Prelude: ‘Once a jeeper, always a jeeper’
This unusual build came my way, when we were attending ‘Gokak Offroad Rally 2012’ in Gokak, Karnataka (
http://www.team-bhp.com/forum/4x4-ex...er-2012-a.html), if you go through my participant’s experience in above thread, you will get to read the name of photographer who accompanied me. She accompanied us in few OTRs and was amazed by Jeep/Gypsy’s ability to go anywhere, camaraderie among offroaders and definitely fun/adventure quotient. While coming back from Gokak, she mentioned her desire to buy a Jeep. I simply overlooked her statement thinking as an impulsive decision/temporary fad which would soon go away. But, I was wrong ! during next few OTRs we had few long discussions and I tried my best to convince her not to go for a Jeep. I tried to convince her to go for a Gypsy with AC and in fact found a very well modded 1.6 Gypsy king, ready for OTR but she was hell bent on buying a Jeep. After few more futile attempts, it was time to search a Jeep. Next question is which Jeep?
1) CJ3B/340 etc
2) MM540/550
MM540 didn’t cut ice as it’s big and bulky, as this Jeep would be used only for recreational purpose, we didn’t want LWB. Once, it was decided that SWB is what we are looking for, next question came what and where. Initially we decided to buy a Jeep from MP and rebuild at Bhopal which has great number of Jeep mechanics with reasonable rates or buy a ready to offroad SWB. Saw few ready to offroad/ unrestored SWBs. One thing I really want to admit – price growth of SWB jeeps in last few years must have beaten price of yellow metal. I came across few online advertisements where people were asking more than 2 lacs for their crappy Jeeps. This led us to find a bare basic jeep which can be build as per our requirements. Also what is the fun of getting Jeep build remotely or buying a readymade Jeep which may not suite your taste. Thus, we narrowed down our search for an unrestored 4x4 Jeep. After intensive search on internet and using PR, we came across an original CJ3B minus hurricane engine. This Jeep was a daily runner and fitted with XDP engine, 3+1 gearbox with transfer case etc. initial pics were promising and it was priced 15% above our expectations (still better as most Jeeps were quoted 70% -200% more than what we thought they are worth for). After few more e-mail and telephonic conversations, we almost confirmed the deal and we asked owner to take his jeep to Bhopal (around 150 kms from his place) and we will come to Bhopal from Poona. We already paid him 5000 rs as token amount and confirmed that if we like his Jeep, we will pay rest of the amount otherwise he can forfeit our token amount.
During one conversation, owner confirmed that he has changed two tyres of Jeep to new NDMS, overhauled gearbox, serviced fuel pump, changed glow plugs, changed all oils, replaced battery, 4x4 is working etc.. it gave me enough confidence and made a mistake of trusting that cheat.
Meeting date finalized and as D-day came close I got extremely busy in office and had to stay back. This led prospective owner to visit Bhopal and closed the deal. Prospective owner had limited knowledge of automobile and especially Jeeps and this made whole thing very tough. I made a detailed check-list which covered almost everything and was on call throughout the deal but you can not check everything over phone . though we didn’t get pure lemon but yes we got rotten orange and this we realized once we received Jeep in Poona, will cover more about this later. False information coupled with blurred communication during visit led us to finally buy the Jeep in impression that whatever told by previous owner is true.
This is what we got after search
Next step was to complete paperwork. We left Jeep at Bhopal to complete paperwork, one more reason for leaving jeep there was to get it rebuilt at Bhopal not in Poona. As its tough to work on jeeps in Poona comparatively (less experienced mechanics, spare scarcity, and price difference). After 20 days, all paper work were completed, ownership transferred, tax paid, insurance done. In these 20 days heart took over mind and we decided to build jeep in Poona. Our decision was based on few reasoning’s;
1) We will be able to see day to day progress and can make quick decisions on anything
2) We will procure all parts which would give us clear history of everything which went into making this jeep
3) Last and most important – we will learn few more things about this subject called ‘JEEP’. Though I have worked on various jeep projects, but I never worked on ‘end to end’ jeep build
4) We will work by our own (not 100% but yes 60%-70%). Actually it was outcome of above point. I always wanted to work on jeep by myself rather than just overseeing and coordinating everything.
In last week if December 2012, jeep was transported to Poona and it was parked at my house till we start work on it. At that time, I was away in deep Konkan area on exploration trip and then Mahindra Trophy event. I couldn’t get time to even think or even start this Jeep. During this period, I met Rahul (voodochild) and got to know his immense automobile knowledge. He also wanted to work on a Jeep and we both laid out a plan on what needs to be done.
One fine day in February, I tried to start Jeep to drive it for few kilometers and OTRS to estimate what work is required. Initial observations:
1) Jeep didn’t start, worn starter, Rebuild starter.
2)
Tyres: No tyres were new, no spare tyre. Owner mentioned that two tyres are new, but we found that two tyres are actually bought second hand from the market and had 10% grip remaining. Remaining two tyres had totally worn out, cracked and were total SCRAP.
Conclusion: all tyres need to be changed
3)
Wiring: Wiring was total junk, it had patches everywhere, only headlights and amp meter was working. Ignition switch was getting hot due to problem somewhere in circuit.
Conclusion: brand new wiring has to be made
4)
Gearbox and transfer case: transfer case levers were non-functional. Second gear was slipping and gear shifting was not as smooth as it should be
Conclusion: gearbox and transfer case has to be opened and overhauled if required. We were also pondering on option of replacing existing system with 550 gearbox, transfercase, front and rear diffs, etc. but we left it for later
5)
Engine and fuel pump: though there were no staring problem and power drop but there was back compression and excessive smoke. We could have simply change rings and could have drive for 15,000-20,000 kms (which might take 4-5 years for owner to drive these many kms). But again, there was no point in doing partial work. Though previous owner confirmed that he had serviced pump, buy there was no sign of it
Conclusion: we decided to dismantle engine and assses condition of every part inside. We also decided to get fuel pump serviced and recalibrated.
6) Body: Body was ok, except few small rust patches, rest everything was manageable.
7)
Steering and brake: Brakes were horrible, master cylinder was leaking, brake drums were jammed. Previous owner might have worked on them decades back. Steering feedback so so
Conclusion: we were very clear from the day one that whatever Jeep we will buy, we will install front disk, rear drum with booster. Reason being, it would be driven by a lady who has limited exposure to Jeeps and their unique characteristics, and we can not compromise on safety. It was decided to open steering box as well, service it and refit.
In a nutshell, almost everything either needed to be changed or repaired. We never thought that we will end up doing so much of work. I and Rahul decided to:
1) Overhaul engine and fuel pump
2) Overhaul gearbox and transfer case. We finally made our mind to move to 550’s 4+1 gearbox, front and rear diffs along with brakes etc
3) Body tinkering and final mechanical inspection of everything
4) Painting
5) Seat, hood, wiring and trial run for few days
6) Eliminate niggles and finishing touches
Work is on full swing now and we are expecting to finish this Jeep by mid June. I will be updating this thread on daily basis now.
Regards,
Shubhendra Singh