87 Grand Wagoneer on 94 Cummins 3500 chassis

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MajorPain999
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87 Grand Wagoneer on 94 Cummins 3500 chassis

Post by MajorPain999 » Thu Aug 12, 2021 5:23 am

This build has been a dream of mine since about the time i got my Grand Wagoneer around 4 years ago. Due to an unexpected transmission failure, I decided to go ahead and spend the money to get a suitable donor vehicle. I searched for a few months before I came up with this.
image0 (3).jpeg
It's a 1994 Dodge Cummins 3500 dually. 5.9 12V/NV4500/NP241/Dana 60/Dana 80. Body was absolutely shot but the frame was in relatively good shape. Using a few other build threads of similar concepts as guides, me and a good friend began to draw up how we intended to do it. The Wagoneer's wheelbase was 110" from the center of the wheel wells and the Dodge was 137". We cut 20" out on the flattest portion of the frame and welded it back up, measuring from a bunch of different locations to ensure the frame stayed square.
image0 (2).jpeg
image1 (1).jpeg
image4 (1).jpeg
We then removed the Wagoneer's body from the original frame with a cherry picker and two floor jacks. It was super sketchy, but without a 4 post lift, we did the best we could.
image2 (1).jpeg
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Last edited by MajorPain999 on Thu Aug 12, 2021 8:15 pm, edited 1 time in total.
1987 Grand Wagoneer- 5.9 Cummins/NV4500/NV241 In progress

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Stuka
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Re: 87 Grand Wagoneer on 94 Cummins 3500 chassis

Post by Stuka » Thu Aug 12, 2021 6:28 am

Welcome to the forum. This certainly seems to be a popular swap this year :)

If you like, I can move this to build threads if you intend on posting up the full build process.
2017 JKU Rubicon Lifted and stuff
Pevious Jeeps: 1981 J10, 1975 Cherokee, 2008 JK, 2005 KJ, 1989 XJ


Topic author
MajorPain999
Posts: 5
Joined: Mon Aug 09, 2021 7:42 am

Re: 87 Grand Wagoneer on 94 Cummins 3500 chassis

Post by MajorPain999 » Thu Aug 12, 2021 6:53 am

Stuka wrote:
Thu Aug 12, 2021 6:28 am
Welcome to the forum. This certainly seems to be a popular swap this year :)

If you like, I can move this to build threads if you intend on posting up the full build process.
That is fine! I will update with more pictures and info later in the day, and also correct the double posted picture that I missed.
1987 Grand Wagoneer- 5.9 Cummins/NV4500/NV241 In progress


Topic author
MajorPain999
Posts: 5
Joined: Mon Aug 09, 2021 7:42 am

Re: 87 Grand Wagoneer on 94 Cummins 3500 chassis

Post by MajorPain999 » Thu Aug 12, 2021 8:31 pm

This was the finished product after sitting the wagoneer body down on the shortened frame.
image3 (1).jpeg
Next we built body mounts to mount the body at all 4 corners. We did this by basically airing the tires up to ride height to get the frame level, and then leveling the body to the ground. Then lowering the body down to about 1/4" off the frame at the closest spot and squared it up side to side. Then we mounted our mounts to the body and tacked them, remeasured and final weld. The body has a slight rake to it so i will probably be removing the blocks from the rear suspension to correct that. Overall, not too bad, no body cutting needed at all.
image9.jpeg
image6.jpeg
With the body mounted in the correct position to center the tires in the wheel wells, there is a 10" gap from the fire wall to the back of the head of the engine. The front clip will not go back on without correcting this and pushing the engine back. So our next step was to move the Jeep from my concrete slab over to my garage where we had more room to move an engine crane. It also helped to have the roof so the Florida summer rain wouldn't slow down progress on it. With the jeep under the carport it was time to start lifting the drive train and making some cuts for clearance.
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1987 Grand Wagoneer- 5.9 Cummins/NV4500/NV241 In progress


Topic author
MajorPain999
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Joined: Mon Aug 09, 2021 7:42 am

Re: 87 Grand Wagoneer on 94 Cummins 3500 chassis

Post by MajorPain999 » Sun Aug 15, 2021 9:04 pm

image4.jpeg
image3.jpeg
You can see in one of the pictures where we clearance the crossmember for the a/c compressor. New engine mounts were built and then we also had to build a trans mount.
image1.jpeg
I may go back and change the way the trans crossmember bolts to the frame, I think it needs a little more meat in the frame for the mount.
image2.jpeg
This was the end product of pushing the drivetrain back. The engine now has about 1-2" between the back of the head and the firewall. Thats pretty much caught up on where the project is as off today. I am currently test fitting the front clip to see how i am going to make an engine fan, radiator and intercooler work. There will definitely be some cutting being done to the inner fenders and front clip assembly. Then I have to hook the hydraulic clutch up to my manual pedal assembly and then plumb a fuel system. Looking at options for putting the tank where the spare tire would be. I will also be wiring a separate relay box in to run all the added on electronics such as lights and gauges. Nothing from the OEM gauge cluster will work with what it has now so i will be going with Autometer gauges in a sheet metal interlay. I will try my best to update every step of the way!
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1987 Grand Wagoneer- 5.9 Cummins/NV4500/NV241 In progress

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Stuka
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Re: 87 Grand Wagoneer on 94 Cummins 3500 chassis

Post by Stuka » Tue Aug 17, 2021 6:13 am

Most people end up notching the firewall to move the engine farther back to allow for the Rad/IC/AC. You may end up having to cut into the front valance.

Many here have used Blazer/Bronco tanks behind the rear axle. I do not know the width of the Ram frame offhand, but its a good place to start.
2017 JKU Rubicon Lifted and stuff
Pevious Jeeps: 1981 J10, 1975 Cherokee, 2008 JK, 2005 KJ, 1989 XJ


Topic author
MajorPain999
Posts: 5
Joined: Mon Aug 09, 2021 7:42 am

Re: 87 Grand Wagoneer on 94 Cummins 3500 chassis

Post by MajorPain999 » Mon Sep 06, 2021 9:42 am

Took some time to do some basic preventative maintenance on the Cummins while i had access to everything. Cleaned up the valve covers and installed new gaskets and then took the front cover off to take a look at the infamous killer dowel pin.
KDP.jpeg
I made a little tab out of some scrap and found a longer bolt that fit the boss. Used some red loctite and torqued it, i think itll be fine and saved me a bit of cash from buying the kit online.
KDP complete.jpeg
Next I got to work on the radiator/intercooler fitment. I ended up notching the front clip about 3-4 inches and pushed the radiator into that hole for clearance to the engine fan. I then made new feet mounts for the radiator to sit on and modified the stock upper mount to use. With the radiator in place I was able to start making a mount for the intercooler. As of right now I still haven't finished the upper intercooler bracket but it is hanging in its intended location.
Radiator, fan, intercooler.jpeg
assembled clip.jpeg
I have about 1/4" clearance between the radiator and the fan blades at the top of the radiator. I think I may shave an 1/8-1/4" off the fan blades to open up that space a little more. I also still need to modify the factory dodge fan shroud to fit the jeep. All in all, being able to retain the mechanical fan is going to be great for cooling. I couldn't find an electric fan that generated anywhere near the CFM of the OEM mechanical fan.

I also fitted the fenders to see where the tires were going to sit in the fender. Looks like the axle got moved slightly forward from where it was on the Jeep frame.
fender fitment.jpeg
Those are 33's on it currently, they came off the dodge truck when i bought it. Looks like i have plenty of room for 35's. Maybe even 37's. :-bd
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1987 Grand Wagoneer- 5.9 Cummins/NV4500/NV241 In progress

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