Builds Stretched 1-Ton FJ40 (4 Viewers)

[EWheeler]

@Mike Shull

How is she coming along Mike?

 

[Mike Shull]

@Mike Shull

How is she coming along Mike?

Hi Evan! I’ve paused for a few months to finish a few home remodel projects which we were waiting for materials to arrive.

I ordered exhaust manifolds from Summit, and my transfercase is expected within the next 1-2 months. The frame extension piece should be ready soon and I’ll jump back on here in a few weeks.

How are your projects going?

Mike

 

[Mike Shull]

My frame extension should be ready for pick up on Friday and I plan to extend the frame towards mid-October. I will be cutting my frame at a diagonal. My drawing skills are limited so I drew the cut marks as straight lines.

Thanks again to @Tank5 for the donor frame. I will use that to splice the outside, then place the new pieces on the inside. A sample from the donor frame is below.

 

[DangerNoodle]

I've usually heard that it is recomended to split the frame at a 45° on the length of the frame, but I'm sure someone with more experience can give some advice. @Godfather90 may know.

 

[Mike Shull]

I've usually heard that it is recomended to split the frame at a 45° on the length of the frame, but I'm sure someone with more experience can give some advice. @Godfather90 may know.

You are correct. I will be cutting the frame at an angle.

 

[Broski]

That is enough for one weekend. The left axle shaft is about two weeks out so I am on to other projects.

View attachment 2690116

View attachment 2690117

Really liking where this build is going !
Just curious, did you just weld the C on in the original orientation or was there some caster added.

 

[Mike Shull]

Really liking where this build is going !
Just curious, did you just weld the C on in the original orientation or was there some caster added.

Hi there and thank you! Yes, I set my Cs at 3-4 degrees positive caster.

 

[Mike Shull]

Hi there and thank you! Yes, I set my Cs at 3-4 degrees positive caster.

@Broski , I should also mention that I set my front differential, and the rear for that matter, at around 12 degrees upwards from center. I achieved this temporary in the front with shims on the cast leaf spring mount and by relocating the left mount. I will do a 4-link eventually and my Cs are relocated to accommodate the extra angle.

 

[Mike Shull]

I need one more FJ40 frame center section. Please let me know if you have a section that is 25” in length.

Progress today:

 

[Mike Shull]

It looks like @Tank5 has another frame piece. Thanks for saving the day. I really appreciate it, @Tank5.

 

[Mike Shull]

Thanks again, @Tank5. Your donor pieces worked perfectly. Next up: scab plates and fab inner frame rail.

 

[Mike Shull]

More progress…

 

[Mike Shull]

The extension is almost done…

 

[Mike Shull]

Rear frame plates are in.

 

[Mike Shull]

More progress and I’ve ordered the fuel tank…

 

[mr jits]

You'll want to box those perches in.

 

[Mike Shull]

You'll want to box those perches in.

Thanks for the tip. Just to confirm, did you see that I have a piece of 1/4” angle under the gussets, which is on top of the factory mount? I thought what I did was already overkill

Do you still think that I need to box it in? Perhaps there is something else that I’ve missed.

 

[Broski]

FWIW I think they well hold up just fine.

 

[mr jits]

Thanks for the tip. Just to confirm, did you see that I have a piece of 1/4” angle under the gussets, which is on top of the factory mount? I thought what I did was already overkill

Do you still think that I need to box it in? Perhaps there is something else that I’ve missed.

Yes, I'd still box them in. Mainly to have a clean surface that doesn't trap mud and dirt, but reinforcing the open triangle is something you won't regret.

 

[Mike Shull]

Help needed. I finally received my bellhousing adapter to mate my NV4500 to my gen IV LS and it appears that the transmission shop sold me the wrong case. I asked for a 1996 or newer and it appears that I got the older case with the narrower bolt pattern. I don’t believe that Advanced Adapters sells a bellhousing for this configuration. Thoughts?

UPDATE: AA does sell the correct bellhousing (712577). This bellhousing was back ordered when I initially inquired and there is currently (12/2021) a waitlist of 63 people ahead of me. For this reason, AA recommend the 1996 gearbox initially.