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M38a1 build

Discussion in 'Builds and Fabricators Forum' started by DanStew, Dec 11, 2010.

Page 2 of 7
  1. Mar 31, 2011
    DanStew

    DanStew Preowned Merkin salesman Staff Member

    Lexington, South...
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    4,585
    Well I found some time to mock up the drivetrain to be mounted. I had to cut out much of the grill, but dont worry I ended up cutting the rusted and dented original grill instead of my great condition wall hanging m38a1 grill, so no harm was commited ;)

    Well It looks like I can get about a 16-18 inch rear driveshaft in it. I will be getting the intermediate shaft, for the Samurai tcase to tracker 5 speed, tomorrow so i can know exactly how much rear shaft I will end up with. Also looks like the tranny shifter will end up really close to original location. The Tcase shift looks to be where the PTO shifter will come into the tub. I am crossing fingers I can have the motor mounts made this weekend :)

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    DanStew, Mar 31, 2011
    #21
  2. Apr 1, 2011
    pathkiller

    pathkiller Member

    Lorton, VA
    Joined:
    Apr 17, 2005
    Messages:
    878
    Great progress, Dan. I wouldn't worry at all about any accusations of Jeep blasphemy. A running Jeep with any engine is better than an old soldier sitting in a field slowly rusting away to nothing. I think your drivetrain makes a lot of sense and should be a good runner. My latest crackpipe dream is a Mercedes OM617 5 cyl diesel swap in my CJ5. Something about a 25mpg Jeep that can burn 100% homemade renewable fuel appeals to me.
     
    pathkiller, Apr 1, 2011
    #22
  3. Apr 1, 2011
    duffer

    duffer Rodent Power

    Bozeman, MT
    Joined:
    Sep 17, 2009
    Messages:
    4,514
    Having put a lot of miles on behind a 617, it would probably be one of the last choices I would elect for a Jeep. A lot of torque-yes, but only after the turbo is fully effective. There is close to nothing there at low rpm. I made the mistake once of taking the 79 300SD I had to the Muddy Creek trailhead (Absaroka-Beartooth Wilderness, north of Yellowstone NP and probably around 8000') for a backpack trip. Very small parking lot with steep access ramp (maybe 20%)-downhill into the lot. I just about couldn't get out of there because I could not get enough speed to kick in the turbo and it didn't have enough power to get up the ramp without it. I think it took me 5 attempts before I managed to creep out out there. They are also certainly not maintenance free and do eat cams. Then there is the cheap parts thing.

    All that said, once on the road it was nice and got respectable mileage-low 30's. It would go over Homestake Pass (a moderately steep stretch of I90) at 80 mph and never shift down. I have an 82 300CD that was my father's with that mill but it is going to get sold soon, along with his 380SL. No desire to deal with Benz's expensive parts anymore and I would much sooner work on a Willys.
     
    duffer, Apr 1, 2011
    #23
  4. Apr 3, 2011
    DanStew

    DanStew Preowned Merkin salesman Staff Member

    Lexington, South...
    Joined:
    Sep 22, 2002
    Messages:
    4,585
    HOORAY!!! Got the motor mounts finished, the motor is sitting without the aid of the hoist.

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    The suspension is sitting nicely with the weight on it. Next is to make the transmission crossmember, and then the Tcase cradle. :) Once I get the Transmission mounted, I will put the tub on for a test fit.
     
    DanStew, Apr 3, 2011
    #24
  5. Apr 5, 2011
    DanStew

    DanStew Preowned Merkin salesman Staff Member

    Lexington, South...
    Joined:
    Sep 22, 2002
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    4,585
    The engine and transmission are sitting pretty.
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    A buddy is coming over tomorrow to help me put the tub back on to test fitment. :) Next is to make the Tcase cradle to hold it in place and to shorten the dirveshaft between the tranny and tcase. :)
     
    DanStew, Apr 5, 2011
    #25
  6. Apr 6, 2011
    DanStew

    DanStew Preowned Merkin salesman Staff Member

    Lexington, South...
    Joined:
    Sep 22, 2002
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    4,585
    It Fits!! It Fits!!

    I got the body on the frame today to see the fitment for the powerplant.
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    It is nice to see I can reach behind the engine to get at stuff.
    http://i172.photobucket.com/albums/w10/DanStewIII/jp27.jpg[/IMG

    with the fenders on
    [IMG]http://i172.photobucket.com/albums/w10/DanStewIII/jp28.jpg
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    Here is what it looks like in the tub
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    It looks like for me to fit the Tcase I will have to cut into the center floor a bit. Either I have to notch the passenger side tool box, or I will cut out about 2 inches from it and reweld it so the tool box will be whole, but a little smaller.

    I do have to say I have alot of room in the engine bay with this motor. Can't wait to get it driving.
     
    DanStew, Apr 6, 2011
    #26
  7. Jun 26, 2011
    DanStew

    DanStew Preowned Merkin salesman Staff Member

    Lexington, South...
    Joined:
    Sep 22, 2002
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    4,585
    Got another project underway for the Jeep. Since I am modifying the floors a good bit to work with the drivetrain, i couldnt use a factory gastank, and I would hate to spend $500 for a new tank, only to cut it up. So I made a tank. Wasnt overly hard, especially for this old of a jeep. It is an underseat tank.

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    Sitting in the jeep
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    Fits real good, i have to fully weld the seams up and add the filler neck, and purchase some bungs to weld on for the fuel lines. I will be using a CJ3a sending unit and gauge with the tank.
     
    DanStew, Jun 26, 2011
    #27
  8. Jul 9, 2011
    DanStew

    DanStew Preowned Merkin salesman Staff Member

    Lexington, South...
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    Sep 22, 2002
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    4,585
    Got my driver seat mounted today. Now I get to work on the steering column position an the pedals and work on the brake setup.
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    DanStew, Jul 9, 2011
    #28
  9. Jul 9, 2011
    aallison

    aallison 74 cj6, 76 cj5. Has anyone seen my screwdriver?

    Green Cove...
    Joined:
    Nov 24, 2006
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    1,929
    Does that seat sit up as high as it looks like it does?

    Impressive. I was looking at my Sammy today thinking it would be cool to find a 2a glass tub...........
     
    aallison, Jul 9, 2011
    #29
  10. Jul 9, 2011
    DanStew

    DanStew Preowned Merkin salesman Staff Member

    Lexington, South...
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    It is sitting at a good height. Not high at all. The passenger seat is just sitting on the floor so it maybe looking really high.
     
    DanStew, Jul 9, 2011
    #30
  11. Jul 10, 2011
    Patrick

    Patrick Super Moderator Staff Member

    Los Alamos, NM
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    Sep 22, 2002
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    It does look like it's up really high.
     
    Patrick, Jul 10, 2011
    #31
  12. Aug 1, 2011
    DanStew

    DanStew Preowned Merkin salesman Staff Member

    Lexington, South...
    Joined:
    Sep 22, 2002
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    4,585
    Got some more done. I got the XJ power brake setup mounted, and the sidekick clutch cable mounted. I still need to get my dang drill back from my father in law so i can drill and bolt the plate down completely. The pedals are ready to accept the brake pushrod and the clutch cable.

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    I made a simple spacer out of a piece of tube and made a flange on the MC side for the brakes to bolt on, and then welded the other end to the plate.
     
    DanStew, Aug 1, 2011
    #32
  13. Aug 2, 2011
    gcoupe

    gcoupe New Member

    Joined:
    Apr 27, 2011
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    any pick from the pedals??? I am trying to make the same to my M38A1. Are you going to change the steering column also???
     
    gcoupe, Aug 2, 2011
    #33
  14. Aug 2, 2011
    DanStew

    DanStew Preowned Merkin salesman Staff Member

    Lexington, South...
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    I can get some later. I am using intermediate pedals. I also am going to use an intermediate column, but it going to be cut in half to get my column output higher on the firewall.
     
    DanStew, Aug 2, 2011
    #34
  15. Aug 2, 2011
    DanStew

    DanStew Preowned Merkin salesman Staff Member

    Lexington, South...
    Joined:
    Sep 22, 2002
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    I did a little more today. I drilled the holes and botled the brake firewall plate all the way. Connected the clutch and brake to the pedals. Cut down the dash to CJ height and installed gauge panel.

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    DanStew, Aug 2, 2011
    #35
  16. Aug 3, 2011
    gcoupe

    gcoupe New Member

    Joined:
    Apr 27, 2011
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    thanks for the pics.... Keep on working your project...!!! <br>By the way, what do mean by saying "intermediate pedals"??? I have made my own pedal set and I will make also and a custom base for the steering column which came out of a YJ Wrangler...
     
    gcoupe, Aug 3, 2011
    #36
  17. Aug 3, 2011
    DanStew

    DanStew Preowned Merkin salesman Staff Member

    Lexington, South...
    Joined:
    Sep 22, 2002
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    The pedals are from an intermediate CJ5 (72-75) They work real good for the early jeeps cause the tubs are near identical. Just jeep slang in use :)
     
    DanStew, Aug 3, 2011
    #37
  18. Aug 3, 2011
    wheelie

    wheelie beeg dummy 2024 Sponsor 2023 Sponsor

    York, PA
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    Dang Dan, yer kickin' it booyyyyyy. I'm liking this project. Keep it up.
     
    wheelie, Aug 3, 2011
    #38
  19. Aug 26, 2011
    DanStew

    DanStew Preowned Merkin salesman Staff Member

    Lexington, South...
    Joined:
    Sep 22, 2002
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    4,585
    Well getting going on the tranny tunnel, firewall plate and floors. Mocked up the firewall panel with some real thin gauge steel, now i got it out to thicker stuff.

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    DanStew, Aug 26, 2011
    #39
  20. Aug 27, 2011
    DanStew

    DanStew Preowned Merkin salesman Staff Member

    Lexington, South...
    Joined:
    Sep 22, 2002
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    Got the tunnels done and they fit great. I still need to cut out a hole for the Tcase, but i need to mount it first.

    Tunnels with gas tank fitment.
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    Tunnels with seat and gas tank.
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    DanStew, Aug 27, 2011
    #40
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