FJ60 1-ton Superduty build

sixty · 07-26-06, 11:30 AM

Thought I would start a thread for my FJ60 build since I have started to put it together. This all started when I picked up a set of Superduty dually axles that I traded the spacers & Dana 80 for the Sterling. Here is the plan:

TBI350 (Already there)
700r4 (Already there, rebuilding myself & installing a 4wd output shaft)
Ford NP203 w/ 27 spline input using a np208/700r4 adapter
Northwest clockable adapter to Ford driverside drop NP205
2002 front Superduty Dana 60 w/ 4.10's & ARB
2003 rear Ford sterling 10.5" w/ 4.10's & posi (until I get a Detroit)
8-bolt hummer beaqdlocks recentered with Superduty pattern.
the wheels came with almost brand new 36" goodyear for almost free so I'll probably run them for a while until I get the scratch for some TSL 38's.

I need to figure out steering but I may just go with the bent draglink that all lifted Superduties use until I can figure out some highsteer setup by milling the knuckles. anyone have ideas or info on balljoint Dana 60 highsteer I'd appreciate it

I bolted up the sterling last night... can you say BEEFY?:

sixty · 07-26-06, 11:35 AM

sorry for the quality of the pics... I only had my cell phone

Here is the 60 front.... I need to outboard about 4.5"

2badfjs · 07-26-06, 11:47 AM

thats sick!

and very cool

tclndcrz · 07-26-06, 04:40 PM

damn son thats awesome

have a pic of the whole truck. the yellow is pretty sick lookin

kling-on · 07-26-06, 05:03 PM

http://www.offroadunlimited.com/Prod...5&idproduct=42

this maybe ??? cross over for a stock(lifted) supper duty

sixty · 07-26-06, 06:38 PM

Quote:

Originally Posted by kling-on

http://www.offroadunlimited.com/Prod...5&idproduct=42

this maybe ??? cross over for a stock(lifted) supper duty

They want close to $500 for that knuckle and it only puts the drag link above the springs.... I'm going to look into making something similar to dana 44 arms.

tclndcrz, heres a pic of it on the side of a volcano at close to 12,000':

Mace · 07-26-06, 08:53 PM

We need to trade diff covers

sixty · 07-27-06, 09:33 AM

Quote:

Originally Posted by Mace

We need to trade diff covers

pick me one up from blue torch or great lakes & you've got a deal

Tapage · 07-27-06, 02:52 PM

Quote:

Originally Posted by sixty

tclndcrz, heres a pic of it on the side of a volcano at close to 12,000':

11799..!!!! where is .. which Volcano . ?

sixty · 07-27-06, 04:31 PM

Quote:

Originally Posted by Tapage

11799..!!!! where is .. which Volcano . ?

I thought the GPS coordinates were a give away, eres tan flojo

Wish it was in central america but its Mauna Kea on the Big Island of Hawaii. Its actually 14,000 feet high but I went up the back side where I used to hunt for chukar partridge & sheep. got caught in a bliizzard there one year & it dumpe about 2 feet of snow & the temp dropped to about 25*F

Maybe someday I'll make it down south & we can wheel some Volcanos together

LC_Hamma · 07-27-06, 10:55 PM

It looks like Dynatrac has a better option for your BJ steering:
http://www.dynatrac.com/products_pro...rknuckles.html

Are you going to run rod ends or tie rods? I'd really like to see a hysteer arm that accepts rod ends in double shear....

Tapage · 07-28-06, 09:58 AM

Quote:

Originally Posted by sixty

I thought the GPS coordinates were a give away, eres tan flojo

algo de eso puede haber .. pero gracias por la info

sixty · 07-28-06, 11:07 AM

Quote:

Originally Posted by LC_Hamma

It looks like Dynatrac has a better option for your BJ steering:
http://www.dynatrac.com/products_pro...rknuckles.html

Are you going to run rod ends or tie rods? I'd really like to see a hysteer arm that accepts rod ends in double shear....

I picked up the stock steering linkages (beefy) yesterday so it looks like i'll be going that route & if it turns out to be a problem then later I'll figure out high steer.

The dynatrack knuckles are nice but they don't fit the unit hub bearing spindles, so it would be all new parts and not have the metric lug patter. Tera makes some that should work & they are about $800 a pair... still too rich for my blood so far....

a double shear arm sounds $$$$ its probably easier to make the arms bigger & then use larger rod ends/ bolts

sixty · 07-28-06, 11:08 AM

Quote:

Originally Posted by Tapage

algo de eso puede haber .. pero gracias por la info

De nada amigo!

sixty · 07-28-06, 11:25 AM

Heres a few pics of the beginning of the outboarding process. I have to outboard 4.5". I made the section I outboarded long to hopefully sprea the torsion load accross the frame. its all 1/4" plate, excuse the overhead welds..

I was having trouble filling the chamfered edge & still get good pen, they'll look much better after some griding & painting

Let me know what you guys think... I'm adding some more gusseting to add rigidity.

I also thru in another cleare rear axle shot for posterity

sixty · 07-28-06, 11:29 AM

Oh yeah, I've been using my new Mitech plasma and once I got the hang of it there is no better tool for a project like this... it will cut 1/4" with little clean up at about 2-3' per miniute.... awsome & they are only $430 on Ebay shipped!

Tapage · 07-28-06, 12:06 PM

This super mega ultra rear axle .. comes in a ford 350 ... ?

And you plan run 44" . ?

sixty · 07-28-06, 12:25 PM

Quote:

Originally Posted by Tapage

This super mega ultra rear axle .. comes in a ford 350 ... ?

And you plan run 44" . ?

Its Fords equivelent of a dana 70... Ford uses them in all 3/4 ton & 1 ton trucks. this one came out of an power stroke 1ton so it has the upgraded (3 bearing I think) pinion.

I'm going with 38's when I can get the $$ so I should have no fear of breaking the rear! you shoud have seen the dana80 I traded for this thing... that pumpkin was huge!

Tapage · 08-01-06, 12:07 PM

Quote:

Originally Posted by sixty

Its Fords equivelent of a dana 70... Ford uses them in all 3/4 ton & 1 ton trucks. this one came out of an power stroke 1ton so it has the upgraded (3 bearing I think) pinion.

When I saw this 3rd member I think .. that was huge .. ! tu run over 40" tires .. less than I thought it hurt your clearance .. ?

Quote:

Originally Posted by sixty

I'm going with 38's when I can get the $$ so I should have no fear of breaking the rear! you shoud have seen the dana80 I traded for this thing... that pumpkin was huge!

Why use huge axles .. refering to 3rd members .. with less clearance and weight in your aplication if you can run a mire " light " duty axles as Toy and no worryes about the strengt.

sixty · 08-01-06, 01:11 PM

Quote:

Originally Posted by Tapage

Why use huge axles .. refering to 3rd members .. with less clearance and weight in your aplication if you can run a mire " light " duty axles as Toy and no worryes about the strengt.

Because I needed width and an axle that would have the matching metric bolt pattern as the superduty front. the only other full width fullfloater axle that would have more clearance would be a Dana 60 rear and I would only have gained about 1" and would have had to add Disc brakes w/ no parking brake & redrill the flange etc... and it would not have been as strong (but probably more than enough)

I'm not losing that much more clearance from my previous fullfloater cruiser axle & the large 38's will more than make up for that.

Tapage · 08-02-06, 11:44 AM

Quote:

Originally Posted by sixty

(but probably more than enough)

Sure yes .. !

Quote:

Originally Posted by sixty

I'm not losing that much more clearance from my previous fullfloater cruiser axle & the large 38's will more than make up for that.

Yesterday I take a measurement of my rear clearance with 37" MTR in good overal Shape ( maybe 5 k milles on it ) my rear SF TLC axle ..

11.75" was my number ..

with 38" and your actuall Steeerling axles .. maybe 11" .. ?

sixty · 08-03-06, 02:47 PM

Quote:

Originally Posted by Tapage

Sure yes .. !

Yesterday I take a measurement of my rear clearance with 37" MTR in good overal Shape ( maybe 5 k milles on it ) my rear SF TLC axle ..

11.75" was my number ..

with 38" and your actuall Steeerling axles .. maybe 11" .. ?

I'll know in a month or so...

fj40charles · 08-03-06, 03:55 PM

Do you need to worry about welding the rear axles tubes? I've heard about the sterling axles tubes coming loose.

sixty · 08-04-06, 10:10 AM

I've never heard of it.. I'll hve to check into that... Thanks!

fj40charles · 08-04-06, 11:22 AM

Quote:

Originally Posted by sixty

I've never heard of it.. I'll hve to check into that... Thanks!

Here are the threads.. Also, there seems to be an issue with the pinion nut coming loose.

http://www.pirate4x4.com/forum/showt...rling+problems

http://www.pirate4x4.com/forum/showt...=sterling+axle

sixty · 08-04-06, 03:03 PM

Quote:

Originally Posted by fj40charles

Here are the threads.. Also, there seems to be an issue with the pinion nut coming loose.

http://www.pirate4x4.com/forum/showt...rling+problems

http://www.pirate4x4.com/forum/showt...=sterling+axle

Thanks for the links,
I don't think I'll have issues spinning tubes since I won't be pulling huge loads and my frame is going to be the weak spot anyways.. This is also an 03' 10.5" so I'm sure ford has fixed most of the problems over the last 25 years, but who knows.... this is still a major upgrade from the toyota full floater I removed.

I may be going 6BT someday but until then I wont worry...

07-26-06, 11:30 AM	#1
sixty IH8MUD Addict Join Date: Sep 2004 Location: Back in Vegas Posts: 538	FJ60 1-ton Superduty build Thought I would start a thread for my FJ60 build since I have started to put it together. This all started when I picked up a set of Superduty dually axles that I traded the spacers & Dana 80 for the Sterling. Here is the plan: TBI350 (Already there) 700r4 (Already there, rebuilding myself & installing a 4wd output shaft) Ford NP203 w/ 27 spline input using a np208/700r4 adapter Northwest clockable adapter to Ford driverside drop NP205 2002 front Superduty Dana 60 w/ 4.10's & ARB 2003 rear Ford sterling 10.5" w/ 4.10's & posi (until I get a Detroit) 8-bolt hummer beaqdlocks recentered with Superduty pattern. the wheels came with almost brand new 36" goodyear for almost free so I'll probably run them for a while until I get the scratch for some TSL 38's. I need to figure out steering but I may just go with the bent draglink that all lifted Superduties use until I can figure out some highsteer setup by milling the knuckles. anyone have ideas or info on balljoint Dana 60 highsteer I'd appreciate it I bolted up the sterling last night... can you say BEEFY?: Attached Images

07-26-06, 11:35 AM	#2
sixty IH8MUD Addict Join Date: Sep 2004 Location: Back in Vegas Posts: 538	sorry for the quality of the pics... I only had my cell phone Here is the 60 front.... I need to outboard about 4.5" Attached Images

07-26-06, 11:47 AM	#3
2badfjs 80s muncher Join Date: Jan 2005 Location: colorful colorado Posts: 4,960	thats sick! and very cool __________________ SOLID ROCK OFF-ROAD http://www.solidrockoff-road.com/ 1991-92 80 series sliders available, WITH CAT PROTECTION! It's how YOU want it, i'm just here to build it for you. SLIDERS FOR 40s' 60s' and 80s' plus a little bit more

07-26-06, 04:40 PM	#4
tclndcrz IH8MUD Addict Join Date: Mar 2003 Location: Bozeman MT TLCA# 14430 Posts: 996	damn son thats awesome have a pic of the whole truck. the yellow is pretty sick lookin __________________ -Thomas Crumrine TLCA #14430 88 FJ62 33x12.5 BFG A/Ts, front parabolics, ARB bumper, warn xd9000, 2badfjs sliders, aussie lockers, longfields, durabak, flowmaster, rear disks...

07-26-06, 05:03 PM	#5
kling-on Kool Arrow Join Date: Apr 2003 Location: Pimpin part in SanAntonio TX TLCA# 15374 Posts: 1,370	http://www.offroadunlimited.com/Prod...5&idproduct=42 this maybe ??? cross over for a stock(lifted) supper duty __________________ 82 FJ60 OME Heavy 33BFG's 410's & quicklock ARB bull & side bars and warn 12k down for repairs 85 FJ60 Trail beater SM 420 crawler box lockers 456,38's bobed & choped with a Metal Tech cage 85 SR5 new DD want am I thinkin GIT-R-DONE!!!! TLCA #15374 low riders want SWITCHES... 4 wheelers want SHIFTERS www.jkcustoms.com

07-26-06, 08:53 PM	#7
Mace what he said Join Date: Feb 2002 Location: Las Vegas Posts: 10,689	We need to trade diff covers __________________ I am kinda gay....... My Myspace http://profile.myspace.com/index.cfm...endid=75712409 "Mary Poppins: In every job that must be done, there is an element of fun. You find the fun and - SNAP - the job's a game."

07-27-06, 10:55 PM	#11
LC_Hamma The Anti-Leafer Join Date: Nov 2002 Location: Dallas, Georgia TLCA# 3343 Posts: 1,608	It looks like Dynatrac has a better option for your BJ steering: http://www.dynatrac.com/products_pro...rknuckles.html Are you going to run rod ends or tie rods? I'd really like to see a hysteer arm that accepts rod ends in double shear.... __________________ '73 FJ55 http://forum.ih8mud.com/fj55-iron-pig-preservation-society/76835-pig-chebby-avalanche-trim-%3D.html '73 FJ40 http://s132.photobucket.com/albums/q...&addtype=local '78 FJ40 - project in pieces '93 Ram W350 5 spd. SRW CTD '99 Ram 3500 4X4 5 spd. DRW CTD '74 BMW 3.0CS

07-28-06, 11:25 AM	#15
sixty IH8MUD Addict Join Date: Sep 2004 Location: Back in Vegas Posts: 538	outboarding pics Heres a few pics of the beginning of the outboarding process. I have to outboard 4.5". I made the section I outboarded long to hopefully sprea the torsion load accross the frame. its all 1/4" plate, excuse the overhead welds.. I was having trouble filling the chamfered edge & still get good pen, they'll look much better after some griding & painting Let me know what you guys think... I'm adding some more gusseting to add rigidity. I also thru in another cleare rear axle shot for posterity Attached Images

07-28-06, 11:29 AM	#16
sixty IH8MUD Addict Join Date: Sep 2004 Location: Back in Vegas Posts: 538	Oh yeah, I've been using my new Mitech plasma and once I got the hang of it there is no better tool for a project like this... it will cut 1/4" with little clean up at about 2-3' per miniute.... awsome & they are only $430 on Ebay shipped!

08-03-06, 03:55 PM	#23
fj40charles IH8MUD Lifer Join Date: Dec 2002 Location: Texas Posts: 1,121	Do you need to worry about welding the rear axles tubes? I've heard about the sterling axles tubes coming loose. __________________ 69 FJ40 with some minor mods... 2000 Cummins powered Dodge with some power enhancements. DO NOT SUPPORT TRAIL GEAR!!!!! bad ethics = bad business! http://www.paypalsucks.com

08-04-06, 10:10 AM	#24
sixty IH8MUD Addict Join Date: Sep 2004 Location: Back in Vegas Posts: 538	I've never heard of it.. I'll hve to check into that... Thanks!