My Flat Fender Build

[en480c4]

So, I'm currently between TJs, and I'm daily driving an AEV JKU. After a few initial mods, I had to admit that it really needs nothing. So I decided I wanted/needed another project. I know the flatties get love here, so I figured I'd put together a build thread here. There's a ton of general knowledge here, and it's one of the more active Jeep-based forum communities, so it seems like a good place to share.

I had been putting money aside to save up for a new mountain bike. If anything, that gives you an idea of the budget I was working with. About 3 hours away in southern VT I found a package deal I decided to jump on. It was a 1948 CJ-2A and a Hotchkiss M-201 tub with an MB/GPW front clip on an M38A1 chassis with an L-head swapped in. I wasn't sure what combination I was going to use, but the in the end, the ease of using the straight, solid 2A frame with the body and running gear from the A1 chassis won out.

And for those that don't know, the US gave France tens of thousands of MBs and GPWs after WW2. They reconditioned the best and broke the rest down for parts and ran them until 1955 when they started manufacturing licensed copies of the Willys MB. They made them from 1955 - 1967 and the French army used them until the 1990's. The tub I got is from 1957, and other than a previous owner filling some factory holes and plating over solid front floors, it's solid and has a cool patina I will be keeping.

For those that remember, I am still working on a 1962 Willys pickup with my father, so that's in his garage. This is going to be a much more modest build in my driveway/yard.

Photos from the FS ad:

 

[en480c4]

I grabbed a U-Haul pickup and trailer in July and grabbed the 2A, the M-201/GPW body and all the spare parts. I went back in August to get the A1 chassis. Once I got everything home, I was able to take stock of what I had.

 

[en480c4]

So, the 2A body had cool patina, with layers upon layers of paint. It also had Big Willy sliders and new floors and hat channels from Classic Enterprises. But the entire body was wrapped in sheet metal that was riveted in place, so I knew it wasn't going to be something I would use. I found a buyer who essentially wanted the floors and hat channels, and will be returning the sliders to me once he finishes breaking down the tub. This allowed me to strip the 2A frame down and get the repairs done that it needed.

General cleaning and painting:

Axles pulled and more cleaning and painting:

Flipped over and replacing shackle hangers:

Replacing and relocating body mounts for the military tub:

 

[en480c4]

With the money from selling the 2A body and other spare parts, I was able to buy new springs, shocks, shackles and hardware. Then over Labor Day weekend, I pulled the drivetrain from the A1 chassis.

I tucked the engine, transmission and transfer case away in the shed until I get back to them.

I also pulled the D25 and Dana 44 axles and got them cleaned up. They're in better shape than the D25 and D41 that were under the 2A, and the Dana 44 is better for a future locker.

So that pretty much gets it current. Next step will be getting the chassis back to roller status, routing brake lines and wiring and getting ready to reinstall the drivetrain and tub.

If anyone in New England needs an M38A1 chassis or CJ-2A axles, let me know.

 

[joe98tj]

Gonna be a fun build! We have 2 members in our club down in CT with flat fenders. One is a sunday cruiser and the other got turned into a nice wheeling rig.

 

[en480c4]

I was able to fit some time in the Willys while scraping, priming and prepping the house for paint.

I spent some time cleaning up the springs. They were shipped with no packaging, so I had to remove the shipping labels and hit the abused paint with the wire wheel. Then I got some primer on them.

Then I got some satin black on the axles.

No photos, but I was able to get some satin black on the springs and then today it was time to have a roller again. Big milestone!

Next up will be steering and brakes.

 

[Oberst Oswald]

Once had a 1949 CJ3A and a 1981 CJ7. Restored both pretty good mechanically but rust was an issue I couldn't handle back then. So sorry I sold them 30 years ago.

 

[en480c4]

So this week I ordered a BUNCH of parts.

I also finished pulling the steering box, master cylinder and pedals and got the frame prepped and painted.

And I got the pedals and master cylinder plate primed.

I got the newer style crossmember installed.

I got the drivers side rear crossmember trimmed.

And yesterday I got the new transfer case mount, new brass fittings and pre-bent brake lines run.

Next up I need to get the master cylinder installed, pedal assembly rebuilt and the Ross steering box rebuilt as well.

 

[en480c4]

So, lots of progress, but no posts. Most of my time has been taken up by trying to get the house painted before the weather turns.

I was able to get the pedal assembly back together and working well. I also started tearing into the Ross steering boxes I have and inventory what I needed for parts. Finally, I got then disc brake conversion brackets primed and painted. And the guy who bought the 2A body dropped off the sliders. It was great to just throw one on to see how it’s going to look.

Then this weekend was the fun. I pulled the front clip off the tub and pulled the tub off its stand. Then I tipped it on end so I could get to the bottom. I’ve decided to go with a passenger side under-seat poly tank and cut a passenger side filler so I can keep the drivers side pioneer tools. So that meant I could cut off the MB/GPW-style fuel sump. I also cut out a few rough spots on the hat channel and fabbed up some new sections.

The nice thing is that once I’m able to top-coat underside of the tub, I can put it on the chassis and will only need to slide it out of the way to put the drivetrain back in.

Man, I wish I had a garage. But it’ll be good to get this somewhat back assembled before winter and I can worry about getting it running in the spring.

 

[en480c4]

We’ve been lucky with some unseasonably warm weather, so I’ve tried to keep making progress.

I was able to finish cleaning and painting the drivetrain. After missing that the chassis had already been modified to take an MB/GPW’s running gear and tub, I tried to land the 2A era drivetrain and it didn’t fit. Once I realized what was up, I moved the transmission crossmember back 1 1/2” and things are good to go. The joys of picking up someone else’s project!

I also modified the tunnel opening for the larger T90 and D18 position, and I picked up some OD green for the underside. New body mount bushings and hardware came in, so I wanted to get the bottom painted so it could go on the chassis for the winter. I still need a few more cans so I can get the firewall and inside of the front clip done. But it’s coming together well.

I’d really like to get the disc brake conversion done before the weather turns. And I can rebuild the steering box and the driveshafts inside over the winter. But if there aren’t any major issues with the engine, having a runner some time next summer seems possible.

 

[MeanGreen86]

This is an awesome build so far! Following this

 

[en480c4]

I was able to rear inner fenders painted, so that meant it was time! Flat fenders are so much fun… I was able to get the body on by myself. It’s not bolted on, but I did slide a few body mount bushings in there.

I may have climbed in shortly after I took these photos, sat down and made some vroom-vroom noises!

Still lots to do, but things like this are a huge motivator!

 

[en480c4]

I was able to get the front disc conversion done today. I’m hoping to get the rears done tomorrow. My goal was to get the brakes done and bled before putting the project up for the winter, and just focus on rebuilding the steering box and drive shafts so they’re ready in the spring.

And I decided I wanted to see everything put together.

Edit:

I had to add another from this morning. Seeing it mostly in one piece is incredibly exciting.

 

[RocknLJ]

Love the way this is moving along.
Always wanted a MB since riding in my uncles in 1967 and watching all the episodes of Rat Patrol as a kid.
Like the fact it has some decent upgrades such as disc brakes.
Keep the pics coming….pondering if I could sneak an MB project past the wife.

 

[psrivats]

If you decide you need replacement body parts, this place has good reputation on the older jeep forums. Everything is made in the USA.
https://www.classicent.com/

I got a corner from them for my CJ-3B and it was a good experience.

 

[Zorba]

Love the pintle hook in the first batch of pix - some of them sell for stupid money, but I'd use it myself. Wonderful job you're doing!

 

[en480c4]

Love the way this is moving along.
Always wanted a MB since riding in my uncles in 1967 and watching all the episodes of Rat Patrol as a kid.
Like the fact it has some decent upgrades such as disc brakes.
Keep the pics coming….pondering if I could sneak an MB project past the wife.

Thanks. And while MB/GPWs are small, I’m not sure they’re that small! Hahahaha.

I did hit a snag today… I got the PS rear disc conversion in and made good time. It came apart and went back together with just some minor fitting of shims for the calipers. The DS rear definitely did not cooperate. I could not get the hub off. I tried heat, the BFH, and I even managed to break the Harbor Freight hub puller. I guess I’ll try renting a better quality puller and trying again. I’m not sure my little propane torch is hot enough, either.

If you decide you need replacement body parts, this place has good reputation on the older jeep forums. Everything is made in the USA.
https://www.classicent.com/

I got a corner from them for my CJ-3B and it was a good experience.

Awesome, thanks! You can never have enough too many resources for an almost 80 year old Jeep! The biggest thing I need is ALL of the body accessories. Handles, footman loops, brackets for the spare and Jerry can. I’m hoping I can salvage the GPW grille. It is… not straight. So fitment is a bit of an issue.

Love the pintle hook in the first batch of pix - some of them sell for stupid money, but I'd use it myself. Wonderful job you're doing!

The pintle is in pretty good shape. It mostly just needs to be cleaned and greased. It operates very stiff. But it and the bumperettes are going to make it onto the Willys one way or another!

 

[en480c4]

Well, another 2 hours or so and I still can’t get the hub off. So I’ve ordered a new one and will take a cutoff wheel and cold chisel to get this one off.

Otherwise, I got more of the body bolts in. And I went to hook up the clutch linkage and realized I lost the frame-side bracket. So that’s been ordered too.

So, in the meantime I’ve tucked it back next to the shed. I’ll figure out how to get it covered for the winter.

 

[AdventurePig]

Great thread. Here’s a few pics of past rigs we’ve owned. Both started as fairly knackered basket-cases and were made fairly roadworthy. (As fast as a t90 will allow anyways. )

1947 Cj2A
1963 Cj5

We always had great luck with Kaiser-willys for parts. That and border parts here in socal, though, i don’t know if they’re still around.

Also, there’s a guy making vintage style canvas tops for flatties and CJ5’s who is active on the CJ2a board - screen name is Jpet and he owns Bam-Bam the MB rockcrawler jeep that’s all over youtube. (Edit: Looking at his site, he MAY have stopped selling tops for the moment, but you can at least take a look at what he does and maybe email him and see if he’ll resume making them in the future?)

https://classicjeeptops.com/summer-tops/

 

[en480c4]

So, I spent another 1.5 hrs trying to get that hub off. At this point I’ve run out of weather and patience. Anyone in northern New England have a decent offset Dana 44 with 5.38s? I’ll happily redo the disc conversion on the PS at this point!