Vonhagen Offroad Hoz 73 FJ40 build up...

[Hoz FJ40 CO]

So this is my 4th FJ40 in a year. You could say I am a bit OCD when it comes to Cruisers, especially FJ40's.

I currently have a 79 FJ40 stocker sitting in moth balls waiting for a ground up in a couple years but wanted something fun to play with offroad for the time being so I bought this.

Here's the good and bad about the rig. Anytime you buy something sight unseen there is always risk. I feel I got a good deal on this rig so the risk for the unknown was worth it to me.

Anyway I've learned alot from my previous builds and know now where to start and where to end.

So here goes for the Stage 1 Mechanical build through Vonhagen Offroad for my 73 FJ40.

This started off as a safety inspection for the drivetrain and a thousands later and many new parts I feel this truck is safe for on or offroad fun. I do have some plans for this truck as far as Stage 2 interior modifications and Stage 3 paint and body repair but for now I am concentrating on drivetrain and safety.

The best way to start a build with friends is wrenches and good beer. The truck has all the right parts but someone didn't take the time or have detail to put this truck together correctly. Currently taking this poser rig and turning it into a true offroad machine.

 

[Hoz FJ40 CO]

Here's the list of cool mods on the truck.

Man-A-Fre front flat fenders, Man-A-Fre front bumper with stinger, Man-A-Fre rear swing out tire carrier with Cooler attachment. Full Metal Tech family cage, 383 V8 (non stroker) motor that has been balanced, twin stick transfer case, Fj40 stock axle in front with mechanical locker and minitruck rear end with mechanical locker. Also has power steering, front disk brakes, new clutch, SUA with High Steer and newly acquired 73 Factory Hard top with Rear hatch door, Sliders (unknown vendor but very solid almost overkill and 37 BFG Krawlers on 17 inch aluminum wheels.

 

[TCSTARK]

I like that front bumper. Any idea who manufactured it? And,.. Nice can collection.

Sent from my iPhone using IH8MUD

 

[Hoz FJ40 CO]

I like that front bumper. Any idea who manufactured it? And,.. Nice can collection.

Sent from my iPhone using IH8MUD

Not sure if its Man-A-Fre or not but Mike (Vonhagen Offroad) can fabricate this bumper for you if you like. I'm sure he'll comment on this thread. You can PM him for details.

Yes the empty's really stacked up that night

 

[Hoz FJ40 CO]

The first part of the project was peeling those big azz 37's off and see what we are dealing with under the rig.

Here's what we found from the previous builder (or half azz home built) that needed attention right away.
1) Passenger side front hub did not turn from 'free' to 'locked' and the drivers side hub turned just fine.
2) The bottom of the pan was wet (dripping wet) and needed attention.
3) The odometer cable was not attached.
4) The front drive shaft for the 4WD was extremely loose. Actually I can't believe it had stayed on. While I'm lenghening the front shaft I will make sure the rear drive shaft gets checked and balanced as well.
5) The power steering hoses were not tucked neatly under the hood (like they should be) but were just waiting for a branch or some brush to grab them and rip them out.
6) The rear drums brakes were wet. Peeled them apart to find the rear axle seals were smashed (probably when they replaced them in a half azz hurry and were leaking.
7) Banging sound coming from the rear end. Pulled the rear diff and found that the pin for the locker was broke in 3 places (more comment on that later).
8) Aftermarket heater just bolted in under the dash and not working. (more comment on that later).
9) Family cage is just bolted to the inside of the body (not acceptable to me). Mike is going to tie in the family cage to the frame. Making it a true and safe cage for wheeling.
10) Just moved to WI and am having Vonhagen Offroad fabricate custom wider front flat fenders (to stay legal, apparently only 2 inches of the tire are allowed to stick out from the body. So when I drive this in town or to work I want to stay legal. Also fabricating some awesome custom rear fenders for the same issue that Mike and I have designed. Its nice to work with a builder that can make something from an idea you have chicken scratched on a napkin.

Items 8,9,10 are wish list things that will be handled and built within the next 30 days...stay tuned.

So with a nice list of safety items to handle, parts are ordered and coming in new boxes daily. Everything is being handled with attention to detail and care. Just the way I like it.

 

[Hoz FJ40 CO]

1) Passenger side front hub did not turn from 'free' to 'locked' and the drivers side hub turned just fine.
Found that the front hubs had not been greased or had lack of grease for a long time. Pulled the hubs apart and restored them to new condition. Regreased the hubs and they are turning nicely. Also drain and fill the front differential fluid.

2) The bottom of the pan was wet (dripping wet) and needed attention.
We took down the oil pan and found that someone used Black RTV on the oil pan. Ordered a new rubber gasket for the pan and installed. Changed the oil and put new oil and filter on. Checked the transmission and axle seals, rear main seal as well and those are dry.

3) The odometer cable was not attached.
I'm guessing that when they did the V8 conversion that they just decided not to hook up the odometer. I like to know somewhat how fast i am going so we ordered a universal odometer cable that fits the factory cluster to the chevy transmission.


4) The front drive shaft for the 4WD was extremely loose. Actually I can't believe it had stayed on.
No kidding there was so much play in this thing you could darn near jiggle it loose by hand. Having the drive shaft custom lengthened and balanced. Also replacing the u-joints for good measure.

5) The power steering hoses were not tucked neatly under the hood (like they should be) but were just waiting for a branch or some brush to grab them and rip them out.
Getting new hoses for the power steering and tucking them nicely under the hood so they are not exposed when offroad.

 

[Hoz FJ40 CO]

6) The rear drums brakes were wet. Peeled them apart to find the rear axle seals were smashed (probably when they replaced them in a half azz hurry and were leaking.
Swapped out for a Dana 44 axle with rear disk brakes.

7) Banging sound coming from the rear end. Pulled the rear diff and found that the pin for the locker was broke in 3 places.
Apprently the stock pin for the rear diff was or rather is used inside the locker. The factory pin apparently couldn't take the torgue from the V8 and snapped the pin. Mike is fabricating a custom hardened steel pin for the rear diff so handle the torque. This is a one off so I will let you know how it holds up. Also shattered pin had broken some of the teeth off the ring and pinion gears. New ring and pinion gears showed up today. Just waiting for the custom pin to get finished then will put the rear diff, along with a new rear seal back together.

8) Aftermarket heater just bolted in under the dash and not working.
We still haven't pin pointed what heater is in this truck. I don't think at this point that it matters as it will end up in the scrap pile. I've done alot of research on Flex-A-Lite aftermarket heaters and will get that ordered and installed. I heard they pump out a lot of heat and they also come with the defrost tubes and have three speeds. I am excited about this product.

9) Family cage is just bolted to the inside of the body (not acceptable to me). Mike is going to tie in the family cage to the frame. Making it a true and safe cage for wheeling.
Mike did this on a MUD members previous build and it turned out really nice. So I am looking forward to getting mine all tied in as well.

10) Just moved to WI and am having Vonhagen Offroad fabricate custom wider front flat fenders (to stay legal, apparently only 2 inches of the tire are allowed to stick out from the body. So when I drive this in town or to work I want to stay legal. Also fabricating some awesome custom rear fenders for the same issue that Mike and I have designed. Its nice to work with a builder that can make something from an idea you have chicken scratched on a napkin.
I'll post up pics when these are made and ready to roll.

 

[Hoz FJ40 CO]

Attach the factory hard top to the 40 as well as a custom rear tailgate made by Mike. I need to get a pic of that gate and will post when I have it. I need to have the small barn doors restored but am not in a hurry to get that done. I got some sweet offroad attachments for tools and tool bags from Doc with his MPAC rack items and will have a write up on that later. But those products are attached to the custom rear gate.

The factory rubber for the hard top was in tact so I reused that and it worked out great. We also used custom weather stripping from tub to hardtop to cut down on the noise level in the cabin. I will find the color for the hard top to match the body this spring or summer but my first priority is staying warm in these WI winters.

Here's a few pics of the hard top of the Cruiser. Looks pretty good for homemade camo.

 

[Gruntled]

Looks like a nice rig mate. I like how you've written out the problems followed by the solutions, it makes for good reading

 

[Hoz FJ40 CO]

Looks like a nice rig mate. I like how you've written out the problems followed by the solutions, it makes for good reading

Thank you I appreciate that.

 

[fusionrx]

Like the plate "forgiven 1". Can you elaborate?

 

[subzali]

Looks like a Lockright or Aussie in your rear diff. Couldn't you just call them up and get a replacement pin? I know the first one broke but there's no telling what kind of abuse it was put through. Why is it a poser rig?

 

[hawkeyealum]

Gee Hoz....considering my 40 is currently in Vonhagen's garage having some work done I feel like there should be a picture of them hanging out together.

Maybe I'll give him a call and make it happen

 

[vonhagenoffroad]

Here ya go hawkeye, since Hoz hasn't uploaded the pic I sent to him last night.....

 

[hawkeyealum]

Mine looks better

 

[Hoz FJ40 CO]

Geez you girls have no patience...

 

[Hoz FJ40 CO]

Mine looks better

@fusionrx : thanks man, its my witness.

@Subzali: I think its a Lockrite. I know it has an Aussie in the front and I think Lockrite in the back. I'd rather have overbuilt then have to tear the rearend apart again cause I went cheap on the pin. As far as the poser rig, there is just too much evidence that this was slapped together to drive on the street. I'm correcting that issue.

@hawkeye : you have a beautiful rig brother, however I dont see your pride and joy tearing it up offroad anytime soon. Before I sell it, whenever that is, I will put the pretty on it as well...haha

 

[hawkeyealum]

touche my friend.

Looking forward to seeing pictures of yours on the trail

 

[Hoz FJ40 CO]

Been a while since I've updated this thread.

I've been researching and pondering a new heating system for noname. The truck came with some weird heating system that didn't work. We are guessing it was from an old CJ but can't find any information on it. It would have cost me a hundred dollars/maybe more to get it rebuilt plus the fact that it took up alot of leg room I was trying to figure out what to do.

I did alot of reseach on aftermarket heating systems and finally came to a decision to buy the Flex a Lite 640 Mojave Heating system along with the Flex a Lite 650 Heater assembly. It pumps out 12000 btu of heating power and has three blower speeds. The cool thing that the add doesn't tell you is that it has two twin fans on each side. So this heater can burn you out in less than 5 minutes. All for $300 including shipping.

Mike did a wonderful job of concealing the heater and some custom bits that you'll see in the picture. He built a custom box that pushes the core of the heater into the firewall so there is ample foot room. Also this keeps all the heater hoses in the engine compartment of the truck. He built an access panel in the rear of the heater box in case I would ever need to get back there. Once its painted it will blend in beautifully with the engine compartment. Another neat thing by pushing the heater back into the engine compartment is that its hardly noticable that its in there at all. Except for the three way switch you'd never see the heater. Making room for other neat doodads that I'll add later.

 

[Hoz FJ40 CO]

We were working through some of the old wire to determine what needed to stay and what needed to go and decided to scrap the entire wiring system for a new one. Mike is working on designing and making an affordable wiring harness for a V8 conversion Land Cruiser. Mike rewired the motor (its an 010) block so fairly simple on his end. Here are some pics...