3rd time is a charm build

[rockcod]

Having started 2 previous 40 builds and then abandoned them and sold due to life getting in the way, I am fully committed (or should be committed!) to seeing this one through. The goal is to have my sons driving it on the trails at the 45 run this year.

The new project is a 72 FJ40 with a 350, SM420, 3 speed t-case, power steering, 4" SUA lift springs, 2" body lift, 5 new BFG KMII's and wheels, crappy roll cage, painless wiring harness, rear tire carrier with LED tail lightshard top and a very rust free straight body. With the major components I was looking for already in place, I pulled the trigger on the vehicle and started gathering my parts for what I wanted this 40 to become.

The plan is:
SOA
Hi-steer
4 wheel disc brakes
ARB lockers
York compressor
Family cage
tube fenders
sliders
hard half doors
twin stick t-case
Autometer Phantom gauges
dash box



My first 2 builds before I let them go and finally the new one.

 

[rockcod]

Started tearing into the steering box mount and front bumper to get going on the SOA. Found some very scary things, non rated bolts, holes cut into the frame horn and some truly scary welds. As I got a little deeper into the 40, it became very apparent some people do not need to have a welder or hand tools. There was a bolt, holding the steering box on that was drilled halfway through so the bumper bracket could be attached!! The frame had more booger welded plates and brackets on it and needed to have the motor relocated. One of the previous owners placed the motor within 1/4" of the firewall, and the entire drive train was too high in the frame. I took a deep breath, gathered my thoughts, and decided to call Georg at Valley Hybrids. Georg put me in touch with Don of FC Fabrication, if you have not seen his work, it is absolute art!!!

 

[rockcod]

Booger welds, bracket mania and an ill placed motor.

 

[rockcod]

Got the cruiser up to FC187, the man is very busy and was able to fit me in and did some kick ass work and he had it finished in time for me to pick it up after the Stockton swapmeet. Don removed all the unnecessary bracketry, sleeved the frame, repositioned the steering box, repositioned the drivetrain and fabbed new motor mounts, fabbed a skid plate/trans mount and made a new front bumper. Georg set up my new ARB and was also picked up after the swapmeet. Thanks again Don and Georg, you guys are awesome!!!

 

[rockcod]

The frame sleeved, steering box mount and cross member gusset. The front of the frame is stout as hell!!

 

[rockcod]

The motor mounts are bomb proof now. The motor mounts on the frame rails are tied together with a cross over tube, and the inside of the frame is stitch welded and gusseted for the motor mount attachment points. The skid plate doubles as the trans mount and cross member, as well as being the attachment for the anti wrap bar (yet to be fabbed)

 

[rockcod]

The new look front end. Shaved the front housing of brackets and started the cut, the axle is going out to get hot tanked. I purchased Ruff Stuff's mini spring over kit since i am not doing a shackle reversal and the spring over kit for the rear axle. I found a set of FJ55 rear springs and stock FJ40 front springs, cleaned them up and painted, new bushings.

 

[rockcod]

Kind of put the cart before the horse, I sold the springs that were on the cruiser before I was ready to install the new springs or the SOA axle housing. We put the new springs in temporarily and set them on top of the old axle housings for now. Once the new housing is back from the hot tanking the caster angle will be taken care of, but for now this is how it sits. So far the WB has been stretched to 98".

 

[rockcod]

ARB, FJ60 knuckles, hi-steer arms and hubs cleaned and waiting for the axle.

 

[cruiserjunkie]

Rockcod you are really getting after this project dons work is always amazing wish i was close enough to have him work some magic on my junk looking great

 

[Tapage]

looking really good .. bit overkill at the frame horns ..

 

[indianporfavor]

Really nice looking fab work, should be a fun project to watch

 

[chicago]

Don is a fab GOD!!
he is what I aspire to.
Looking great and making GREAT TIME on it!!
Hope to see it at the 45 run.

 

[rockcod]

looking really good .. bit overkill at the frame horns ..

Considering what the frame horns looked liked to start with I dont think it is overkill at all, I just call it really stout!

Don is a fab GOD!!
he is what I aspire to.
Looking great and making GREAT TIME on it!!
Hope to see it at the 45 run.

Yes he is!
The 45 run is the timeline I am working on, the kids will be pissed if I dont have it running by then, my oldest and his cousin want to wheel it.


I was able to get some time on it today, but not too much to show for it (photo-wise that is), except a little sheet metal work. The twin stick got fitted, welded and painted (waiting for paint to dry to install), front shackles drilled and put in, waiting for the rear drive shaft to come back so I can get the pinion angle set and the perches welded in.

 

[Slowerthanu]

Looks great!

 

[julstirn]

nice job

 

[rockcod]

The front axle housing has been cleaned and blasted, found a little time this morning to make a diff guard. Bought a 10" pipe cap from the local metal yard, lopped it in half, drilled a few holes for drainage and filling and threw some weld at it. A productive 90 minutes for me.

 

[rockcod]

I think I have A.D.D. I have a hell of a time trying to stay on task, I am jumping all over the place on this thing and nothing is getting done. So today I told myself I am going to finish up the twin stick install and tunnel cover mod. I am not a sheet metal worker and this took me forever to finish today, didn't help the PO hacked a couple of good sized holes and had done a crappy patch job on another. All in all pretty happy with the way it turned out, now I just need to do some grinding and filling.

 

[Poser]

As per your request Tony man!

 

[rockcod]

Thanks Steve!!!!