1963 Us Navy Dj-3a

[Fireball]

That last project for the weekend was installing the cast iron ARB diff cover on the rear axle.

When I got the Jeep, the vent in the axle tube was plugged and there was a vent hose coming off the rear cover. Since I needed some sort of vent, I drilled and tapped one into the new cover next to the dip stick hole:

Well, that confirms it's a Dana 44. It says so right there. 19 spline Detroit Locker on display:

New cover with vent line installed with a Lube Locker gasket:

I ran the vent up under the hood next to the transfercase vent to keep it out of tire spray:

 

[Jw60]

Swap the seatbelt bolt for a button head bolt or maybe a plow bolt with some plow blade as a washer?

 

[Bubblehead617]

The first project this weekend was a vanity project.

I love the way it turned out. I wish I had done this a long time ago:

MUCH mo' bettah!!!

 

[Fireball]

It was a beautiful day yesterday and this Jeep needs to be exercised. First we took it to the post office to mail some bills, and then I drove it all over the property for a good 40 minutes:

Lots of side hill testing. I used the level on the camera for these pictures:

Up/down hill testing too. The camera is level, and the climb to get to this spot was MUCH steeper. I turned it around on the side hill just above and went back down forward:

Up, down, left or right side hill, the carb did great. Fingers crossed for the Rubicon.

I don't know why I enjoy it so much, but I put it in a ditch to flex it again. This ditch has less grass so it's easier to see things:

It's not winning any ramp test against modern offroad stuff, but given the short flatfender springs, it does pretty good. You can see the angle between the front/rear axles here:

 

[Fireball]

Today's project was making removable gas can mounts.

I started with cutting the padding off the bottom of the roll bar on the passenger rear fender:

I found some 1 3/4" roll bar clamps on Amazon:

The can holders will get a rubber pad under them to hopefully prevent some noise:

I need to make something to attach these gas can mounts to the clamps:

I thought about a one piece mount for both cans, but decided to keep them separate so I can add just one if I want. I started with some shallow C-channel:

The short side can weld directly to the clamp, but the other needed a filler piece. I tacked them together on the Jeep:

Off the Jeep. Ready for some gussets and finish welding:

Gussets added, welding done:

Painted and installed. They are very solid and wiggle the Jeep when you try to wiggle the can holder. Very easily removable:

Cans in place:

I'm using friction cam straps that I cut to length. They seem solid:

I also have a strap for the spare. The spare will need to come out to get to the gas cans. That's not ideal, but it is livable:

The next project is the shelf. I think I'm going to mount it about three and a half inches over the cooler. That will allow for packing some stuff under it:

 

[Fireball]

Still dinking away at this thing, but trying not to do any major projects at this point.

Added some Velcro-on handles to the roll bar to keep people fromt grabbing the rollbar itself for support. Don't need to crush any hands if it rolls:

Some day in the future, I'd like to add outer upper bars and some welded on handles in the corners. Not now though.

I figured out that a RotopaX 2/5 gallon container slips perfectly into this spot for water:

Then I started on brackets for the removable shelf. I needed to remove some roll bar padding:

So I could fit some 1 /34" clamps with angle iron to support the driver's side of the rack:

I have smaller square u-bolts holding the rack to the angle irons:

Now the other side needs support. I was going to make legs that bolt to the floor, but now I'm leaning to suspending it from the roll bar main hoop.

 

[Jw60]

Support to floor or opposite side and same level, if there is room around the spare tire. The higher up the roll bar you support the shelf the more likely it will damage the merchandise in the cooler if the roll bar is needed. That would ruin the trip.

You may be able to use straps to suspend the tray with lower straps for stability but at that point just use an emt leg to the floor.

 

[Fireball]

Support to floor or opposite side and same level, if there is room around the spare tire. The higher up the roll bar you support the shelf the more likely it will damage the merchandise in the cooler if the roll bar is needed. That would ruin the trip.

You may be able to use straps to suspend the tray with lower straps for stability but at that point just use an emt leg to the floor.

Sorry man. It got suspended.

Clamped in place for tack welding. Towels are for weld spatter:

Final fitting after welding and trimming things. It's super solid. Moves the whole Jeep when you try to move the rack. It will do the job and is easily removable:

Now the brackets are drying overnight:

I decided to use an ammo can as many others have to add a glove box/console. This DJ-3 has no native storage at all. No glove box, no tool box. Nothing. This at least gives me a dry place to keep the registration and first aid kit.

I already have three holes drilled in the bottom of it here:

I added three matching rivuts in the tunnel and floor of the Jeep and made a 1.5" spaver for the back:

Fits great. Doesn't block access to either the low range lever or the manual rear brake line lock in the floor step up:

I decided I didn't want the now useless carry handle rattling around making noise so I snipped it off:

First aid kit and registration in their new home:

I also needed to move the fire extinguisher higher up to clear the shelf when it's installed. I switched to a velcro style mount in the process:

 

[Jw60]

Sorry man. It got suspended.

Clamped in place for tack welding. Towels are for weld spatter:

Final fitting after welding and trimming things. It's super solid. Moves the whole Jeep when you try to move the rack. It will do the job and is easily removable:

Now the brackets are drying overnight:

Looks good!

 

[ScottInAZ]

love that rack, and yeah, the 50 cal can makes for a GREAT waterproof compartment for paperwork and other stuff you need out of the weather in the Jeep... with the new seats, I may have to trade mine out for the narrower 30 cal can due to the seat bolsters being in the way of opening it easily

 

[3b a runnin]

Sorry man. It got suspended.

Clamped in place for tack welding. Towels are for weld spatter:

Final fitting after welding and trimming things. It's super solid. Moves the whole Jeep when you try to move the rack. It will do the job and is easily removable:

Now the brackets are drying overnight:

I decided to use an ammo can as many others have to add a glove box/console. This DJ-3 has no native storage at all. No glove box, no tool box. Nothing. This at least gives me a dry place to keep the registration and first aid kit.

I already have three holes drilled in the bottom of it here:

I added three matching rivuts in the tunnel and floor of the Jeep and made a 1.5" spaver for the back:

Fits great. Doesn't block access to either the low range lever or the manual rear brake line lock in the floor step up:

I decided I didn't want the now useless carry handle rattling around making noise so I snipped it off:

First aid kit and registration in their new home:

I also needed to move the fire extinguisher higher up to clear the shelf when it's installed. I switched to a velcro style mount in the process:

You may need one of these yet.

 

[Fireball]

Nothing really new to show, but I did put brand new gaskets on the Jerry cans to prevent fumes and started to put everything back in the Jeep so I can plan the packing for the Rubicon.

I've got a friend coming along on the trip who is bringing most of the camping gear. He's coming down here in the few weeks and we'll do a dry run camping out of the Jeep somewhere on the property.

Here's the space available with the spare and gas cans. All the tools and recovery gear will fit under the seats:

Under the rack, there is already space reserved for a dry tub, cooler, and 2.5 gallons of water:

The dry tub will have spares, possibly the high lift scissor jack, extra Jeep fluids, and sill have space left over. We'll see what else packs in there.

There is room for stuff under the rack on the passenger fender and on top the dry tub:

I'm working on my packing list now. There is a bunch of stuff that lives in the TJ Rubicon that I'll move over tp the DJ for this trip.

 

[neohic]

Nothing really new to show, but I did put brand new gaskets on the Jerry cans to prevent fumes and started to put everything back in the Jeep so I can plan the packing for the Rubicon.

I've got a friend coming along on the trip who is bringing most of the camping gear. He's coming down here in the few weeks and we'll do a dry run camping out of the Jeep somewhere on the property.

Here's the space available with the spare and gas cans. All the tools and recovery gear will fit under the seats:

Under the rack, there is already space reserved for a dry tub, cooler, and 2.5 gallons of water:

The dry tub will have spares, possibly the high lift scissor jack, extra Jeep fluids, and sill have space left over. We'll see what else packs in there.

There is room for stuff under the rack on the passenger fender and on top the dry tub:

I'm working on my packing list now. There is a bunch of stuff that lives in the TJ Rubicon that I'll move over tp the DJ for this trip.

Looks like about as much useable space in there is being well taken up. Looks great!

 

[timsresort]

Nothing really new to show, but I did put brand new gaskets on the Jerry cans to prevent fumes and started to put everything back in the Jeep so I can plan the packing for the Rubicon.

I've got a friend coming along on the trip who is bringing most of the camping gear. He's coming down here in the few weeks and we'll do a dry run camping out of the Jeep somewhere on the property.

Here's the space available with the spare and gas cans. All the tools and recovery gear will fit under the seats:

Under the rack, there is already space reserved for a dry tub, cooler, and 2.5 gallons of water:

The dry tub will have spares, possibly the high lift scissor jack, extra Jeep fluids, and sill have space left over. We'll see what else packs in there.

There is room for stuff under the rack on the passenger fender and on top the dry tub:

I'm working on my packing list now. There is a bunch of stuff that lives in the TJ Rubicon that I'll move over tp the DJ for this trip.

Packing a flatfender for the Rubicon is an art. I used to take a photo of it once I figured it out, but things change-you get a different tent or chair and it messes the whole thing up. Are you going topless?

 

[Fireball]

Are you going topless?

This is a good question. What's the weather like at the end of June? I'd like to just have my hacked up full length bikini and not destroy the brand new top.

The hacked up top:

 

[Fireball]

Quick Project tonight. I figured out a folding shovel I had fits well in the passenger door sill area.

A rivnut, a strap that hooks in the drain hole, a home made wing screw, and Bob's your uncle:

Paint is drying now. It will get some rubber pads when it goes together to keep things from rattling.

 

[Rozcoking23]

This is a good question. What's the weather like at the end of June? I'd like to just have my hacked up full length bikini and not destroy the brand new top.

The hacked up top:

It’s a mixed bag of weather. Two years ago it was hot and last year was cooler in morning where you needed a coat but warmed up during day. You should be fine with half top, most of the group runs with just sun shades.

 

[timsresort]

Last year was perfect for me. Much cooler than in the past. That weather held all the way through the JJ, in late July, and it was a dream to not be boiling our brains mid day on the trail. Anyway, I don't want to say you don't need a top, because a thunder shower is likely. But topless on the Rubicon? Doesn't get any better. In 35 years, I have never taken a top, just a sun shade. Have we gotten wet? Yes.

 

[Fireball]

Have we gotten wet? Yes.

Bikini top it is!

I'm going to attempt to waterproof the canvas bags my tools will be in under the seats. Other than that, a little water shouldn't hurt anything else.

 

[Fireball]

With some paint and some rubber tape, the shovel is snug and doesn't rattle:

Another pre-Rubicon item is something to keep the tool bags under the seats from sliding out on steep downhills or a flop. The whole seat mounting setup will probably get replaced next year, so I'm keeping it simple and easy. These metal plates will thumbscrew into the seat mounting frame:

Tomorrow night is cleaning up the plates, drilling holes, installing rivnuts, and more painting.