Full Build: 1978 Jeep DJ5 Goes From Hauling Mail to Hitting the Trails

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It’s hard to make a DJ5 Mail Jeep cooler than it already is, but Carcass managed to do just that and build an off-road monster that delivers on its mission of conquering any terrain and keeping its character in the process. The guys sought a unique right-hand drive project that could maintain its allure no matter the project’s direction while providing the off-road performance few vehicles can match on the trails. They did this by stripping down the retired mail Jeep and starting from scratch.

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PARTS USED IN THIS EPISODE:
Covercraft: Carhartt SeatSaver Custom Seat Covers
More Info: http://httpslink.com/pn_pt_17271_60c8d7d70e0eb

Duralast: Duralast Wheel Hub Assembly
More Info: http://httpslink.com/pn_pt_16958_603eb0000bccc

EBC Brakes: GD Sport Rotors
More Info: http://httpslink.com/pn_pt_16959_603eb04685c78

EBC Brakes: Yellow Stuff Sport Brake Pads
More Info: http://httpslink.com/pn_pt_16960_603eb07d53e27

Summit Racing: QA1 Shocks & Struts
More Info: http://httpslink.com/pn_pt_16970_60469ea702d19

RockAuto.com: Caliper Mounting Brackets
More Info: http://httpslink.com/pn_pt_16961_6080359f6a3e2

Summit Racing: Allstar Performance Master Cylinder – AAF-ALL41064
More Info: http://httpslink.com/pn_pt_17272_615618f9e159c

Summit Racing: Artec Industries Axle Trusses
More Info: http://httpslink.com/pn_pt_16967_607f46b45cecc

Summit Racing: Earl’s Performance EFI Vapor Guard Hoses
More Info: http://httpslink.com/pn_pt_17239_60b7da9b5fe99

Summit Racing: Kluhsman Racing Components Shifters
More Info: http://httpslink.com/pn_pt_17269_610c3e5236462

Summit Racing: LizardSkin Original Ceramic Insulation
More Info: http://httpslink.com/pn_pt_18268_61796d3e9e1a7

Summit Racing: Mile Marker Locking Hubs
More Info: http://httpslink.com/pn_pt_16956_603eaf90277e2

Summit Racing: MSD Ignition Box
More Info: http://httpslink.com/pn_pt_17231_610c3eae01456

Summit Racing: Polyurethane Motor Mounts
More Info: http://httpslink.com/pn_pt_16962_603eb0ce13794

Summit Racing: PSC Hydraulic Assist Steering System
More Info: http://httpslink.com/pn_pt_16964_603eb1d92d9d9

Summit Racing: Quick Fuel Carburetor
More Info: http://httpslink.com/pn_pt_17240_610c3e7858a00

Summit Racing: RCI Aluminum Fuel Cell
http://httpslink.com/pn_pt_17238_60b7da57cb716

Summit Racing: Richmond Gear 488 Ring & Pinion Gears
More Info: http://httpslink.com/pn_pt_16954_608033c337299

Summit Racing: Russell Street Legal Stainless Steel Brake Line Kit – RUS-696500
More Info: http://httpslink.com/pn_pt_17273_615618e106ff1

Summit Racing: Single Stage Paint Royal Blue Pearl
More Info: http://httpslink.com/pn_pt_16997_60633ca39c24d

Summit Racing: Single Stage Paint White
More Info: http://httpslink.com/pn_pt_16996_60633c73c2bb1

Summit Racing: Summit Primer Sealers
More Info: http://httpslink.com/pn_pt_16995_60633c439f5f3

Summit Racing: Summit Racing Aluminum Differential Cover
More Info: http://httpslink.com/pn_pt_16957_603eafc67767b

Summit Racing: TeraFlex Transfer Case Seal Extension
More Info: http://httpslink.com/pn_pt_16963_603eb0f0cf21b

Summit Racing: Yukon Grizzly Lockers
More Info: http://httpslink.com/pn_pt_16955_603eaf4d21064

ARP: Bolts & Fasteners

Benchmark Abrasives: Premium Cutoff Wheel

CRC Industries: CRC Power Lube

Duralast: Starter, Battery & Alternator

Tom Wood’s Custom Drive Shafts: Driveshafts

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25 thoughts on “Full Build: 1978 Jeep DJ5 Goes From Hauling Mail to Hitting the Trails”

  11. Will never trust any jeep unless it has leaf spring suspension after spending a few months in the hospital because of a TJ deciding to lose left rear shock and both springs at 55_60 MPH going down the road causing the body mounts to fail on the passenger side and sending it rolling for a few hundred yards I love to watch 1996 and newer model jeeps get crushed into nice little cubes, junkyard trash deathtrap

    Reply

  14. A stock DJ comes with a rear locker and outperforms a stock jk even being only two wheel drive. Crazy to say and probably piss people off but I only say it because of my experience wheeling the Vegas desert with my buddy in his jk.

    My Dj was converted to a 2wd “CJ” by a niche’ company in the 90’s before I got it but was still stock 2wd engine Tranny/drivetrain.

    Reply

  16. Crap. They tossing a jeep and killing a title when all it took was a fiberglass tub. This is irresponsible and a big slash to the jeep community. Please quit messing with jeeps if all your doing is boneyarding the classics because you dont want to get your hands dirty pretty boys.

    Reply

  19. I sure would like to know what it would cost to go through a rig like this from front to rear. Hardly ever do we get to know what these cost it's cool that you can hook up all these neat new parts and fabricate up whatever you need but these shows are designed not for the shop owner these are designed to get guys like me out there and turning wrenches and doing stuff on these vehicles and saving one from the crusher. But I don't have the bankroll that these shows are putting into them my go-to dial for parts is not summit. But I like what's going on here and I would love to know what it would cost ultimately to do something like this or have it done by someone that would be two different prices. Even just knowing all the parts that were thrown into this because although a great build it's probably not cost-effective for me to build something like this on a regular shoestring budget. So more or less just a dream build.

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