1HZ install into a 1978 FJ40 (1 Viewer)

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some random shots
the cage
the tuffy box layout
the steering box reinforcement plates
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okay, so this is the tuffy box location
trimming the fender for the PS box...

will add more later tonight
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one of the downsides of SUA/front mounted shackle is the chance of hitting a rock, hard chunk of dirt, log etc and breaking off the military wrap on the fixed end.
one of the ways to reduce the possibility is a shackle protector. i have been working on this idea for a long time, well since i snapped the fixed end eye off when i broke through the wiperous creek in Feb roughly 25 years ago. the spring nailed a rock buried under the ice and dislodge the rock a good foot. i was able to extract myself (yes i was wheeling alone in the mountains), then i used the winch to suck the spring back to where it roughly shoudl have been and i wheeled for another 2 hours and then a 1 1/2 hrs home. since then i always thought if there was a deflector at least the spring would remain intact and you could drive home.
this is my solution.
a 1/2" plate sheild mounted to the front bottom lip of the bumper with a gusset to the frame mount. it would take a severe hit to bend this setup and even then the spring would be protected.
you have to mount the protector far enough ahead to allow for normal spring flex and travel. remember the harder the bump the further ahead the shackel with flex.
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clearence concerns for the lower rad hose
the upper rad hose location
the rad installed
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some custom armor for the headlights
trying an idea
bending the rod
making the jig
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Looks great Wayne! I love the innovation and you are giving me so many ideas for my refurbishment.

Keep up the great work!!

Cary
 
8274 and Lancer 140s nice, I like the adjustability of the Light Force
 
This is like a full on rebuild..... i wonder if its as expensive as hilltop cruisers style of build
 
welll......i do know this thread and that truck is making me DROOL!~~
 
so i have to ask how the rancho's that you have choosen compare to an OME? What is the timing for completion of the project? what kind of rims and rubber are you going to finish it off with?
 
the decision was made to go with a suspension seat for the driver.
a bracket was made for the front and rear of the seat. the height when locked is the very close to the factory 1978 drivers seat.
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we need to locate 2 batteries, one for the daily operation of the vehicle and one for the winch and back-up for when the owner is in the middle of no where.

location was selected for the daily battery between the air box and the firewall but leaving room for the AC and heater lines.
since the battery will be sitting high up in the ending compartment a very strong support needed to be made. my Dad was here while it was under construction. 'a bit overboard, don't yah think?'. i guess he has never seen a factory battery stand!!

first the adapter for the frame, must be able to be bolted on both sides. a hole for the frame rivit.
then the pieces roughed up
test fitting the stand.
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