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1970 Dj-5a Lhd Dispatcher 100 Ex-postal "rattletrap"

Discussion in 'Builds and Fabricators Forum' started by Rustman, Dec 31, 2019.

  1. Dec 31, 2019
    Rustman

    Rustman Member

    Charles Town, WV
    Joined:
    Dec 28, 2019
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    87
    When I was 17 and driving around my Dad's hand me down 84 Toyota pickup with rust holes you could put your head through I decided I wanted an old Jeep. I really can't remember the series of decisions that landed on Dad and I driving 3 hours to look at an old Postal Jeep in Philly. I wanted it but was terrified of the thing with the shaky front end and leaking master cylinder. My father, oddly being the braver man at the time, drove it home while I drove the family van following. At a stop at an I-95 rest area he also demonstrated in the parking lot two things (1) that the old Jeep can REALLY GO FAST and (2) that beside the other idiosyncrasies to be worked out the throttle would stick.

    When I bought her she had a black paint job and silver wheels. this was over the clown paint job of it's former life as a 'Water Ice' truck. Must be a Philadelphia thing. Everywhere else I go they just call it Italian or Shaved Ice. 'Water Ice' seems both redundant and pedantic... I drove it in black for a while and then decided to make her Rustoleum blue and stencil on "McHales Postal Service" and "USN". When I parked it I'd hang a life ring from the mirror. It brought a lot of attention at the car show and blue grass festival in Deale, MD that year.

    After bringing her home the next few months saw a new master cylinder, new wheel cylinders, new king pins and nylon bushings on the front axle and a host of other minor things. I drove her as a primary car for a couple of years and decided I wanted a 4x4 so I went back to my other roots and got an 84 Toyota pickup, 4x4 this time. But that's another story. The Jeep stayed around and in fact was used for parts runs for the pickup quite often.

    I then got married and the Jeep was used less and less, we were poor so it was parked with the insurance and registration dropped. And it was parked for fifteen years! This year I decided to resurrect the old girl. So two new (used) tires to replace the two worst on the Jeep so she would at least roll into the trailer was followed by some fresh gas, replacing the condenser points which had corroded into an art project and tearing the carb halfway apart to clean it enough to make things go. On November 30th 2019 Rattletrap moved under her own power! And left a murder scene in my driveway as I realized the transmission cooler lines are as porous as a screen door.

    I travel a lot for work so much of December nothing happened but ordering parts off the internet. But that's changing now. Pictures and more of the story in the next post.
     
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  2. Dec 31, 2019
    Rustman

    Rustman Member

    Charles Town, WV
    Joined:
    Dec 28, 2019
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    87
    Classic 3/4 pose showing the layers of paint shedding off:
    Engine compartment with the GM 153 engine:
    Kaiser Jeep VIN tag. I refer to her as the "Last of the Kaisers" because somewhere around there things must have switched to AMC/AM General:
    I've been searching out the manuals when I started I never had the Service Manual, only a Universal Jeep CJ/DJ one, never the correct one for this model. The service manual was a recent eBay find and as a bonus the lubrication chart was with it as well. I believe the only manual I'm missing now is the Operators Manual.
     
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  3. Jan 2, 2020
    Jeff Bromberger

    Jeff Bromberger Quarantined in the Garage

    Dallas Metroplex...
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    Jun 28, 2019
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    I have a bunch of new parts for a 10 inch brake solid axle, if you need. Bearings, that goofy tie rod end (LHD only) and a new kingpin kit. Also, new square U bolts in case you need to reinstall the Clark front axle.

    I have an odd feeling that maybe you already did a front axle swap...
     
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  4. Jan 3, 2020
    Rustman

    Rustman Member

    Charles Town, WV
    Joined:
    Dec 28, 2019
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    Jeff,

    Thanks for the offer. The Kingpins were redone when this was my daily driver. The axle is the original Rockwell, still a solid, still 2wd with Kingpins, but it's not a Clark, it's a round axle, not square. Not sure the brake size. Not sure about my tie rod end. The steering components were all ok enough for Maryland inspection all that time ago. But as I proceed I'll let you know.

    Thanks
     
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  5. Jan 3, 2020
    ojgrsoi

    ojgrsoi Retired 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Weatherford, TX
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    FWIW

    DJ5A, B & C all came with 10" brakes.
    D, E, F & G all came with 11" brakes.
    L & M came with something else. :shrug:
     
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  6. Jan 3, 2020
    Rustman

    Rustman Member

    Charles Town, WV
    Joined:
    Dec 28, 2019
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    87
    Mark thanks! I did the brakes almost 20 years ago. And I know they need work now as they don't work :D Ask me how I know :shock: (Pulling back into my drive after the inaugural test run I almost hit the horse trailer. Turns out the parking brake does still work...)

    Anyway I don't know yet what parts are needed. I'm figuring one of the lines rusted out somewhere. It's on the to-do list.
     
    Last edited: Jan 3, 2020
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  7. Jan 3, 2020
    Rustman

    Rustman Member

    Charles Town, WV
    Joined:
    Dec 28, 2019
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    Here is the before and after pictures of my carburetor. In between I took it apart down to every component I could. Removed all the grease, carbon, dirt and varnished gas by soaking in a Crockpot with Pinesol. Rebuilt using a rebuild kit from Mike's Carburetors and some new Fillister head screws from Fastenal. Aluminum and linkages were painted with Alumi-Blast spray paint, multiple coats then baked in the oven for a few minutes at 200 degrees. I followed directions to the crossed t and dotted i. Upon reinstallation the carb performed flawlessly!! I pulled the choke, cranked her over, once the fuel pump had filled the bowl Rattletrap started right up. I eased off the choke, had to adjust the idle speed slightly to keep her running, but after that she was perfect. It was my first carburetor rebuild and I'm still amazed. So my advice if you've never done one before and are getting ready to is; simply follow directions, take lots of photos as you take it apart so you know how it goes back together and just be methodical.

    That was the morning of New Years's Eve. I'm still amazed at my success.
     
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  8. Jan 4, 2020
    Jeff Bromberger

    Jeff Bromberger Quarantined in the Garage

    Dallas Metroplex...
    Joined:
    Jun 28, 2019
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    Parts for the older 10 inch system are harder to get than the more current 11 inch system. If you need stuff that's not local to you, I've "got a guy" here in Texas, about an hour from my front door, who specializes only in DJ5 parts. :rofl:

    I just was forced to swap front axles because of a rare part that needed to be replaced and isn't manufactured any longer. In the process, I have the added perk of going up to the larger size. As I mention in my "regular" thread, I now own a 1974/1975/1976 DJ5 "half C, half D", all depending upon which part you're talking about!
     
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  9. Jan 7, 2020
    Rustman

    Rustman Member

    Charles Town, WV
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    Dec 28, 2019
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    Would your guy be John Rose? Apparently he worked for the Post Office as a fleet mechanic for a long time before making this his business. He certainly knows his stuff on the Postals.
     
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  10. Jan 7, 2020
    Jeff Bromberger

    Jeff Bromberger Quarantined in the Garage

    Dallas Metroplex...
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    Jun 28, 2019
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    Indeed. His back yard is a sorta graveyard for postals. He has everything there, except for that one tie rod end I was struggling to find.

    If you visit, and you should, be prepared to spend time. My first ended up at 3 hours, and we talk via phone every 3 or so weeks now.
     
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  11. Sep 2, 2020
    Rustman

    Rustman Member

    Charles Town, WV
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    Dec 28, 2019
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    Updates! I know it's been a LONG while. When the pandemic really got out of hand I was overseas for work. I remained there as "essential personnel" for several weeks, getting home mid May. Then I spent the summer doing all kinds of stuff around the house including setting up a workshop from two 20 ft shipping containers. Finally in the last couple of weeks I resumed working on Rattletrap.

    I had to move her out of the way to get new gravel for that drive. To do so I first needed to replace the hoses for the transmission cooler. Along the way I found and fixed a long time ATF leak. Seems one of the inverted flare pipe connections out of the transmission had been loose for some time. The gas tank is still out so I stuck a gas can under the floor dropped the fuel line in and after filling the fuel pump recharged the bowl on the carb she started right up! I moved my gas can out of the way and drove Rattletrap down the lane to my main drive and to in front of my shop.

    The gas tank was a mess. It had taken a hit from a stump or something well before I bought it, and when I cleaned it out I discovered several pin holes in the bottom. Since these tanks are pretty unobtainable I decided to fix it. Many, many, many, many hours later I straightened it, mig welded in a patch, leaded in all the pin holes from my welding, smoothed it with Bondo and painted it. Still needs another coat. I also hit the fuel filler and gas tank straps.

    I need a body grommet and fuel filler hose. I can get both from Walcks. I think... There are two that look right of each. For the Truck and for the Wagon. I sent an email to them last week asking for dimensions so I could compare and get the right ones but haven't heard back yet.





    Matt
     
    Last edited: Sep 2, 2020
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  12. Sep 24, 2023
    Rustman

    Rustman Member

    Charles Town, WV
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    Dec 28, 2019
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    Looking at getting some of the proper size and look tires for Rattletrap: the stock rims are 4.5x14. I'm looking at the STA Super Traxion tires in the E78-14LT size. The listed rim on the company website is 5.5x14 will they work? Ideally I'd like to put STA Super Transports on the front, as the Jeep being 2wd originally had "standard" tread on the front and mud & snow on the rear. but the Super Transports in that size are currently impossible to find.

    Thanks
    Matt
     
  13. Sep 26, 2023
    Buildflycrash

    Buildflycrash More or Less in Line. 2024 Sponsor 2022 Sponsor

    Gulf Breeze FL...
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    That tire will fit your wheels.

    How about a little jeep update? It’s been a couple years. Driving it much? Any new photos?
     
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  14. Sep 26, 2023
    Rustman

    Rustman Member

    Charles Town, WV
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    Work and life have gotten in the way. I haven't even started it in a long time. I need to order a fuel pump. It seems to have gone belly up.

    I bought a donor vehicle to get a lot of the rare parts from. Goal is to bring it out to the Mason Dixon show in a couple of weeks. Working on it will be all I'm doing for the week before the show.

    Matt
     
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  15. Sep 30, 2023
    Rustman

    Rustman Member

    Charles Town, WV
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    Today's tasks were to replace the fuel pump. (easy). Replace the fuel line (challenging but accomplished). and Determine what brake parts I need (that one went sideways).

    First the original AC Delco fuel pump finally gave up. I'm kinda sad, it had a nice prominent "AC" on the side and my new pump has nothing. But it was an easy swap and fuel is flowing again. I went to install the pre-bent stainless fuel line I bought from Summit a year or two back, I suspect it was for a 6cyl. Everything was going mostly ok until it was pointing somewhere past the carb. I managed to rework it and cut it down to fit. Along the way I realized looking in the manuals again that the hard fuel line terminates before the carb and is connected with a rubber hose for the last several inches. Mine goes all the way.

    Now to the brakes. I jacked up Rattletrap, blocking up all four wheels so I could work on the entire system. I pulled all the drums, the mechanics all look fine, the wheel cylinders show now sign of leakage. the brake lines look pretty bad on the outside and the master cylinder is dry and rusty. the fluid went somewhere... I think I might just replace all the brake lines, the master and all four wheel cylinders. Just do it all.

    Anyway. This is where things get interesting. The left front wheel, when I went to remove the drum I noticed it had a lot of extra play on the hub. Like I could move the hub in and out over a 1/4". Hmm, says I, this can't be good. So I pull apart the hub... Now I've replaced/repacked dozens of trailer wheel bearings. I know I must have done these hubs when I was a teenager, but I can't recall doing them specifically. I have never seen anything like this before.

    That is the outer bearing cracked into multiple pieces.
    This is the inner bearing somehow shoved into/over the grease seal. To get the inner race off I had to cut it with a grinder. Turns out bearing races are really hard steel. I chipped two cold chisels before figuring out that wasn't working.
    Here's the outer bearing cleaned up. The inner race is in threee pieces now, the cage is blown out one side.

    I don't know how this happened or what I did with this Jeep 25 years ago to cause that kind of destruction. I just am really happy that I caught it today and that the bearing, the grease seal, the two washers, the nuts are all readily available. They are the same as the Dana 27 axles of the era. Just have to decide which place to order them from.


    Matt
     
  16. Oct 4, 2023
    Buildflycrash

    Buildflycrash More or Less in Line. 2024 Sponsor 2022 Sponsor

    Gulf Breeze FL...
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    Amazon or Summit.
     
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  17. Oct 5, 2023
    Rustman

    Rustman Member

    Charles Town, WV
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    Dec 28, 2019
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    Neither. For bearings, I ordered Timken from NAPA. For the other parts Kaiser-Willys.

    Matt
     
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  18. Oct 5, 2023
    Rustman

    Rustman Member

    Charles Town, WV
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    Dec 28, 2019
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    The donor Jeep provided me with another factory seatbelt and a set of the proper seat brackets. I was able without too much work to fit one of my pair of Smittybilt seats to them. Later I'll take this seat back out and use the brackets as a template to bend up another pair so that both are the same height/angle. The current driver side ones don't quite do it.


    Matt
     
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  19. Oct 8, 2023
    Rustman

    Rustman Member

    Charles Town, WV
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    Dec 28, 2019
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    Was out of town for a few days. Came back to boxes from Napa and Kaiser-Willys. Started tearing out my wheel cylinders to rebuild them. Ruh-roh! The first one I got to was 1 1/8" on the front left. Went back over the books. Yup correct for the DJ Jeeps in 69-70. Rear is still the 13/16". 10" drums all the way around (have to it in those baby 14" rims. So I have big honking front cylinders on 10" brakes. I went back to the Napa website and ordered rebuild kits for the 1970 Jeepster.

    My former self wasn't too bright and replaced the right front with a 1" one. Luckily I still had the axle from the donor Jeep so I pulled a cylinder from it. Now 3 of my 4 cylinders say "Wagner Lockheed" on them. the 4th just says "Westinghouse" not that anyone sees them. I figure after cleaning them up I should paint them before installation. What color were they originally? Were they painted?

    Matt
     
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  20. Oct 8, 2023
    vtxtasy

    vtxtasy oldbee 2024 Sponsor 2023 Sponsor

    Tucson, AZ
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    Hot Pink clear coated. "not that anyone sees them" :D
     
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