African expedition FJ/HJ60 Build for Jesus

jonesy54 · 09-22-09, 08:21 PM

Quote:

Originally Posted by Ducks

Master Locks are extremely easy to pick. Don't know if that is a concern or not. You may be able to shoot them but someone with a simple pick set can open them right up.

true.

A lock is just for an honest man anyway. If somebody wants in, they'll get in...

Mikesta · 09-22-09, 09:04 PM

guys... I know this has been said before, but I really think this thing should be rolled or look like crap when it gets to liberia. Building something this clean in the US is ok. But destined for Liberia.... I'd make the exterior look like crap.... but the innard bullet proof. Don't overdo the exterior. It will be on the list of rigs to steal.

On another note, really enjoying this build.

sandcruiser · 09-22-09, 11:13 PM

those tires look like a good choice for the wet season. You might suggest that they put something else on during drier months-- an AT w/ more plies. Rutted, dry mud is tough on tires.

Master makes some brass combo locks that hold up pretty well in the elements. You can set your own combo. A patient thief could try every permutation in a few hours. But it would take a decent amount of patience.

Out of sight is better than "big box with lock" for most security, in my experience.

be sure to service the injector diaphram on the injector pump while you have easy access. Cheap part, easy job, big problem if torn.

Fuel filter is a very good idea. Racor makes some that have a cleanable element. Put it closest to the tank to catch gunk that would otherwise clog the stock filter.

Looks like a fun build.

zuluzeugma · 09-23-09, 03:58 PM

Quote:

Originally Posted by Mikesta

guys... I know this has been said before, but I really think this thing should be rolled or look like crap when it gets to liberia. Building something this clean in the US is ok. But destined for Liberia.... I'd make the exterior look like crap.... but the innard bullet proof. Don't overdo the exterior. It will be on the list of rigs to steal.

On another note, really enjoying this build.

Were gana hit it with a coat of epoxy based white paint as all the NGO landcruisers are white and don't get messed with. Were trying to think of things we can do to make it less desirable as a vehicle to steal

Quote:

Originally Posted by sandcruiser

those tires look like a good choice for the wet season. You might suggest that they put something else on during drier months-- an AT w/ more plies. Rutted, dry mud is tough on tires.

Master makes some brass combo locks that hold up pretty well in the elements. You can set your own combo. A patient thief could try every permutation in a few hours. But it would take a decent amount of patience.

Out of sight is better than "big box with lock" for most security, in my experience.

be sure to service the injector diaphram on the injector pump while you have easy access. Cheap part, easy job, big problem if torn.

Fuel filter is a very good idea. Racor makes some that have a cleanable element. Put it closest to the tank to catch gunk that would otherwise clog the stock filter.

Looks like a fun build.

They will have the option of buying a set of the local A/T's in the dry season if they so choose. After taking to my father in law, he agreed that a set of boggers has probably never made it to Africa and they may do very very well. If they turn out to be way to rough when the roads are dry, they can get a set of the local tires, thats why we are sending them with 16" non USA split rims cause thats what all the guys over there are used to seeing. 16" tires are easier to get too.

We are hiding everything we can. Some stuff (like lights) will have to be on the exterior of the vehicle.

Thanks for the hint on the injector pump. I'll check it out.

************************************************** ***************************

Rear axle parts came in today. The cruiser should be rolling by the end of the weekend if not before.

zuluzeugma · 09-27-09, 07:52 AM

Got the rear axle rebuilt and Aussie Locker installed. (That thing SUCKED! the front was easy; but with the stupid c-lips, wow, annoying...)

Pic 1: New wheel bearing installed
Pic 2: This is my super Ghetto axle stand. I took two big old connecting rods, welded them to old brake discs and then c-clamped them to the table...
Pic 3: Aussie installed (2 hours later; did I mention how annoying that was?)

zuluzeugma · 09-27-09, 07:58 AM

Pic 1: Axle done and in place. I'm going to paint those drums, I promise =)
Pic 2: Again, Axle installed, Dakar spring... (these bad-boys are STIFF)
Pic 3: Suspension is done, axles are done, brakes are done save a 1" bore MC on order.; Shes starting to come together. More to come...

sandcruiser · 09-27-09, 11:38 AM

looks good. the axle stand is a good re-use of scrap.

zuluzeugma · 10-09-09, 10:31 AM

Got the 16" Non-USA split rims back from the powder coating (Thanks DK Ind. out of Marshall, TX!!!) Got the Boggers mounted up with tubes. They look awesome!

IrollwithTojo · 10-09-09, 07:40 PM

Those steelies with the SS look sick

-Carl

solli · 10-10-09, 12:45 AM

Nice

chappysfj40 · 10-10-09, 08:14 AM

wicked cool

ScottyDog · 10-10-09, 09:24 AM

Very nice.... Now if you had a pull plow to send with the tractor....

zuluzeugma · 10-11-09, 07:57 PM

Pic 1: Battery trays (Thanks Ruff Stuff Specialties)
Pic 2: Battery
Pic 3: 1" bore Brake MC

zuluzeugma · 10-11-09, 08:08 PM

We are building the Roof Rack from scratch; mostly because it needs to be "kind of" custom. Were making high walls on it so some random person can't just reach up there and grab stuff while stopped. Were making the floor and walls out of .065 6061-T6 perforated aluminum. The sub-structure is made from 1" 6061-T6 .125 wall square tube.

Pic 1. Ryan Martin Doing some design and lay-out of rack.
Pic 2/3: Me laying down some TIG tacks.

chappysfj40 · 10-11-09, 08:15 PM

I love the tig!!!!!

zuluzeugma · 10-11-09, 08:19 PM

Started working on the first of two tool boxes. I'm sure I'm gana get flamed like crazy for the plan, but I think it will work well for their needs.

We Wanted to give them ample storage space but also not sacrifice the "whole" back area. additionally, Ben really wanted to have some extra seating in the far back. Taking all this into account, I went to work on a "picture I had in my head".

Pic 1: Started by using the old interior panel as a pattern to cut around.
Pic 2: Plasma cut to make a panel of .125 6061-T6
Pic 3: Fit up inside the FJ60

zuluzeugma · 10-11-09, 08:30 PM

Pic 1: Decided to make it 14" wide
Pic 2: I've had this idea in my head for a while on making revolving "lazy susan" type drawers and so I set out with that in mind. The drawer has a 21" diameter and is 5" deep; it should be plenty big for wrenches, sockets, etc. Above this will be a large compartment for tow strap, shovel ,etc; the lid of this will have a seat cushion for a "small" person to sit on.
Pic 3: What it will look like once rotated out 180 degrees. I know its kind of hard to visualize right now, but I *think* its gana work.

Micah · 10-11-09, 09:11 PM

I am looking forward to see how this tool box comes out.

zuluzeugma · 10-12-09, 10:01 AM

A few of the guys were able to turn the building of the bumpers into class projects for credit. Here are some screen shots of the SolidWorks models. The have done impact, static, and dynamic finite element analysis for both. In both the front and rear, the most important thing is that the bumper is hard to "stand" on. They have a big problem with people jumping on the truck and taking a ride.

The front is pretty straight forward. 1.5" .120 DOM with 3/16 plate.

The rear is made from 6-5/8" sch. 40 oil-field pipe; yes, we know its redneck, but we needed some air tank volume and it will also be hard to stand on once its powder coated and muddy. Hopefully, it will get pretty slippery. =) It will have a swing-out tire carrier (using a 3500# trailer axle spindle from poly performance), two tow points, and a receiver if they need to tow something.

Pic 1: Front bumper
Pic 2: Rear bumper
Pic 3: Rear bumper

boerboel313 · 10-13-09, 04:31 AM

What size are the Swapers and how much lift did you get out of the dakar springs. I saw the pics but whats the measurments?

Nice build and good luck.

Michael Hanson · 10-13-09, 05:40 AM

This is a great plan and good cause. MIke

zuluzeugma · 10-13-09, 06:56 AM

Quote:

Originally Posted by boerboel313

What size are the Swapers and how much lift did you get out of the dakar springs. I saw the pics but whats the measurments?

Nice build and good luck.

The tires are 33"X10.50X16. The lift is supposed to be a 3", but right now, its probably a 5" cause theres very little weight on the truck. The drive-train is still sitting on the floor.

jonesy54 · 10-14-09, 01:15 AM

I know the 2F is a chunk but what's the weight difference between the 2F and the 2H? significant?

zuluzeugma · 10-14-09, 07:17 AM

Quote:

Originally Posted by jonesy54

I know the 2F is a chunk but what's the weight difference between the 2F and the 2H? significant?

Not 100% sure... Probably couple hundred pounds more???

Ducks · 10-14-09, 09:19 AM

Quote:

Originally Posted by jonesy54

I know the 2F is a chunk but what's the weight difference between the 2F and the 2H? significant?

They weigh almost exactly the same.

CIS Auto Web's Diesel Land Cruisers

zuluzeugma · 10-14-09, 09:26 AM

Quote:

Originally Posted by Ducks

They weigh almost exactly the same.

CIS Auto Web's Diesel Land Cruisers

Yeah, I'm not surprised. I have the head off right now and it "feels" just like a 2F head. I thought the block looked quite a bit thicker, but maybe not.

CruisinFJ60 · 10-14-09, 09:38 AM

i need a plasma cutter...

zuluzeugma · 10-14-09, 09:56 AM

Quote:

Originally Posted by CruisinFJ60

i need a plasma cutter...

HAHA, yeah, they are awesome. The local rep from Thermal-Arc is LeTourneau University Alum and donated a plas cutter and several TIG machines.

Pic 1: Plas cutter
Pic 2: TIG machine

CruisinFJ60 · 10-14-09, 10:29 AM

Quote:

Originally Posted by zuluzeugma

HAHA, yeah, they are awesome. The local rep from Thermal-Arc is LeTourneau University Alum and donated a plas cutter and several TIG machines.

Pic 1: Plas cutter
Pic 2: TIG machine

I need a Tig too for some of the crap i need to do / do
Mig works ok for some but others tig is either required or nearly required.

Such is life.

oh and if i had something about the size of what you have there... id be really really really really happy! all i would need is a small 2 bedroom with kitchen and small living room!

zuluzeugma · 10-20-09, 07:23 AM

Lots of work done this weekend

I'll highlight the major things: We got the substructure for the roof rack complete. I started to build the second tool box and got got one of the lazy Susan drawer working and it works PERFECTLY. Eric Shook and Ben Reed worked on the front bumper for several hours which is coming along and looking great! The front bumper will be fully plated in with 3/16" so the winch is totally concealed. All one will see is the roller fair lead and hook hanging out. The built the major sub structure from 1/2" plate and the tubes from 1.5" .120.

Eric Shook Cuts pieces of 1/2" plate for front bumper sub structure

Me TIG welding the drawer the rest of the way up

Kyle Schubert cuts out tool box structure with the plasma cutter

Front bumper mounting plate made from 1/2 Carbon steel plate

Winch on Winch plate soon to be connected to front bumper

Ryan Marin continues to TIG weld the roof rack together

More TIG welding

And again

Kyle Schubert cleans up the edges of tool box panel after cutting with the plasma cutter

More roof rack construction (Ryan Martin)

The finished tool box drawer. I was "kinda" happy with it. The next one is going to come out significantly better. I figured out some better manufacturing processes

Installed grease zerk for easy rotating as aluminum on aluminum tend to gaul

TIG weld on tool box drawer

Finished tool box drawer from bottom

Front Bumper beginning to come together

More bumper fit up