, brakes just done, and good transmission. All new wiring, and LED tail lights. Clean title, and the simple fact that it is a mail Jeep is cool...

The Objective: A Unique Daily that I can afford to drive, but still use for my normal needs.

The Plan('s): I don't know... I have two ideas in my head. A lowered down hot rod style playing on the fact that it is already 2WD. Lowered Jeep's are rare... The other option is a 4WD conversion, and mild lift. The drawbacks there is added weight, and it's been done...

-Lowered Plan: Axle flipped rear, notched front frame, front axle moved forward. This plan requires a different engine. The oil pan occupies the space the front axle would need... The easiest solution for me is a engine swap... The GM 4.3L V6 is what I'm looking at. I found out the '90's Cherokee came in a 2WD that has the perfect replacement front axle. disc brakes, and no kindpins. Win-win.

-4WD Plan: Spring-over up front, Jeep axles, and a 4WD tranny/T-case combo to bolt to the 4.3. Cheap, and effective. The up side is that this option is a piece of cake, and I could do a bit of trail riding. Down side is the extra weight, and...it's been done...


The Current Plans:

1. Remove factory doors and fab up hinged half-doors. Making removable tops to make them whole doors.
2. Add passenger seat.
3. Body Work/Paint.

What I'm starting with. I drove it home (Only a couple miles). That was a hoot to drive on the right side with the door open with manual drum brakes.

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0739.jpg

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0740.jpg

Perfect floors!
http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0742.jpg

Only a couple spots of surface rust under it!
http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0743.jpg

Extra crap gutted out. I have no need for a mail tray, or fifty empty packs of cheap smokes...

I left the radio power wires in it, and tied them up. It will be getting another radio, but not the current "system." No real interesting stuff hidden inside. Other then a brick next to the parking brake handle. I think the brick IS the parking brake. lolx

Going to try and find a pair of nice low backs, and another one of them lap belts for a passenger seat. I think my Silverado seats are just to bulky...

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0745.jpg

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0744.jpg

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0746.jpg

Cool auto cross build. Gives me some insight on what I'd be looking at digging into the '76.

http://www.offroadfabnet.com/forums/showthread.php?t=7568

[mDust]

Haha! I can't believe there are no other comments... This is awesome! That is one interesting 'economy' vehicle. Built tough and cheap.

Why are you planning on getting rid of the sliding doors?

Isn't there an endorsement or something needed to drive vehicles from the right side? Maybe it's just my state...:think:

[blaze15301]

nice find altec. i can't wait to see what you do with it.

[altec]

The square tubing is ordered for the doors. Found Speedway Motors has door latches, and strikers that I think will work. Pondering using early '90's Miata door handles for the outside. Simple design, and aren't bad looking. Still don't know about the inside handle...

I found out Tractor Supply is discontinuing the Valspar tractor paint. So I need to go soon to get the paint for this.


Haha! I can't believe there are no other comments... This is awesome! That is one interesting 'economy' vehicle. Built tough and cheap.

Why are you planning on getting rid of the sliding doors?

Isn't there an endorsement or something needed to drive vehicles from the right side? Maybe it's just my state...:think:

Well, I've MIA recently. Between a new job, and most of my internet time going to tool sites. That might be part of the lack of interest. :(

Most people would rather have a car payment, and a new fancy car. I'd rather have something different, and no car payment. Oh, and cheaper insurance, and cheaper reg...

Honestly, the doors just don't do it for me. They look like an after thought, and make a hell of a racket when you hit a slight bump... So, I plan to make normal Jeep half doors, and then make inserts that I can slide right into the top with the door open, and when the doors close they will be pinched in place. Then have the top sectioned skinned by a friend who does upholstery. So all I have to do to get them off is open the door, pull them up, and throw them in the back. :D

No endorsement that I know of in MD. That seems silly to need one. driving on the "right" side has it's drawbacks, but so does the left...


nice find altec. i can't wait to see what you do with it.

Thanks. It really fell into my lap. I was doing a tune up on a DJ5 at work, said it was neat and a bud said he had one. A week later the deal was struck. Haha.

[altec]

If I didn't mess with the DJ soon, I was gonna go nuts. So I pulled the fenders off...

First fender off. Gotta love Jeep designs... Around eight bolts, and the fender is off... Of course, the over flow bottle, coffee can, and turn signal wires had to be unhooked first.
http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0786.jpg

Oh no! Firewall rot! Oh well, easy enough to fix...
http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0785.jpg

Other fender off. This one the fresh air inlet for the heater, an the washer fluid bottle had to come off. The bottom bolt on the front gave me trouble. Ended up rounding off, and had to use a extractor socket.
http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0787.jpg

How it looks now. The main reason I went ahead and did this is the motor is still fully covered! I was shocked to see that the core support/grill is still very rigid!
http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0791.jpg

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0792.jpg

Tube Fenders: Yay, or Nay?

[mDust]

Yay if you go the off road direction...otherwise nay.

[altec]

I'm feeling the same exact way. Before I didn't even think about tube fenders because I was planning for a lowed street setup. Now that I'm leaning toward 4WD, they are a option.

I found JCWhitney has a pair of fenders for around $270 shipped. Cheapest I've found. However, since I already have the metal laying around, I may try the tubes before spending the money on replacements...

[Snowman]

I say you leave it bone stock as far as height and drop a small block V8 in it.

[TLHarrell]

Must. Do. This.

http://thereifixedit.files.wordpress.com/2012/05/white-trash-repairs-the-ford-taurus-saurus.jpg

[AmEv]

♫We're the Flintstones♫

[altec]

Crack pipe down, guys! :banana:


I say you leave it bone stock as far as height and drop a small block V8 in it.

At the very least I would want to level it out. Right now it is raked, and I don't like it...

I have a 350 I could drop in. I want to stick with a smaller engine simply for gas mileage.

Although, some mounts, and a freshened up junkyard tranny would be all I need to drop in the 350. "For laughes." :think:

[blaze15301]

turn it into a drag car.

[altec]

I've had some 32" tires rotting away, and I had a idea... lolx Sadly, they rub... The bumper brace, and the frame. Probably just gonna lop the braces off, and see if I can adjust the stops.

The back needs trimmed, but I also need to do something about the sagged springs, so I'm going to wait. Get some Wrangler flares, and either repack the springs for now, or just order new ones...

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0800.jpg

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0801.jpg

Stretched... Euro trash style!
http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0802.jpg

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0803.jpg

Pirate4x4 poser shot! lolx

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0806.jpg

[TLHarrell]

Longer lug nuts and a spacer?

[altec]

No need to space them. This is simply a temp setup so I have four tires that are the same size. When I swap axles, I'll be getting wheels, and tires as well. Since most all the axles I'm looking at are slightly wider, it should work out in the end.

But, longer lug nuts wouldn't help. You would need longer wheel studs to support a simple through-hole. However most spacers you buy will have holes that you bolt to the original studs, and their own studs built in. So no modding it needed.

Like this.
http://www.4wheelparts.com/Wheels/Wheel-Spacers.aspx?t_c=11&t_s=107&t_pt=7576&t_pl=103343&t_pn=aly11300&gp=1&utm_source=google&utm_medium=froogle&utm_campaign=product&emlprox=out

[TLHarrell]

*studs* That's what I meant. It's been a looooong week...

Gonna be interesting to see this turn into a real 4x4.

[altec]

Ordered some rear TJ fender flares from JC Whitney (Free shipping code FTW). Also got some wire for welder.

Oh, and a random bit of info. When the title was done in '10 the vehicle was reported to have 330,000 miles. The odometer currently reads 13,500 miles roughly. So either it has 413,000 miles, or the odometer is broke.

[blaze15301]

Hey if you can use any parts off a 73 monte carlo let me know. I have to junk my car now since it has a rotted frame. thus is why i stopped making post.

[altec]

I'm sorry to hear that bud! :( If you don't mind, snap some shots of the rotted areas of the frame. I'd like to see. My '81 Chebby had a rotted out frame. I found a new a frame! But most of the time it can be repaired. Unless surface rot has made it to thin (That was my problem).

[blaze15301]

I cant take pictures. The whole is right where the mount for the trailing arm of rear end. The only way to actully fix it would be for me to pull the body completly off the frame cut a large section of the frame off and re weld new metal in. i would have to do this to both the passenger side and the driver. If i could find a new a frame i would do it but they are so rare.

[altec]

Take a large tree, or build an A-frame. Use a come-along/chain hoist to lift the body off the frame with cloth straps. Roll the chassis out, and slide a table, or 2x4 frame under. My only tip is to just cut the bolts off on the body side. I'd be willing to bet they are froze up. Cut the heads, then deal with the rest when you get the body out of the way. I'm sure somewhere like Energy Suspension sells a bushing/hardware kit.

Anything can be fixed!

My bed on a picnic table. We used to pull motors out of boats using a tree, and a rope "back in the day."
http://i13.photobucket.com/albums/a269/Mrjunior/Truck%20Project/100_5662.jpg


On Topic:

It would seem my poser-shot came back to bite me... Snapping the main leaf on the driver front... Now I'm just going to see about some different springs... To the junk yard!
http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0819.jpg

[altec]

Got home today and the Fedex man left me a present! Sorry about the crappy picture. Best angle/lighting I could get in the shop. It may not look that great, but it is perfect! The angle of the flare follows the door opening perfect, and with my plans of as little lift as possible the larger opening will be great! Just gotta measure everything out, make some marks and start cutting! th-smile

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0825.jpg

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0826.jpg

[altec]

Cut, and roughly on. I used a jig saw, and a cut off wheel to make the cuts. My only jig saw blade broke in the old trusty B&D, so I had to make a run to the hardware store to get more. Only one real problem spot I'll need to handle. No big deal.

I'm happy how it turned out. Taking that door off, and adding the flare really makes it look more like it's Jeep kin. Which is cool. You'll notice the tire sits in a lot. When I get some new axles, they should be wider, and fill them out. Right now, it does look a little silly.

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0828.jpg

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0831.jpg

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0830.jpg

Hopefully tomorrow I can get the other flare hung, and my other two tires mounted so it sits right... Then pull it out for some better pictures.

[altec]

Driver side done (Wink).

Take the door off. I don't know how you should get the back bottom slide off, but I just ripped it out... Then unbolt the door latch mechanism.

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0838.jpg

After the door is off, I take the bottom slide off. All but the bolt inside the cab shear off... When that is done I mark out my cuts. First I figure out where the inner fender well is. Drop that down a hair more, then mark a line. From there, I add another line above that one the thickness of the top of the flare. That is where I line the top edge of my flare for marking the cut out. Front-to-back is eye balled, and positioning on the line is the same.
http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0839.jpg


And cut! This time I left the area that goes into the floor pan. More on that later!
http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0842.jpg

Two hang the flare I use two top holes already drilled in it. marking a line straight up, and slightly over the top edge on both holes. Then I hold the flare where I want, and put a little dot on the body in the same place. It just so happens the center of the hole to the top of the flare is 1". So I measure one inch down on the mark I already have on the body and put a second. Drill a pilot hole, and hang with self-tapping screws. Piece of cake! The rest of the mounting holes will be drilled from the back side.
http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0844.jpg

A step back.
http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0845.jpg

It is now 8:30, I'm tired, and need a shower. So the tires will have to hold until tomorrow!

[altec]

All my tires now match...

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0850.jpg

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0848.jpg

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0849.jpg

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0851.jpg

How does a posi work? It just does! :)

http://i13.photobucket.com/albums/a269/Mrjunior/trucks/IMAG0852.jpg

Immediate things to do?

Body:
-Trim ends of flares/Add a few more bolts
-Make half-doors
-Make tube fenders
-Add mirrors (TJ mirrors?)

Chassis:
-Repack rear leaf springs
-Replace front leaf springs

Powertrain:
-Add new overflow bottle
-Replace radiator

[AmEv]

Going to adjust the speedometer to compensate for different tire size?

[altec]

Nah, I'm used to off speedos. Plus since the powertrain ain't staying, there is no real need to bother with new gears for the speedo. I'll get it taken care of when I get the transfer case in it. Or get a GPS speedo! :)