How Barry Engineered the Perfect Old-School Jeep Without Losing Its Soul

Barry Spangenberg knows exactly what he’s doing when it comes to building the perfect trail rig. His 1947 Willys CJ2A, lovingly dubbed “Grasshopper” by his wife, proves that sometimes the best builds are the ones that don’t scream for attention. This isn’t some over-the-top rock bouncer or trail queen - it’s a thoughtfully engineered machine that looks stock but performs like a modern crawler.

The beauty of Barry’s approach lies in his restraint. While most builders go straight for the flashy mods, Barry focused on the fundamentals that actually matter when you’re picking lines through technical terrain. He kept the original L134 Go Devil four-banger under the hood, paired with the stock T90A transmission and Dana 18 transfer case. The magic happens in the details though - those Jeff’s X98 gears in the transfer case deliver a final drive ratio of 77:1, giving Grasshopper the kind of crawl ratio that makes gnarly rock sections feel manageable.

Anyone who’s wheeled an old flatfender knows the two biggest complaints: stopping power and steering feel. Barry tackled both head-on with solutions that work. The four wheel disc brake conversion using Brennan Metcalf’s trackick disc conversion transformed the Jeep’s stopping ability completely. He initially ran the system off the original master cylinder before upgrading to a Willwood dual reservoir setup mounted on the firewall for easier maintenance access.

The steering modifications showcase Barry’s fabrication skills perfectly. He managed to keep the original steering column and wheel while completely modernizing the system underneath. A brass bushing machined by his brother connects to a double cardan U-joint, followed by a telescopic shaft running to a Saginaw power steering box. The clever part? An electric hydraulic pump from a Volvo provides the power assist at the flip of a switch, eliminating the need to rob power from that little Go Devil engine.

Protection was clearly a priority as Barry’s confidence grew on increasingly challenging terrain. After bending multiple skid plates, he had his brother fabricate a 3/8" thick piece that extends four inches back to protect the parking brake. A matching 3/8" clutch pedal guard that looks like a ski keeps the crossmember safe during rock contact. Sliders across the spring mounts complete the armor package, letting Barry drag the belly across obstacles without worry.

The suspension setup strikes that perfect balance between capability and maintaining the classic look. Rancho 2" lift springs provide just enough extra clearance without going overboard, while 7.50x16 square-shouldered NDTs with custom grooving deliver the traction needed for technical sections. Stock Dana 41 rear and Dana 25 front axles handle the torque just fine with the modest power output.

Barry’s attention to detail extends beyond the mechanical bits. The custom canvas top, wind jammer, doors, and side panels all came together using materials he had lying around. When he decided a full roll cage was necessary for safety, he modified and fabricated the entire structure himself, then reworked all the soft goods to fit properly.

The knuckle stud conversion using two-hole passenger side knuckles from a Dana 27 out of a Willys wagon shows the kind of research and sourcing that separates good builds from great ones. M38 tie rod ends and custom-fabricated tie rods and drag links complete the front end upgrades, creating a system that’s both strong and precise.

What makes Grasshopper special isn’t any single modification - it’s how everything works together as a complete package. Each upgrade addressed a specific need or weakness, building capability systematically without losing the character that makes these old Jeeps so appealing.

Grasshopper represents everything that’s right about building classic 4x4s. It’s capable without being obnoxious, modified without losing its soul, and built by someone who clearly understands that the best trail rigs are the ones that get used regularly. Barry’s five-year journey with this CJ2A proves that sometimes the most rewarding builds are the ones that never really end - there’s always one more thing to tweak, improve, or perfect.

You can follow Barry’s adventures and see detailed build information at The CJ2A Page, where he continues sharing his knowledge with fellow flatfender enthusiasts.