M38a1 Build or Project Blasphemy

[DanStew]

I am bringing the build over from USJeeps

Here is the jeep

I now have a drivetrain for it.

Picked up a suzuki 1.6L 16valve motor with samurai tranny, Tcase, sidekick tranny/tcase and a 2WD sidekick tranny, engine wiring harness, and other doo dads with it. It looks like I am missing the power steering pump and such for the motor, exhaust manifold and i have a v belt water pump pully, and a vbelt and serpentine belt pully for the crank. So I have a few things to figure out but I probably wont mess with that until I get the motor mounted and decide which tranny combo. Heck I still have to full weld up the suspension mounts so i can go forth setting it up. Gonna be interesting, it should tee off the jeep gods, but I think this drivetrain will make a fun little cruiser.

 

[lowrange2]

I AM slightly curious why you chose a Samurai drivetrain. I have an 88 and that's been the biggest PITA drivetrain that I've dealt with. The divorced t-case is cool if I could keep it right side up...

 

[DanStew]

Main reason is i wanted a 5 speed tranny to get better highway usage. The samurai/sidekick setup is small enogh to fit the short wheelbase of the early cJ5. I do not plan on stretching wheelbase at all.

 

[LBarr2002]

I'm glad you went with the 1.6 instead of 1.3... you'll be much happier. I can't wait to get mine in.

 

[DanStew]

I did have plans to get the VW diesel if i got the 1.3L

 

[DanStew]

Well got the engine mounted to the frame today.




this is what it looks like with the engine/tranny mocked up


It sits nicely on the mounts. No hoist helping it. I still need to make the Transmission crossmember and the Tcase cradle. I am going to test fit the body on it when i do get the trans crossmember installed. It should fit up real nice.

 

[97TJGUZZY]

this is such a cool project, cant wait to see more progress!!

 

[DanStew]

The engine and transmission are sitting pretty.




Tomorrow the tub will be put on for a test fitting.
Next is to make the Tcase cradle to hold it in place and to shorten the dirveshaft between the tranny and tcase.

 

[DanStew]

It Fits!! It Fits!!

I got the body on the frame today to see the fitment for the powerplant.



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
[ATTACH]8730[/ATTACH]
[ATTACH]8731[/ATTACH]
[ATTACH]8732[/ATTACH]

Here is what it looks like in the tub
[ATTACH]8733[/ATTACH]
[ATTACH]8734[/ATTACH]

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.

 

[infidel_6]

Lookin' good Dan! When the news sucks I know how and why it does, lol.

 

[DanStew]

Our news never sucks hahahaha

 

[DanStew]

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.








Sitting in the jeep



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]

Got the tank pretty much done tonight. I still ahve to get the bungs for the fuel inlets, and cut a hole for the fuel sending unit. Last will be epoxy sealing it. But for now it will get put in the rig and i will work on the seat mounts for the seats.




IT FITS!!!!

 

[nota944mechanic]

Like a glove!

 

[DanStew]

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.



Thanks Chis for the seats!!!!

 

[Five-O]

Looks real good....

 

[89s rule]

looking real nice Dan.

 

[BB1980]

Sweet. Just don't get T-boned from the driver side!:eeek:

 

[DanStew]

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.




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]

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.