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Thread: MUTT SUV Project - Stage 1 Complete

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    Cool 6.5 Inches High Travel Lift

    Stage 3: Frame modifications
    MUTT SUV Project   Stage 1 Complete -1340591
    Stage 2 suspension complete: IFS + IRS e-Diff Locks, 1.5' Lift, 35" Tires

    Stage 1: 5 speed hi-low 4x4 Drive Train, 2.3 TD with Intercooler Engine

    MUTT SUV Project  - Stage 1 Complete -388744
    AM General Jeep M825 MUTT | 3 C Turbo Diesel

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    Arsalan,
    MUTT Front fender & Back lights set for sale. Brand new for 7,000. They are not 'take outs'. email me if you need 'em.
    TLC FJ90 SWB ~ 1KZ-TE ~ 50mm OEM Lift

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    @ Sarmad
    Sorry for replying late. Busy with work and the Project.
    I am not replacing any MUTT component with originals, as I am completely transforming it into something different and modern.

    By the way I still have the engine. This time I am including the carb with it also. It has all the engine components except distributor cap.
    -Carburetor
    -Engine Motor / Block
    -Exhaust Manifold
    -Air Intake / Filter
    -Starting Motor
    -Fly Wheel

    The engine is running, but requires overhaul as it has blow (ring, sleeves...)

    I am also replacing
    -all 4 tires,
    -steering box,
    -gearbox,
    -differentials,
    -cross drive / shaft axles,
    -hubs,
    -Toyota 3C gearbox adapter plate (just got made).

    Let me know if anyone interested. They are all in running condition and 4x4 tested. No major sound from the Diffs. Gearbox Syncronizer is slightly weak but capable off-road and on-road.
    AM General Jeep M825 MUTT | 3 C Turbo Diesel

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    Arsalan,
    I may be interested in the steering box, gearbox & diffs. What's the listed price for them ?
    TLC FJ90 SWB ~ 1KZ-TE ~ 50mm OEM Lift

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    Default M825 Takeout Items for Sale

    Please contact me at my cell 03008492791 or PM for further inquires.

    MUTT SUV Project  - Stage 1 Complete -5059MUTT SUV Project  - Stage 1 Complete -5059
    AM General Jeep M825 MUTT | 3 C Turbo Diesel

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    What's the latest, no update for a long time.
    TLC FJ90 SWB ~ 1KZ-TE ~ 50mm OEM Lift

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    Alot of extensive mechanical mods had happened since then. Will post details by next week with pictures.

    Exterior mods are yet to happen though. Other than initial delays my project is moving along smoothly. I have not elaborated on my project details on this thread, but believe me I am achieving precisely what I wanted from this project.

    Project Started on 1 September 2009. As of Today 4 Months have elapsed. Expected project duration 6 - 8 Months. Aiming to attend the March Cholistan Rally (not participate) on my Jeep.

    Expecting provisional completion of the project by End February 2010, and fully functional by May 2010.
    AM General Jeep M825 MUTT | 3 C Turbo Diesel

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    that mutt looks like in pretty good shape to start with. good find. Good luck and enjoy building and driving your 4x4. hope to see you off road.

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    Quote Originally Posted by salmanchaudhry View Post
    that mutt looks like in pretty good shape to start with. good find. Good luck and enjoy building and driving your 4x4. hope to see you off road.
    Thanks salman,
    Looking forward to its mechanical test by next weekend.
    AM General Jeep M825 MUTT | 3 C Turbo Diesel

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    I had been busy with work and the jeep modification so did not post any progress, but her some.

    Engine: since day 1 of the replacement the engine was faulty and defective. The turbo seals were leaked, engine blow, and oil in the radiator. I have had the gasket changed 7 times uptill now, had the turbo changed, removed oil cooler lines, faced head, faced cylinder head back plate, pressure tested block and head, & completely overhauled the engine with new piston, boarig, bearings, values, and beagin. The trouble is still there and it seems ther is a hairline crack in the head water / oil gallery and I got a junk head. F**k. The mods that I have done is 1.5" engine bay lift. 1st Time oil chamber had very low capacity, so got a new one made.

    Drive Train: I am very happy with it. I replaced the 4 speed mutt gearbox with a SSR 5 Speed 4x4 Hi Low gearbox (plus shafts). Replaced the original diffs with 4.875 Ratio. Replaced the fornt hubs with auto locking disk brake hubs. Modified the rear hubs with an add on Disk Brakes. Replaced the front axles with CVs and Modified rear with CVs & Cross Combo. Replaced the front coil springs with rigid 2inch lift. TLC Long Travel front shocks and stirdy Isuzu Rear Shocks. Replaced the steering box, assembly, and rods. Added power steering, servo brakes, and shaft hand brake. Replaced the tires with 265/55/R17 AT on negative offset 17"inch steel alow rims.

    Next Mech Mods: Camber and lift rear suspension for added stability and capability. REPLACE THE HEAD.

    Upcoming Other Mods: Electric Radiator Fan (water fording capability), Air Snorkle with air fliter assembly.

    Body Fabrication: Inspiration from the following pictures
    AM General Jeep M825 MUTT | 3 C Turbo Diesel

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    MUTT SUV Project  - Stage 1 Complete - 49369attach MUTT SUV Project  - Stage 1 Complete - 49370attach MUTT SUV Project  - Stage 1 Complete - 49371attach
    Attached Images Attached Images    
    AM General Jeep M825 MUTT | 3 C Turbo Diesel

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    Default Custom body fabrication

    You have amazing plans to convert the MUTT to these awesome looking vehicles. InshaAllah you will be succesful in your project.

    I am also planning a same project. Kindly intimate the following:

    a. where in Karachi could a custom chassis be built.

    b. What is the approximate cost and time required for custom body fabrication (like the ones shown in the pics). is there any facility in Karachi where this could be done.

    c. How is it possible to fit these BIG bodies on the small chassis of MUTT.

    Awaiting your kind reply.

    Thanks,

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    Quote Originally Posted by shellcrack View Post
    You have amazing plans to convert the MUTT to these awesome looking vehicles. InshaAllah you will be succesful in your project.

    I am also planning a same project. Kindly intimate the following:

    a. where in Karachi could a custom chassis be built.

    b. What is the approximate cost and time required for custom body fabrication (like the ones shown in the pics). is there any facility in Karachi where this could be done.

    c. How is it possible to fit these BIG bodies on the small chassis of MUTT.

    Awaiting your kind reply.

    Thanks,
    Dear Friend,

    MUTT does not come with a chassis. It has a monococ body i.e. the structural load is ditributed amongst the entire body. Hence there is no chasiss or "gadri" that can be taken out.

    a. Golimar Chowk, Shersha, & Hub would be a good starting point

    b. Typical Bus / Truck body fabricators should be able to do the job such as Sindh Engineering works, but I doubt they would do a small project. So your options are limited to the choices in point "a." Cost & Time wise depeneds on the material, workmanship, finish, accessories e.t.c. give it 3 to 6 months and cost from 50k upto 150k

    c. Again there is no Chassis. The body frame would need to be fabricated around the MUTTs existing structure.

    Hope the info is helpful.
    AM General Jeep M825 MUTT | 3 C Turbo Diesel

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    Quote Originally Posted by aisheikh View Post
    I had been busy with work and the jeep modification so did not post any progress, but her some.

    Engine: since day 1 of the replacement the engine was faulty and defective. The turbo seals were leaked, engine blow, and oil in the radiator. I have had the gasket changed 7 times uptill now, had the turbo changed, removed oil cooler lines, faced head, faced cylinder head back plate, pressure tested block and head, & completely overhauled the engine with new piston, boarig, bearings, values, and beagin. The trouble is still there and it seems ther is a hairline crack in the head water / oil gallery and I got a junk head. F**k. The mods that I have done is 1.5" engine bay lift. 1st Time oil chamber had very low capacity, so got a new one made.

    Drive Train: I am very happy with it. I replaced the 4 speed mutt gearbox with a SSR 5 Speed 4x4 Hi Low gearbox (plus shafts). Replaced the original diffs with 4.875 Ratio. Replaced the fornt hubs with auto locking disk brake hubs. Modified the rear hubs with an add on Disk Brakes. Replaced the front axles with CVs and Modified rear with CVs & Cross Combo. Replaced the front coil springs with rigid 2inch lift. TLC Long Travel front shocks and stirdy Isuzu Rear Shocks. Replaced the steering box, assembly, and rods. Added power steering, servo brakes, and shaft hand brake. Replaced the tires with 265/55/R17 AT on negative offset 17"inch steel alow rims.

    Next Mech Mods: Camber and lift rear suspension for added stability and capability. REPLACE THE HEAD.

    Upcoming Other Mods: Electric Radiator Fan (water fording capability), Air Snorkle with air fliter assembly.

    Body Fabrication: Inspiration from the following pictures
    Complete reverse engineering , good luck with the body fabrication I hope you get a good dentor / fabricator to work on it.
    TLC FJ90 SWB ~ 1KZ-TE ~ 50mm OEM Lift

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    Quote Originally Posted by sarmadqureshi View Post
    Complete reverse engineering , good luck with the body fabrication I hope you get a good dentor / fabricator to work on it.
    Thanks sam. I have scared-off 2 fabricators already due to my requirements . Trying to source some stuff prior to fabrications based on which the jeep dimensions would be chalked out, particularly internal seating arrangements which would define the rollbar height. Hopefully fabrication work will start next week.
    AM General Jeep M825 MUTT | 3 C Turbo Diesel

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    Default Edit main thread

    Has anyone got an idea, how I can edit the main thread post.
    AM General Jeep M825 MUTT | 3 C Turbo Diesel

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    Quote Originally Posted by aisheikh View Post
    Has anyone got an idea, how I can edit the main thread post.
    What do you want edited ? Send me the text / pics
    TLC FJ90 SWB ~ 1KZ-TE ~ 50mm OEM Lift

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    Quote Originally Posted by sarmadqureshi View Post
    What do you want edited ? Send me the text / pics
    I meant, I want to edit the starting thread post that I initially placed.

    I have noticed that some of the "sticky" posts get their main posts edited to provide updates.
    AM General Jeep M825 MUTT | 3 C Turbo Diesel

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    Default MUTT body change

    Dear @aisheikh,

    Regarding changing the body of MUTT to something similar to the pics attached by you, kindly intimate some details of MUTTs body structure. What modifications will be required in the body. I think since the size of these bodies is bigger than that of MUTT so these have to be built of fiberglass.

    The suspension would also have to be changed. In my opinion the whole vehicle including the drivetrain will have to be modified.

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    Quote Originally Posted by shellcrack View Post
    Dear @aisheikh,

    Regarding changing the body of MUTT to something similar to the pics attached by you, kindly intimate some details of MUTTs body structure. What modifications will be required in the body. I think since the size of these bodies is bigger than that of MUTT so these have to be built of fiberglass.

    The suspension would also have to be changed. In my opinion the whole vehicle including the drivetrain will have to be modified.
    The body fabrication will be done ontop of the existing MUTT's structure without major alteration to it.
    If you have to do major changes to MUTT's suspension, then you rather not modify the jeep all togther. The reason I started this project was due to its independant suspension and monococ frame.
    I have already modified the drivetrain but it is not visible.
    Fiberglass is the best alternate in my opinion, but unfortunately I can't seem to find a fiberglass fabricator who is willing to take on this project (they seem to get scared due to its complexity)
    AM General Jeep M825 MUTT | 3 C Turbo Diesel

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    Default Body modification

    Thanks bro. Your plans are amazing I must say and with the right tools these are possible.

    Nowadays I'm also searching for fabricators of fiberglass bodies for cars. The vehicles shown in the attached pics have long wheelbase and width as compared to MUTT. Kindly intimate is it possible to fabricate the complete body (of vehicles in the pics as per their original dimensions) on top of MUTT or will their bodies have to be shortened?

    If the original dimensions are to be kept then the wheelbase and width of MUTT's body structure has to be changed, what is your opinion? Also when mounting the fiberglass body, the original body panels of MUTT will have to be removed. If these are removed then will it affect the integrity and strength of the body structure?

    I am planning to mount a Hummer H1 body (made of fiberglass) on top of MUTT, but dont want to compromise on the original dimensions of H1.

    Awaiting your kind reply.

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