Project buildup- Bugly

LukeZero · 06-24-09, 06:40 PM

Most of you know that I traded my Bridgeport CNC mill to Nick (zebrabeefj40) earlier this Spring for his 76 FJ40 buggy.

Since I got it I have...

Put headlights in it.
Made body panels for the rear and sides.
Put taillights and turnsignals in the rear panel.
Got insurance and a license plate.
Found a winshield frame.
Got glass for said frame.
Remade the seat mounts to allow for better shifter access.
Removed the naked lady stickers.
Installed 5 point harnesses
Figured out why the steering sucked (ie no turning radius)
Fixed the squealing belt on the power steering pump.
Replaced the alternator
Built a wire harness for the lights and turn signals.
Finished the front bumper (capped off the square ends)
Found a Warn 8274 on craigslist for $250.
Pulled the rear welded differential carrier out and installed an ARB.
Welded brackets to the rear axle for an anti-wrap bar.
Pulled out the ToyBox and cruiser t-case.
Changed the output shaft in the ToyBox.
Changed the input gear in the 4Runner t-case that came with the buggy.
Assembled the ToyBox and mini t-case.
Installed it back in the truck.
Had front driveshaft lengthened by 10" because new t-case sits farther back.
Identified that rear driveshaft that came with truck was not usable.
Found out that High Angle Driveline makes a Toyota to 14 bolt pinion flange- bought it.
Took apart a Toyota front CV driveshaft and clearanced it to run at 40*.
Plug-welded the holes in the rear output flange from the t-case.
Welded 'ears' on said output flange.
Drilled the CV shaft bolt pattern into said output flange.
Re-bent the Budbuilt dual case skid plate that came with it.
Performed some custom modifications to make it fit properly.

Things left to do before the Cliffs outing in a month.

Build and mount anti-wrap bar.
Have rear driveshaft shortened to correct length.
Run air lines to rear ARB and install switch in dash.
Mount larger tool box in back for field repairs.
Have anti-wrap bar and skid plate powdercoated.
Mount winch in front bumper and wire it.

Things that might get done before the Cliffs trip.

Make some more body panels for the rear inner fenderwells.
Put a new fuel level sending unit in the fuel cell.
Install a fuel level gauge in the dash.
Get some shocks that are the proper length.

I guess we'll see how much progress I make between now and then.

Luke

Gappy · 06-24-09, 06:47 PM

No pics....didn't happen!!

4rnr · 06-24-09, 07:08 PM

Quote:

Originally Posted by Gappy

No pics....didn't happen!!

seriously! we only pretend to care about the tech just for some eye candy.

LukeZero · 06-25-09, 05:55 AM

Quote:

Originally Posted by Gappy

No pics....didn't happen!!

Alright- assholes- here's proof

LukeZero · 06-25-09, 05:58 AM

more proof

LukeZero · 06-25-09, 05:59 AM

bungholes

Gappy · 06-25-09, 06:31 AM

Looks good Luke. Did you paint it or is it blasted? Use to be red if I remember?

LukeZero · 06-25-09, 06:43 AM

Parts of the bumper and spare tire carrier were painted with a red iron paint- I painted over that with semi-gloss black.

The body panels are Mercedes Benz "Argent Silver". that's the only bling on this machine.

zebrabeefj40 · 06-25-09, 06:56 AM

Nice job Luke! You need to add new seats to your "to do" list. Those aluminum seats suck for more than an hour or two. They're even worse if you endo hard...

Looking forward to seeing how well it works on the trail.

Nick

ps I can't believe you took the trucker girls off the kick vents and the pin-ups off the side of the cowl! Bad karma comin yer way now!

zebrabeefj40 · 06-25-09, 06:59 AM

Quote:

Originally Posted by Gappy

Looks good Luke. Did you paint it or is it blasted? Use to be red if I remember?

Tom,

The bodywork was actually beige. As Luke mentioned, my new metalwork didn't make it past Rustoleum primer.

Nick

Gappy · 06-25-09, 07:17 AM

Quote:

Originally Posted by Gappy

Use to be red if I remember?

Obviously I didn't remember like I thunk I remembered.
Either way, look forward to seeing it wheeled again!!

zebrabeefj40 · 06-25-09, 07:27 AM

BTW Luke, the fill plug on a 14 bolt is on the side of the casting next to the pinion. Right next to the traction bar bracket you welded in the way! No need to try and fill through the vent hole on the axle...

Nick

LukeZero · 06-25-09, 07:27 AM

Quote:

Originally Posted by zebrabeefj40

Nice job Luke! You need to add new seats to your "to do" list. Those aluminum seats suck for more than an hour or two. They're even worse if you endo hard...

Looking forward to seeing how well it works on the trail.

Nick

ps I can't believe you took the trucker girls off the kick vents and the pin-ups off the side of the cowl! Bad karma comin yer way now!

I actually like those seats- they seem to suit me very well. We'll see if they get old after more than an hour or two.

LukeZero · 06-26-09, 05:43 AM

One other thing I'd like to do before the Cliffs outing---

move the rear axle back as far as it will go- for a better driveshaft angle and more wheelbase.

toyman317 · 06-26-09, 05:46 AM

Nice work. Looking forward to seeing it on the trail.

Gumby · 06-27-09, 07:14 PM

Luke will be n the trail about the same time ND wins the national championship b

PhilC64 · 06-27-09, 07:38 PM

Luke you'll be on the trail before U of M wins another Championship! Which will be sometime after OSU wins one!

LukeZero · 06-28-09, 06:06 PM

Quote:

Originally Posted by Gumby

Luke will be n the trail about the same time ND wins the national championship b

What sport is ND going to win a national championship in between now and July 24th?

LukeZero · 07-16-09, 06:01 AM

Winch is mounted in front bumper.
Got new wires from battery to winch.
Rear driveshaft is at Action Machine for modification.
Rear axle is located 8" farther back.
Made a winch remote.

Still need to.

Mount skid plate.
Mount rear driveshaft.
ARB air lines to rear.
Move seat mounts for drivers seat.
Complete winch wiring.
Finish up anti-wrap bar.
Mount rear shocks in new axle location.

I'll be at the Cliffs Saturday morning. Will I be able to get to the campground to meet up with people, or should I meet in the parking lot?

Luke

4rnr · 07-16-09, 08:04 AM

Quote:

Originally Posted by LukeZero

I'll be at the Cliffs Saturday morning. Will I be able to get to the campground to meet up with people, or should I meet in the parking lot?

Luke

It may be easiest for you to stay in the lot. You will have access to the camp but most of us will be down in the lot getting breakfast and getting ready to hit the trails.

LukeZero · 07-16-09, 11:43 AM

Quote:

Originally Posted by 4rnr

It may be easiest for you to stay in the lot. You will have access to the camp but most of us will be down in the lot getting breakfast and getting ready to hit the trails.

what time?

4rnr · 07-16-09, 03:25 PM

Quote:

Originally Posted by LukeZero

what time?

Breakfast before the drivers meeting, drivers meeting is at 9.

LukeZero · 07-18-09, 02:18 PM

Alright bitches- Bugly is ready to go...

I finalized the air lines to the rear ARB.

Finalized the winch wiring. Spooled up the cable.

Moved the drivers seat forward a bit so I can reach the dash better.

Moved the rear axle back 9".

Re-did the rear upper shock mounts.

Driveshaft is ready to pick up at Action Machine.

Just need to final weld the anti-wrap bar, install it, install the driveshaft, re-install the skidplate and load it up on the carrier

See you douchebags on Saturday.

LukeZero · 09-01-09, 04:08 PM

So Bugly did pretty well down at the Badlands this last weekend (August 29, 2009)- but he suffered some damage.

1. The traction bar broke (apparently my welding wasn't sufficient)
2. Rear axle wrapped badly and rear springs have an 'S' shape
3. Inverted the front shackles which allowed front springs to relax a bunch, which
4. Allows drag link to rest against pitman arm, which
5. Made lower sector shaft seal on steering box leak.

That, along with the fact that.

6. I can't see out the back with the spare tire mounted in the current location
7. Not much space for tools

So, I dropped Bugly off this afternoon at Barneys Off Road for some upgrades.

Barney and I talked for a bit to figure out what the plan is and since I plumbed his entire house, installed a new furnace and ductwork and only charged him for some of the big items- he kind of owes me.

THE PLAN!!!

3 link the front with 4" lift TJ coils
Rebuild the rear part of the cage (cutting off the frame) to allow for the spare to sit flat behind the seats.
4 link the rear with 4" lift TJ coils.
Relocate fuel cell and increase tool storage area.
Fix steering geometry.

I don't know if it'll be ready for Toys 4 Tots- but I hope to have it back by then for another outing to test the improvements.

Luke

Gumby · 09-01-09, 04:12 PM

I found TJ coils to be way too springy. Stockers run about 175 lb/in. Stock FJ55 leafs are about 350 lb/in. I went with Exploder coils at 300 lb/in and got a lot more stability.

Be sure to capture the coils top and bottom. It makes a huge difference.

LukeZero · 09-01-09, 04:15 PM

Quote:

Originally Posted by Gumby

I found TJ coils to be way too springy. Stockers run about 175 lb/in. Stock FJ55 leafs are about 350 lb/in. I went with Exploder coils at 300 lb/in and got a lot more stability.

Be sure to capture the coils top and bottom. It makes a huge difference.

But you have a bunch more weight on your truck than I do- with all the glass and bodywork.

Gumby · 09-01-09, 07:18 PM

Couple of hundred pounds tops.

Maybe three if the exo is significantly more tube than your buggy.

Maybe your rig is TJ weight. Might be worth throwing it on a scale.