1984 Alaskan Postal Scrambler Build

[bigwalton]

SO COOL! XJs are definitely awesome and I miss ours all the time. I loved that stupid little Jeep. Check out the frame stiffener setup from TnT Customs:

https://www.tntcustoms.com/jeep_parts/xj_frame_stiffeners

We did that and a set of their rock rails that weld to them after the wife rear ended a minivan and we pulled out the damage as a just-in-case. I was impressed with how much strength they'd add and how out of the way they were. Loved the look with the rock rails added too.

Borrowing a TJ from a local friend right now while the LJ is down for some upgrades and it's got the old XJ auto shifter, I went right back to the XJ days...

The S is Mater's brother! So jealous of your interior, that's my ideal FSJ interior right there Obviously I love everything about that Jeep

Glad the kids at least had good enough aim to hit the windshield flush

 

[Randyzzz]

Awesome stuff!

I think Dan at Ruff Stuff started making XJ frame stiffeners too. And be sure to install a C-Rok steering box frame support before the inevitable cracks happen.

http://www.c-rok4x4.com/

 

[JeepScrambler]

Time to get this build back on track. I'm finished with 99% of my landscaping and our lake is so dry we can't get our houseboat in the water. And just had to pull our wakeboarding boat last weekend since it could no longer get it in our lift in our slip due to lack of water. This means I'm back at the body work on the postal!

Last I left on it I was working on the right hand side quarter panel. Hindsight it would have been easier to rust replace the entire bed floor due to a little rust through but mainly pitting. I filled most all the large rust pits and ground them smooth:

Also got the rear body mount support channel all cleaned up, rust converter, then rust encapsulator applied. Also put some weld through primer on the top area where the floor corner piece will be welded to:

Also got the edge of the bed floor where it will attach to the bed corner pieces and wheel well cleaned up, holes filled, ground down, and weld through primer installed. Next is to prep the quarter panel for installation:

This is where I ran into a major problem. The MD Juan replacement quarter panel I have had for a while now with plans to install has some major defects. The main issue is with the angled section of the top of the tub lip. The angle of the taper of the top of the tub is no where near the angle it needs to be. It is not even close. The panel appears to not have been bent over far enough when it was made. These pictures will do a better job of showing what I am talking about:

I have been extremely disappointed in the MD Juan replacement panels I've purchased, but this last one has by far been the worse. If you look back at my previous posts where I changed the left hand side quarter panel you will see the fitment issues I had with it as well. The angle was correct, but it just did not match the original tub lip profile either. But at least that one was somewhat workable. The right hand side panel is so far off it isn't even useable. Pretty discouraging when you finally get back to a project and run into a major issue like this with a crappy reproduction part.... Looks like I will have to source another replacement quarter panel...


Sent via signal flare

 

[gazzo]

That's a real shame. He has been very active on these forums over the last couple years promoting his product as he recognizes it as good advertising. Equally important to his business are experiences like yours, publicity he'd rather avoid I'm sure. I suggest you contact him yourself direct and I think it will all be made good for you. They are nice people.

 

[revho]

Eeeyow that is a big difference...

 

[JeepScrambler]

I actually am a step ahead of you and had already sent a PM to Rommel yesterday on it but haven't heard anything back from him yet. I basically want to check and see if my panel is an isolated incident or if it is a quality control issue on their part and others are experiencing the same thing.

But regardless, this is my third CJ8 quarter panel I have bought that they have manufactured and all have had issues. With my experience it would be tough for me to recommend their quarter panels to anyone. I can deal with the quality issues with the first two quarter panels and make the panels work on a jeep restoration that isn't going for 100% OEM correct, but this last panel isn't even useable for any sort of build it is so far off.

What's worse, the pictures make this last quarter panel look even better than it actually is(if that is even possible). The angle of the tub lip is much worse in person than what the pictures show.

I'm not intending to bash a company at all. Especially one that is making parts for our Scramblers; for that I am grateful. I just want to make sure this is brought to their attention and they can address any problems they may have with their production. And for others to be aware of some of the issues they may have when trying to install these quarter panels.

Are there any other sources out there for quarter panels?

Side note: I love my classic enterprises panels; fitment is always spot on! Sure wish they made a quarter panel and larger floor board repair sections(among other pieces).

Sent via signal flare

 

[gazzo]

Would make a good wall hanging with the sig and all. Whilst waiting to be used that is. Today I took out the flat sheet floor pan the PO had installed in my Overlander ready to weld in the Key Parts floor I got last year. Now these are perfection. Maybe KP might be an option?

 

[Scramblin Man]

I know Dmock has the same issue with the qtr replacement. He ended up cutting the upper profile off and grafting in the upper portion from an OEM tub. Looks like I may have to do the same with my project scram. Been collecting upper profile portions from some junk 7 tubs to use.

Is the wheel wheel profile/shape correct on the replacement qt ?

 

[Scramblin Man]

I meant to say wheel well profile

 

[JeepScrambler]

I will check out key parts and see what panels they all make. When I can, I prefer the classic enterprises stuff. But they don't make every replacement panel so it would be nice to have another source! Does Key make all of their own panels?

The wheel well profile on the replacement tub is different as well. The width of the raised section where the flare would mount is has variations on all of mine; particularly towards the bottom. There also appears to be small hammer marks on all of them around the raised profile. When I get back home I will take a few pictures of this.


Sent via signal flare

 

[JeepScrambler]

As always, no major updates on this postal. I have yet to hear anything from MD Juan on whether or not the top profile of the replacement side quarter panels have been corrected; or at least made consistent. We did try a metal break to fix it ourselves but unfortunately there wasn't any way for us to make the bends necessary. So it looks like I will have to source another panel.

Only major update is our new shed is up, doors are on, and now just waiting on the electrician. No work will be done in this building, it will be used primarily to store vehicles, toys, and equipment.

With the completion of our shed and the addition of extra space means we can finally start working on the original smaller existing shop. This is where all the work will be done to the Jeeps. We had a new door put on it that finally seals and also matches the doors on our new shed along with the garage doors on my house. You can see the new shed in the back right. Will be painting the trim on the old shop to match the sand/tan color of the new shed instead of the existing cream color.

Once I get all the body panels back on the postal the smaller shop will be getting totally a total renovation. By that I mean, insulated, re-wired, framed out walls, etc. There is a big metal sliding door that separates the left 1/3 of the shop from the remaining building. This left (north) 1/3 will be more of a "man cave" once the renovation is done. Just waiting on the weather to finally cool off so I can get back to work on the postal at night.


Sent via signal flare

 

[zr10054]

Those are nice sheds and I like sheds.

 

[jerseyjeeps]

I have worked in the smaller shed during my jamboree road trip and ate some home cookin from the hood of a scrambler right about where that skid steer is parked. You have come along way since then, great to see a plan come together. Thanks again for the hospitality and will see you soon!

 

[Gueon]

As always, no major updates on this postal. I have yet to hear anything from MD Juan on whether or not the top profile of the replacement side quarter panels have been corrected; or at least made consistent. We did try a metal break to fix it ourselves but unfortunately there wasn't any way for us to make the bends necessary. So it looks like I will have to source another panel.

Only major update is our new shed is up, doors are on, and now just waiting on the electrician. No work will be done in this building, it will be used primarily to store vehicles, toys, and equipment.

Sent via signal flare

 

[mhinchliffe]

It's one thing to have square footage, but you my friend have got you some CUBIC footage! That is one heck of a Morton Building. Very nice.

 

[Polarfire]

Hellava shed!

 

[BRKLYNZ28]

Wow that makes my shed look like a out house.

Sent from my SM-N910P

 

[bigwalton]

I missed all of the mention of the seal issues/questions on the AW4/D300. I put the double lipped seal in without grease (I don't recall any mention of it on the instructions, will try to remember to dig them out tomorrow) and ran it without doing anything to the AW4 seal. No apparent issues yet

You never mentioned what you found for the tranny mount. I always have wanted to make a similar swap for the same reason.

 

[JeepScrambler]

Will get some updates posted on the transmission mount! But first, I decided I need to get back to the body work on the postal. My work previously was halted by the crappy MD Juan replacement side panel.

I convinced myself the issues I was having with the panel was just a fluke as my previously installed left hand side panel, although nowhere near perfect, wasn't as bad as my right hand side panel. So I decided to go ahead and order another one since they are the only name in the game I could find when it comes to scrambler side panels.

The new side panel arrived today. Upon opening the box I was less than pleased to find this panel has issues with the top lip profile as well. The issue is different than my previous panel, but still causes some major fitment and finish issues.

As you can see from the pictures, the very top edge of the new panel is bend down on the inside edge, pointing towards what would be the tub floor.

The bend of the top lip is actually much worse than the pictures show and it runs the full length of the panel so it isn't easily fixed (if it can be fixed at all). It looks like MD Juan has lost any quality control they had with their side panels. I know most all replacement panels will need work before they are usable, but this is beyond basic body shop tools to fix. I forgot to take pictures, but the wheel well lip between the two panels is different too.

I still haven't heard anything from MD Juan on my first panel so I doubt contacting them again will do any good. I'm at a crossroads now; pay the shipping to get this second crappy panel sent back and risk ordering a third panel, or see if I have enough top tub edges to graft them on (which will be a ton of extra work that should not be needed). Not sure where to go from here. I'm at a stand still with rust repair until I can get a side panel that is actually usable. Wish we had another choice for reproduction body panels than MD Juan and the junk they keep sending out. As if rust repair isn't bad enough!!!


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[wm69]

Dang man. That stinks. I had high hopes that Juan was working to improve their stuff when he popped up on several Jeep websites and started asking for critiques of their products.