Build 1978 FJ55 BATPIG

[RUSH55]

What is the piece of tubing welded in behind the t-case for?

 

[Ol Yeller]

What is the piece of tubing welded in behind the t-case for?

Extra crossmember?

 

[gonzopancho]

Upper is a replacement crossmember. Look closely and you can see where the OEM one was cut out.

Lower and forward is trans mount.

The angle iron is just there to keep it all aligned while the transmission mount is fabricated.

 

[RUSH55]

I definitely like the angle iron idea, very helpful in keeping the t-case where you want it.

 

[gonzopancho]

Inserts tig welded in at 125amps 1/16" rod. 1/4" mounting plates, 4x 7/16" bolts. Inserts are .75" deep.

 

[gonzopancho]

More

 

[gonzopancho]

Preloaded the crossmember up 1/8" to account for the compression in the trans mount.

Added gussetts. Pulled it once to finish on the bench. Reinstalled, then took the temporary brace off the tcase.

Going to add a couple drain holes.

 

[RUSH55]

Excellent looking work

Who is doing this? Not his first rodeo.

 

[gonzopancho]

Still to do: skid plate (1/8" plate), exhaust, rust repair, body inside hole fills, trans tunnel, measure for drivelines, possibly the fuel tank and mounting while it's on the lift this time. Fuel tank depends on the schedule at the paint shop. It all gets pulled apart before it goes to the bodyshop, so the trans mount can go to powder, exhaust to ceramic coat. Will have to spray can that welded-in cross-member, and the frame rails.

Final assembly gets new lock washers, new hardware, locktite.

 

[gonzopancho]

Excellent looking work

Who is doing this? Not his first rodeo.

Mark. He does a ton of 60s/70s era C10, Camaro, etc work.

in addition to BATPIG, he has the 1976 FJ40 (formerly known as the Goblin), my two stretched FJ40 projects, and the wife's 1965 Mustang.

The 1976 FJ40 is getting a rebuild: LS364/450(*), TR-4050 5-speed, split case with 3:1 lo-range, the locked / 4 wheel disc axles I have from a hjz75, fabricated fenders, 35s on 15x10 widened Toyota wheels, full cage. It's next after BATPIG, more of a trail truck, but staying SUA. Bunch of work upthread on the 4-plus rear bumper.

(*) people have asked if I plan to do wheelies. The answer is, 'No'.

 

[gonzopancho]

Marking it for gusset placement, but it goes back in to weld them.

 

[gonzopancho]

3/16" gussets added. Tig welded at around 200A, manual pulsed, 3/32" filler rod.

Let it cool, then tune up of edges and it goes back in.

 

[RUSH55]

Weld porn

 

[gonzopancho]

Weld porn

Stack of dimes

 

[gonzopancho]

On its own weight. Still 3deg down

 

[gonzopancho]

Skid plate taking shape, continuous piece of 1/8" plate. Hugs the trans crossmember and as tucked as possible all the way back.

 

[gonzopancho]

Front to back around the tcase lower portion is level so when I drag across something it won’t dig.

 

[gonzopancho]

Front and rear edges are 1.5" x3/16". Also adding protection for the trans mount studs. Will drill
holes for trans & tcase drain access.

 

[gonzopancho]

Dimples to give the trans mount studs 1/8" clearance.

 

[gonzopancho]

Welding next