Project "Bruce" or "Luv-it-or-hate-it" M-38

This is a build I created in my mind over the past year or so being without a Jeep.I will tell you the plan in a minute but I wanted to say it took a drastic change in direction after I aquired the Jeep (struggling with the history of the Jeep ) I have had over 20 Jeeps and some were built to the hilt while still using all Jeep parts.I now have returned to the original plan due to personal experiences,budget and fuel prices.
Heres what I am starting with:



When I first bought it,it was supposed to be a CJ-3A.When I picked it up I had a M-38 on a CJ-2A chassis.The body is in excellent shape but it does have a CJ-3A windshield and grill.This got me past the dont mess with history problem,it's already wrong and I dont plan on molesting the body( I wont cut the rear fender unless I have to,I dont plan on it.)

Heres what the plan is:
Suzuki samurai frame
Toyota axles
Toyota 22re for now and hopefully a Toyota diesel later.
35's
Military paint and details for the body.

I have a 4runner for the donor engine and this weekend if all goes well I will be picking up a Samurai chassis with Toyota axles.

The first things I did were the roll cage and seat belts



I bought the cage out of a CJ-5 for $60 off craigslist and cut it and rewelded.The cage is ok but may get swapped out for something fancier later.(I would like a rear hoop)



The seat belts are out of Rhino and are nice quality and fit.I bought Toyota belts first but they didnt look like they needed to be outside .



These are the backing plates for the belts.You can also see the edge of the backing plate for the roll bar.

I hope to make quick progress but time will tell.I will be selling the chassis with a perfect running l-head (12volt,Solex)I am not sure what it's worth?The trans pops out on decel in 2nd other than that the whole thing works well.I have driving it around town for the last 3-4 weeks.

Scott

 

Awesome project, sounds like you've got a good plan. 20 jeeps is a lot...

 

I rented a U-haul trailer again and picked up a donor suzuki with toyota axles,she's a looker !R).The rear end has a lot of slop so I probably need a new 3rd for it.
I took a lot of measurements last night.The springs are exactly the same front and rear.I think I will use the willys springs they are nicer than the samurai packs and my Jeep rode ok.This will also keep me from needing a sway bar with the samurai springs.
I will be using the samurai steering box,I can go to a tracker pwr box later if I choose.It looks like the box will sit right in front of the Jeep grill and the shaft may need a small notch depending on how the body sits.
I have pulled the tub loose and it will be gone this week.I pulled the pedals hoping they could be used but the clutch is cable operated so I probably wont be able to.
The toyota spring perches are about 1/4 inch off the samurais spring mounts so I will be putting on new perches and I have to figure out my steering.

 

good idea for a build. i got a buddy witha zuki, he told me that my 3b and his zuki were almost identical underneith, never really believed him, how close are the two frames? keeping an eye on this one

 

my brothers doing a suzuki escudo/ toyota hilux (4 runner)/ celica project quite similar to this one (only pic I could find)


Here are some pics of jeeps used in the same competition



you can view NZ 4x4 videos at www.suzukixtreme.tv (as seen on TV R))

 

The frames are pretty close,I will show pictures as I make progress and a list of measurements I have taken.I really think suzuki used a Willys as there basis for the samurai,same wheelbase,same width (very close) 60 h.p engine and offset axles.

I had a change in my plan though.I am selling my 4runner donor which is probably best,the length of the engine,trany and transfer case was super long.I have seen the combo in a willys but I dont think it's the best way to go unless the wheelbase is extended.(I want the body stock)
Now I still have the samy frame and Toyota axles so my new options are:
Samurai running gear and a VW turbo diesel.This would be a feather weight.
Jeep 2.5 with my T-90 adapted to a dana 20 and the Toyota axles.
Cost and ease wise the samy stuff is the way to go (excluding the diesel then this cost a little more)But it's a light duty rig. I am easy on equipment so thats probably ok.
The Jeep stuff is more complicated but would be a tougher Jeep and may be better for resale but I dont know.

 

A guy came and picked up the samurai tub tonight so I can get a lot closer look at the frame...

 

i've had some plans on a diesel build with a vw tdi. there are guys who mated the same engine to their t-90 on overland diesel(it's a 3b). i've tried to get in touch with them but no reply yet. i like this swap becuz i have all stock drivetrain minus my 283, course i'd have to get a stock t-90 bellhousing but their still out there. if you got all the stock parts you might check it out.

 

Yeah I will check into that thanks for the lead.The person I thought I could get the samurai engine, trans and axles from just told me it may be a month or 2 before he parts his truck out I wonder why he posted it forsale ? anyway the search is back on.
One thought was a 2.5 Jeep motor with my T-90 and a dana 20.
Scott

 

If you happen to want to cut out the underseat tool box so you can build I roll cage and put different seats in I sure could use it for my m38 resto, my tool box is not the best.

 

Bill,
I dont plan on cutting the body at all if I do I will let you know.

I made some progress today.I am very happy with how close the frame ligned up.The steering shaft will be going through the grill which is ok by me.Anybody want to buy a CJ-2A chassis complete ?runs and drove great.

 

I like it, very neat project. I however wish my m38's tub had been the solid when I started.

 

Sure the steering wont go through your radiator?
Looks good.

 

Yeah,I didnt plan on using one this nice at first but getting one to this condition saved me buying a new top and floors etc. it would cost just as much and would have just been more work.
I had to run down and check out the radiator situation,the stock one would fit just fine .I will probably end up with a different one though.

 

If you were closer to me I would take that 2a frame. Then all I would need is a clean body to put back on it.

 

Anybody that doesnt know at what to look at would say its a jeep chassis
Itll look good when its done

 

2X it looks like a perfect fit. mabey i'll have to convince my buddy to sell me his zuki!R)

 

Update time !
First here's whats been happening so far...My first Toy rear had a bad third,I went to pick up another one and that guy had about 5 bad thirds to choose from luckily though he had the transmission and transfer case that I was looking for,a Toyota short 5spd they used in 82' 83' 4wd's and a gear drive transfer case.I bought new seals (received 4 outer seals,waiting for inners)and bearings for the rear and I got a free third from a guy on another board that looks pretty nice so I will run it and see.I had to degrease and wire wheel all this stuff.
I bought Suzuki U-bolts because thats what was on it and the fronts would not work,somebody bent to fit the old ones I guess.I then bought a Toyota U-bolt flip kit thats pretty nice.I bought poly bushings and new shackles,The shackles came today and I am very impressed, 3/8's plates BEEFY ! This guy sells Jeep shackles on e-bay,special ordered 2 sets of CJ fronts and they got here quick.
I spent most of my time cutting off brackets,motor mounts,spring perches and unused mounts from the axles.Lots of cutting and grinding (not fun) flapper sand disc are great by the way.So the axles and frame were cleaned up.
I cut about 5" off both sides of the stock Toy crossmember and made brakets for it,it hangs very low and if I come across a good deal on a flatter crossmember I will switch it out.I fabbed up body mounts for the front of the tub.The Toy front spring perches were modified and new rears are being used with relocating holes that move the rear back 1".
I have the body about 1/2 mounted,it's sitting higher than I would like but I have to decide tonight if it's worth the extra work to lose 1/2-1".
I got TJ pedals today and they look promissing,I ordered a stainless column for a street rod,just a tube with sealed bearings really I have Sky manufacturing rear disc and a Trail gear High steer coming (sweeeet) also a front knuckle rebuild kit.


pictures:
Crossmember cut off,boxing the end.



Crossmember under Jeep,hangs low.here you can see the gap between the body and frame,pretty much likea 2-3" body lift and the rest of the frame fits pretty tight.



BIG rear sealed axle bearings,3 1/2" across and about 1" thick.I read you could knock these off and then hammer the new ones on...I did...my arms and hands still hurt



This is one of the modified front perches,I filled the locating hole and redrilled it then notched one side to hold the U-bolt and allow for the 2" spring as oppsed to the Toyota 2 1/2" spring.



This is one of the front body mounts.



Rear housing set in place.You can see the new shackles (painted pretty !) and there is a row of 4 body mounts in the middle.



Hey somebody clean this place up !



Thanks !



New U-bolt flip kit and the frame cleaned up.



I think I better update more often,packing it all in is tough
Wish me luck,I dont have alot of time before I lose this garage and will have to relocate my project

Scott

 

The body is 95% attached now.I lowered it 5/8 th's of a inch,that helped the gaps.

This is the front gap,you can see the mount I made under the grill and I cut up a suzuki crossmember to go behind the fender brace (that's my 5% I have left).



Here is the rear gap,the stock suzuki crossmember has rubber pads that lined up directly in front of the M-38 rubber strip,I move it up and now the floor is resting on the rubber.



The middle gap is hard to tell a difference in the pictures so I will wait until I can roll it out to take a look.It looks better in person but I still would like a flatter transfer case mount.I got my axle seals today so hopefully I can roll it out tommorrow for a look.


Scott

 

Looks Great... how much longer until you loose the shop? tic toc tic toc...

why not just box up the 2a frame and run it?

any luck on the motor yet? suzuki? 22re?

PM what you need/want out of the 2a if you still have it please.