1962 Willys M38 A1 - Tube Jeep - Buggy

We at OFF-ROAD like to bring you a little variety from the dirt-loving community, so when we spotted Erik Busarello's weekend play toy, we knew we had to snap some photos and show you what he's put together.

What you see here started from the seed of a '62 Willys M38A1 whose age had left it rusted and a lot worse for wear. However, Erik salvaged the best parts, mainly the cowl section and grille, and began building up a project vehicle. His intent was to build an all-around open-top rig that was capable for back country exploring, a little rock crawling, but mostly high-speed dune and desert running.

With a near blank canvas, Erik was able to layout some specs he wanted for the build.

Erik is part of the crew at Random Precision Mfg. (www.rpmfab.com), a custom off-road fabrication shop in Tempe, Arizona. Over the period of about a year, he gathered parts and put together a complete rig.

Erik's goal with the front suspension was to build it so that it could tackle rough terrain at speed. He chose to design a four-link setup with upper wishbone. The links are all fabricated from 1.75-inch 0.120 wall DOM steel tubing and the lower links are trussed for greater strength.

Erik's goal with the front suspension was to build it so that it could tackle rough terrai

He started with a pile of 1.75-inch DOM tubing and set about building a tubular chassis from scratch. The plan was to build a chassis with an integral six-point rollcage, linked suspension, and to provide all the attachment points needed to mount the drivetrain and wrap the chassis with body panels. For higher speed stability, the wheelbase was stretched to 116 inches.

Looking at the photos in this feature, you'll realize there are tons of unique fabrication touches in this buggy. We'll point some out, and the more you look the more you'll find. Erik employed ample use of a tube bender, CNC plasma cutter, dimple dies, and sheet metal tools in putting together all the metal in it. What you'll also see is some missing paint, a few dings, and plenty of Arizona desert pinstriping. This vehicle doesn't stay at home tucked away in the garage. Instead, it gets used on a regular basis. So you may just run across it out playing in the sandbox.

A trussed Dana 44 with 4.11 gears serves to spin the front tires. The tie rod is mounted above the steering arms for extra clearance and the draglink feeds back to a bellcrank assembly mounted on the top of the front axle.
A trussed Dana 44 with 4.11 gears serves to spin the front tires. The tie rod is mounted a
A clean firewall design was assembled from aluminum sheet after spending time on the shear and sheet metal brake. A '79 Ford 2WD pickup power steering box is mounted in the upper portion of the driver footwell. The sector shaft protrudes through the floor where a pitman arm connects to a relay rod that extends forward to the bell crank assembly on the front axle. Erik fabricated the throttle pedal and brake pedals from scratch. No vacuum brake booster is used on the brake master to simplify the system and keep braking force consistent under all conditions.
A clean firewall design was assembled from aluminum sheet after spending time on the shear
Here is the bell crank assembly on the front axle. The relay rod from the pitman arm (rear) has its movement translated 90 degrees through the bell crank to move the draglink (front) as the steering wheel is turned. This keeps the steering action constant on the live front axle as it cycles through large suspension movements. The relay rod from the pitman to the bell crank matches the movements of the links in the suspension.
Here is the bell crank assembly on the front axle. The relay rod from the pitman arm (rear

The rear of the buggy is supported by a pair of 2.5 16-inch-stroke King coilovers. Further damping is provided by a pair 2.5 triple-bypass shocks. This view also gives you another look at the clean tube chassis design that makes up this rig. Rear body panels were fabricated from aluminum sheet and dimensioned to accommodate the wheelbase stretch and larger tire openings.
The rear of the buggy is supported by a pair of 2.5 16-inch-stroke King coilovers. Further
In the tail of the tube chassis sits a 12-gallon fuel cell in a fabricated belly pan. Tires of choice are 35-inch Goodyear MTRs on 8.5-inch wide lightweight, vintage Enkei forged aluminum wheels. The tire size is large enough to provide good ground clearance in rocks and ruts, but keeps the assembly light enough so the buggy suspension soaks up whoops well. Some 2.0 King air bumps are used here as well to keep the rear axle and chassis from banging metal on metal. The rear 12-bolt axle is trussed top and bottom, runs a Gov-Lock and uses disc brakes, making for discs on all four corners. As with the front, the rear lower links are truss designs to prevent them from bending under load. Driveshafts were custom built at RPM.
In the tail of the tube chassis sits a 12-gallon fuel cell in a fabricated belly pan. Tire

This shot gives you an idea of the level of detail work and thought that went into building the complete tube chassis. All the critical stress points are boxed and braced, but mounting points are combined when possible for best strength and to minimize material use to keep the chassis light.
This shot gives you an idea of the level of detail work and thought that went into buildin
Opening the hood shows more handiwork on this rig. The powerplant is a Chevy 350 topped with a Holley 650 double pumper using manual secondaries. Erik built the headers from scratch to fit snugly into the confines of the chassis. Cooling for the small-block motor comes from a 19x28-inch Ron Davis aluminum radiator.
Opening the hood shows more handiwork on this rig. The powerplant is a Chevy 350 topped wi

Behind the engine sits a TH400 auto tranny with manual valve body and 2500 rpm stall converter. Erik fabricated a custom rear crossmember to support the tail end of the tranny and the Dana 20 transfer case sitting aft of it.
Behind the engine sits a TH400 auto tranny with manual valve body and 2500 rpm stall conve
Details abound on this rig. Here you can see the lower chassis tube that serves as a rock rail with integrated step just outside the Jeep Wrangler steel door. The tube also incorporates a steel plate used to support the rear side body panel and a small dimpled step to allow passengers to climb into the rear of the tub. A small rock light is tucked neatly into the body panel as well.
Details abound on this rig. Here you can see the lower chassis tube that serves as a rock
The grille is original M38A1 and the hood/fender assembly is a fiberglass unit from 4 Wheelers Supply in Phoenix. Erik added a stinger to the front of the chassis. Headlight assemblies were added behind the grille and a pair of Hella driving lights sit behind the stinger.
The grille is original M38A1 and the hood/fender assembly is a fiberglass unit from 4 Whee

One item that really caught our eye and seems to garner Erik a lot of compliments are the rear storage boxes. They're simply recycled surplus ammo cans but have been integrated into the tail of the buggy and cleanly house the LED tail lights. Clever setup!
One item that really caught our eye and seems to garner Erik a lot of compliments are the
The front axle is suspended using 2.5 16-inch-stroke King coilover shocks backed by a 2.5 triple-bypass shocks to keep the front tires under control in the rough stuff. Up-travel is slowed and ceased with 2.5 4-inch-stroke King air bumps. The linked front suspension allows for both good travel and reasonable articulation out on the trail. Limit straps at each corner catch the axle when the suspension tops out.
The front axle is suspended using 2.5 16-inch-stroke King coilover shocks backed by a 2.5
A bird's eye view of the interior reveals a trio of BS Sand suspension seats mounted inside the 1.75-inch 0.120 wall DOM rollcage. No traditional dashboard remains. Erik fabricated an aluminum switch panel above the tubing used to support the steering wheel shaft mount. A small centered panel holds a full set of Autometer Phantom gauges. Since this is a trail rig that sees a lot of time in the desert, a Hi-Lift jack is handily mounted on the rear of the cage should it be needed for extraction or tire work.
A bird's eye view of the interior reveals a trio of BS Sand suspension seats mounted insid