71 FJ40 build up using my 84 xcab chassis (camotoy)

[paranoid56]

figured i would post this over here too as some people dont go over to the pirate board..

well, i bought this gem a few years ago, slowly doing things to it, but never really driving it.
This is what it looked like when i bought it nice eh?


I also have owned this for years now. started out as a bone stock truck, and now its a ARB locked F/R, dual cases, bla bla bla.

This truck served me well, was my DD for years, many trips to the hammers and the rubicon. finally bought a car to be my DD (06 WRX wagon) and ended up rolling the toyota


well, now i have two trucks that i cant drive on the streets. and i need something to mess around with

So, i am going to take the FJ40 body off and put it on the 84 truck frame. using everything from the motor and frame down. (man i hope this is a good idea)

So, started with this today.

just kept taking everthing apart.

[paranoid56]

working alone sort of sucks, but good thing i have a fork lift. getting the flat bed off was a easy with the right toys



had to just take one last pic of my stickers on the back window



before i poked the forks through


luckly this didnt happen till after i had it off the truck, the knot slipped

[paranoid56]

now, this is how the truck sits now.



and just so we know, this is how the FJ40 is sitting now


I am hoping that i will get the FJ40 over to the truck (which is at my work) over this week, and see how it looks

[paranoid56]

well, got the chassis all cut up, took 17" out of the center of the 84 x cab chassis
here is the first cut.


the center part all cut up.


he, never done this before


once cut, i pushed them together, put a bunch of clamps on it and welded it all up.

[paranoid56]

made up some frame plates. outside and inside.


fully welded.


now, the chasis is just right to fit under the body.

next up will be moving the engine back a few inches to match the front bib on the FJ. not sure on the rear drive line yet, as i need some weight on the chassis to see how the driveline angle will be.



FJ40 in the background to size up the chassis

[paranoid56]

well, got the body on, looks like its going to be stetched in order to have a long enought rear driveline.

the FJ40 body fits real nice ontop of the 84 chassis. once i move the rear shock mount, it looks like it will fit right on top.


i also think i want to have the grill at the front of the truck.


a side shot. i figure i will have to add a foot after the door opening. figure that should be the easyest place to do it.



oh, and one small issue. THIS THING IS WAY TOO TALL its right 8ft tall.

i think i am going to move the rear shackle mount to inside of the frame. that should lower it around 3 inches or so. I also think i am going to add a rear fuel cell to add some weight back there to bring it down more.

[paranoid56]

well today, i cut up the body and stretched it. added about 14inches. (well, havent added yet )
here are the cut pics.
man, this was a pain in the ass. took me hours just do do this

[paranoid56]

well, only had sunday to work on the truck, but have had a major headache all damn day..
Didnt get too much done.
started with making a bracket to bold on to the front half of the body, just like the stock set up.


Then i went about making a rear ledge for the new sheet metal to sit on. figured this would be stronger then just welding it directly one.
the hard part was that i had to make that circle shape to match the orginal floor.
so i cut a bunch of slices in it.


then i started shaping it to the shape needed.


and the finished product all ground smothe.


i also drilled holes in it so i could spot weld it on. i also put some small welds on the top to help out.

[paranoid56]

Next up was the floor. I orderd a full sheet of 18ga (4x12 for 80bucks) i also had them shear 2 14"x4' long strips and 2 16"x4' this way i knew they were perfect

so i cut one to fit on the passerenger side and drivers side. then i finished up making the center bump. I had to do some notching on sides to make it fit perfect.


and the finish result. its not welded yet, and not fully done. but you get the idea. I havent figured out if i want to replace the whole floor yet either. the passenger side has been cut up my the PO, and the drivers side is sort of rusted. I guess it would just be as easy to make a full piece. damn, i wish i thought of this when i was out in the shop today

[paranoid56]

well, heres heres the flooring. damn shitty looking. and some extra cut holes thanks to the PO

[paranoid56]

just a pic of a side shot with the side panel on. getting to look a little better.

[paranoid56]

so, i decieded to just hack out the whole floor. and start from scratch.

I left a 3/4" lip on the sides, and cut right up the the front body mount.
Seemed like a good idea

[paranoid56]

So, i made a new center crossmember to help support the new flooring, and body. I am doing the flooring in sections for ease of install. but the rear seemed a bit flimsy. so i rolled some 1/4" beads in it.
I also am raising the drivetrain so i can have a flat belly. But looks like i was a bit off on how high i made that center hump. I am going to cut it gown tomorrow to match the rear of the tub.

[paranoid56]

well redid the center cross member again this time its the same height as the rear part of the tub.



I cut the top off and just replaced the tubing with some 1/2" plate with a nice gusset under it.

[paranoid56]

once that was finished, i started on the flooring. I used 1x1" tubing to make the under floor supports. Hopfully this should hold up well.



now fully welded to the body. its attached to the front body mount, and under the middle of the door opening and to the new xmember.

[paranoid56]

and here it is with the new floor pannels. all with 1/4" beads looks good. and should last a wile. i am going to spot weld it in and put seam sealer on it all. i need to fix a few of the foot well areas, and build a center hump section. but that should be somewhat easy

[tucker74]

Looking great man - that extra room is going to be nice! Any thoughts on bringing the center of gravity down? She's gonna be tippy for sure



Tucker

[paranoid56]

oh yea, i am putting the rear shackles through the frame, that should bring down the rear a few inches. the front of the rears is already frenched into the frame. as for the front, i am contaplating moving the axle forward a little and maybe taking a leaf ouf of each pack to bring it down. Its way too tall as it sits now. almost 8ft tall.

Shane

[Silicon 70]

You are *#%^ing crazy, but we like this sort of thing here. You got some skills to do that on your own. Keep us posted and keep the pictures coming.

[rabid]

holy hell that is a lot of work.

Looks good!

[shelfboy1]

your work is good some how i missed the point i would have sold the 40 bought a body and put it on the frame to me you are stepping down using a pickup and wrecking a 40 for no reason i wish you luck and keep up the good work

[Sporin]

looks great! I envy your fab skills and tools, very cool stuff.

[oldIron]

Originally Posted by Sporin

looks great! I envy your fab skills and tools, very cool stuff.

X2 - great work. I wish I had half the skills you have and the shop. Great job so far, although I would be concerned with the overall height as well, but it looks like you are not looking to cruise this on the highway...

[paranoid56]

Originally Posted by shelfboy1

your work is good some how i missed the point i would have sold the 40 bought a body and put it on the frame to me you are stepping down using a pickup and wrecking a 40 for no reason i wish you luck and keep up the good work

well, the reasion i used the pickup chassis, is that it was already built and a bit lighter then the 40 frame. my pickup already had dual cases, ARBs F/R, just a nice buit up truck.

now the 40 was a pile of rust. had holes everwhere, the whole rear sill was gone, lots of holes in the floor board. the orginal PO swaped a V8 into the truck and did a horable job at it.

I am keeping the FJ40 chassis and building it up slowly (after this build) and putting an alu (or new steel) tub on it and building a nice driver.

Shane

[paranoid56]

Originally Posted by oldIron

X2 - great work. I wish I had half the skills you have and the shop. Great job so far, although I would be concerned with the overall height as well, but it looks like you are not looking to cruise this on the highway...

oh, i will be driving this on the highway this beast is coming down in height very soon. i want to get the body work done first, then its getting dropped. i can get at least 3 inches just from making it almost touch the frame, then another 10 (hopfully) by reworking the suspension

yea, lots of work, but since i have everthing i need (from dismantling both trucks, this built isnt costing me much money. thats the main reasion i am doing it. i am poor


Shane