Builds 1964 FJ40 Diesel build, 5 speed, vw TDI, 35's....Lets not call it a restoration.

HandForged

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I'm a retired Master Diesel tech. In years past I built another fj40 with a 4bt cummins and for me I think I sort of followed the crowd with that swap and I wasn't all that impressed with it. The engine was great but it made the Fj a paint shaker. Me being me, I can't leave anything alone. With this build I wanted solid, quiet and powerful. The VW 1.9 got the nod almost immediately. There's not a ton of "free mods" out there for them but if you know what you're doing there is power there to be harnessed. The ridiculous thing is that it has the potential for as much HP as a 4bt cummins. My main goals for this particular truck are to keep it light... light weight is just as much a power adder as building HP. 200hp in a tiny little beer keg sized engine in a 4,000 pound truck? Come on.... My 200 hp passat is currently getting about 36 MPG, now I'm not going to see that in the Fj but 26-29 is a realistic thing. Power, higher MPG, longevity (my passat was purchased with almost 400k miles showing no blowby and good power).
 
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Even being almost flat?
From what I’ve read about soa, flat may actually be more desirable. I’m clearing 35’s with 4” of sua, so a flat set of springs should be about perfect. Check out Boise CL, someone is selling an incomplete ruffstuff spring over kit.
 

HandForged

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Got out in the rain today to go look at a parts truck 1964 FJ40. F-1 engine, butchered 3 speed, lots of good parts for my truck but not some of the more important ones. Did end up with 9 or 10 riveted OEM wheels though. Now I needs me some hubcaps and powder coating!
 

HandForged

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While I was driving yesterday I had this thought. In the hot rod world they call it a street sleeper. A truck that looks and appears as a stock truck would, essentially hiding all of the goodness under the hood and within the doors. I'm pretty sure this is the direction I will be going with this '40. I want something that doesn't scream look at me, as most do honestly. The Cruiser will draw enough attention on it's own.
 

HandForged

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What sort of power can you get out of these engines?
What is possible or what will live a reasonable amount of time? I have seen one DYNO at 340hp... Now I am sure it ate head gaskets for breakfast. 220-250HP at the flywheel is about the most I would go for a truck I wanted to drive. The other thing to keep in mind with this little engine is that it doesn't have the RPM restrictions of other diesels. These things will rev nearly 5k rpm. 3-3500 is normal. So They have all the low speed grunt as well as the top end rpms.
 

HandForged

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I made a mess today. I forgot that getting these out of the little landcruisers meant blood was to be shed. Wrenches, impact and finally I was done talking and brought out the gas hatchet. I might have made a mess.... Now to clean up the frame, throw this drivetrain away and start measuring for the new one. Makes me wish i had a pressure washer too.

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HandForged

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Here's the little VW 1.9, still sleeping in the passat. I think tomorrow you'll be hanging on my engine stand. Looks complicated but there's only about 10 bolts holding the thing in. Unplug a bunch of stuff, cut some hoses and she is free. I need to get this little tiger out before I can make an adapter plate for the Toyota 5 speed. Bolt them together and set it all in the cruiser to measure for some motor mounts and a new cross member for the transmission. I want to set this as high as I can in the frame and as far back in the engine bay as i can.....you guys will find out why later.


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HandForged

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Today I had a lot to do in preparation for our first snow of the season so I didn't get a lot done. What I was able to do is go up to my private little salvage yard and pulled a steering box, power steering pump, lines and a hydroboost master cylinder for my little project truck. With the engine completely out of the way, I thought this was a good time to go ahead and get the power steering as well as power brakes sorted all in one pop. I'll likely make my own brackets for the frame but now I am on the hunt for a steering column!
 

65swb45

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I made a mess today. I forgot that getting these out of the little landcruisers meant blood was to be shed. Wrenches, impact and finally I was done talking and brought out the gas hatchet. I might have made a mess.... Now to clean up the frame, throw this drivetrain away and start measuring for the new one. Makes me wish i had a pressure washer too.

View attachment 2089284

View attachment 2089285
There’s a lot of little bits I could use from that, even if it’s not an F135.
 

HandForged

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Well, today I sold out a little and ordered a full conversion kit from Diesel Conversion Specialists.... I know, I know. I can make it, I can machine it, I can weld it up and hunt parts and make it all work. All I can say to that is at this point in my life my time is worth more than money. I sat down and figured out how much fabrication time I would have in it, possibility of issues later on with run out and I decided to pull the trigger on the kit. They are a local Montana company, seemed knowledgeable when I called and asked a ton of questions. So deals were made with the wife....and I placed the order. From what I am understanding from several conversations with builders and folks that have already been down this path, the R150f is the only way to go. So that's what I'm doing. I'll pick up the Marlin crawler adapter to put the gear drive case and doubler on at some point.
 
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@HandForged Nice build! I might be a little biased tho. :)

You can see my build in my sig. Next wednesday I will be getting it inspected by the state for tabs, then I should be able to start running it down the road. Keep the momentum up!!
 

HandForged

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@HandForged Nice build! I might be a little biased tho. :)

You can see my build in my sig. Next wednesday I will be getting it inspected by the state for tabs, then I should be able to start running it down the road. Keep the momentum up!!
I'm trying but this is the point in the accumulation of parts where I bleed money. About to pull the trigger on an adapter for the R150 to the gear drive transfer case and then a doubler kit. I have the transfer cases on hand so there is that. I am anxious to get the drivetrain work done so the truck can move around again under it's own power. power steering and all that associated stuff next then when it's running, driving and stopping the real work begins.
 

HandForged

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What sort of power can you get out of these engines?
I wanted to revisit this question because my whole world was turned upside down today. A friend of mine in Germany and I were having a discussion about the 1.9 TDI and their capability. They are EXTREMELY popular in europe. He sent me a link to a company that has a 1.9 TDI making 540 HP at the flywheel on the Dyno. He did also mention that the record currently is 610 HP set by a german engineering company. Now I doubt that thing is anything anyone would call a daily driver but 610HP from a 1.9L 4 cylinder? Just holy mother of god! They are making 350 plus with daily drivers over there and I am hot on the trail of information. I have worked on a lot of these engines over the years and I claim to know them pretty good but I'll tell you now, I ain't too proud to beg when it comes to the details of that those evil geniuses are doing over there. I gots to know.
 
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