4 door Fj45 on 80 series chassis (9 Viewers)

[Blackknight1]

When i received my headers a few weeks ago, i thought they'd come in with collectors as every set i've ever purchased always did. Of course this time , they did not
Now that pissed me off. I could either order some.... which would take weeks to get here , or use the OE manifolds..... that's absolutely out of the question. My last option is , since i will not wait , you guessed it : to make my own....
Found some 3/8 plate around the shop, made a template matching the header down pipe flange . Drilled the three bolt holes and cut the center hole with the oxy acetylene torch.
We then threw them on the lathe and turned those to allow a perfect 3" pipe to fit in nice and snug.
I have some polished stainless exhaust pipe and a Pype muffler waiting to build my exhaust system. The streets and trails will never sound the same again
.

 

[Blackknight1]

I ran out of 16 gauge sheet metal and will only receive some today. We made the center console out of cardboard yesterday and hope to cut, bend and weld the pieces together today....
I finally decided to use a shifter for the 6L90e from Pace Performance and ordered it. It features sport mode and tap shifting . Should be good !
I still need to figure out what to do about the transfer case . Debating where i will install this third stick ..... hummm. We'll see.

 

[Blackknight1]

Good day today. We are moving along . Today we tackled the exhaust system. I had mentioned further up that when i picked up the engine, i also took everything else tha was on the truck including the exhaust system. I chopped it and mocked up the truck's system from it .
Well , my exhaust kit came in . Full polished stainless steel.... 2 into1 going into a single 4" Pypes violator muffler . The exhaust tip will be on the rear passenger side.

 

[Blackknight1]

We also worked on that center console/ safety box . We made it out of cardboard first. Once i was satisfied with the design, we started replicating it in sheet metal. The following pictures will give you an idea of where we're going with this.

 

[Blackknight1]

We kept going with the center console and with the exhaust system. Nice progress on both.

 

[Blackknight1]

Ok . The wheels are prepped and ready for poder coating. That's great . Hopefully i can have the tires mounted by next tuesday.
Meanwhile, the installation of the exhaust system is complete..... looks very nice. . I really like how it came out. Here are a few pictures.

The center console is also taking shape nicely. I wish the shifters were already here . I'd get a better idea , but it's only a matter of time.

 

[Blackknight1]

The exhaust is now fully welded

 

[Blackknight1]

Center condole is coming along nicely too

 

[Blackknight1]

I ran out of matte black paint for the wheels. I will not wait for it to come ..... we'll just paint them ....

 

[Blackknight1]

I called everywhere locall to find some matte black powdercoat paint . No one has any. You guys can't imagine how it feels to have to wait weeks to get the simplest things.
I guess spraying them won't kill me....
As consolation, i finally received my rear window seal and my stainless steel coils for brakes and fuel lines . Not having certain things and waiting for them for so long can get depressing but seeing packages at the door feels like Christmas everytime.
I ordered the Lsa supercharger from Boost district and for whatever reason, that thing is taking its sweet time. I' ll just have to be patient.....

 

[Blackknight1]

Guys,
Now that i think of it, do i need to get a transfer case saver for this build ? Something like this ?

 

[cruzinfj1]

If youre running an 80 case, check out @TRAIL TAILOR mounts and skids. Very nice stuff. I have one on my 80. Does your case end up sitting in the stock location?

 

[Blackknight1]

If youre running an 80 case, check out @TRAIL TAILOR mounts and skids. Very nice stuff. I have one on my 80. Does your case end up sitting in the stock location?

Yes . It does. Thanks for the info. I'll look into it now

 

[GLTHFJ60]

Guys,
Now that i think of it, do i need to get a transfer case saver for this build ? Something like this ?

Remind us on your driveline setup again? You only need that type of mount in certain situations.

Iirc your year 40 would have engine mounts and bellhousing mounts, both to the frame, with the trans and tcase hanging off the back. Unless you're changing the trans, you probably don't need the propeller style mount.

In any situation, ideally you'd have two engine mounts (one on each side of the block) and a single transmission mount near the rear of the trans. That allows the driveline to pivot under load and not stress anything.

 

[Blackknight1]

Ok. Great day today ! My center console is pretty much done. We'll build the door and install the lock tomorrow. My wheels are painted and look brand new. I installed the black boxe's shifter in its place and hope to connect the cable to the lever tomorrow.
Here are a few pictures of what we got done

 

[Blackknight1]

Remind us on your driveline setup again? You only need that type of mount in certain situations.

Iirc your year 40 would have engine mounts and bellhousing mounts, both to the frame, with the trans and tcase hanging off the back. Unless you're changing the trans, you probably don't need the propeller style mount.

In any situation, ideally you'd have two engine mounts (one on each side of the block) and a single transmission mount near the rear of the trans. That allows the driveline to pivot under load and not stress anything.

Thanks. That's exactly the way i have it. The 4 door fj45 has a 6 liter V8. A 6L90e mated to an OEM HF2Av Toyota Transfer case with a Northwest Fab Black box.

 

[GLTHFJ60]

Affer writing this post, I realize it's super wordy. I'm sorry about that, but hopefully it explains the situation. My doubler is also an ecobox, with a np205 tcase.

Thanks. That's exactly the way i have it. The 4 door fj45 has a 6 liter V8. A 6L90e mated to an OEM HF2Av Toyota Transfer case with a Northwest Fab Black box.

OK, so in that case with the doubler, you probably should have this type of setup (this is what I have);

- Two engine mounts (one on each side of the block in the middle of the cylinder config, as reasonably possible)
- One under the trans tail housing, or towards the rear of the trans case (usually the trans factory mount location)
- one additional tcase mount at the back of the transfer case

Reason being, that's a ton of weight hanging off the back of the trans (with a doubler) and may break things. Either pull out or break the mounting bolts, or I've seen the trans tail housing break.

This is problematic though because three legged stools are the most stable, and having a fourth "leg" behind one of the three legs is weird. If not positioned correctly that fourth "leg" can be problematic. Despite that, the weight has, and I mean needs to be, to be supported with a doubler.

This is how I addressed it. Key thing is that the mount on the rear of the transfer case needs to bolt on at the crank centerline, or as close as possible to it, so that when the driveline rotates under load, it doesn't try to tear the mounts apart. That's what I did on my truck, which has a doubler, and it has been working well for 5 years. The pics below show the crossmembers, but the tcase mount location is similar to the propeller mount location, just configured differently.

 

[Blackknight1]

Affer writing this post, I realize it's super wordy. I'm sorry about that, but hopefully it explains the situation. My doubler is also an ecobox, with a np205 tcase.



OK, so in that case with the doubler, you probably should have this type of setup (this is what I have);

- Two engine mounts (one on each side of the block in the middle of the cylinder config, as reasonably possible)
- One under the trans tail housing, or towards the rear of the trans case (usually the trans factory mount location)
- one additional tcase mount at the back of the transfer case

Reason being, that's a ton of weight hanging off the back of the trans (with a doubler) and may break things. Either pull out or break the mounting bolts, or I've seen the trans tail housing break.

This is problematic though because three legged stools are the most stable, and having a fourth "leg" behind one of the three legs is weird. If not positioned correctly that fourth "leg" can be problematic. Despite that, the weight has, and I mean needs to be, to be supported with a doubler.

This is how I addressed it. Key thing is that the mount on the rear of the transfer case needs to bolt on at the crank centerline, or as close as possible to it, so that when the driveline rotates under load, it doesn't try to tear the mounts apart. That's what I did on my truck, which has a doubler, and it has been working well for 5 years. The pics below show the crossmembers, but the tcase mount location is similar to the propeller mount location, just configured differently.

View attachment 3480986View attachment 3480987

Thanks. That's exactly what i worried about looking at my setup. The transmission plus the doubler and the transfer case seem way too heavy to be supported by just that one cross member . It worried me that it would not be long before it would start breaking things.... i would hate for that to happen in the middle of nowhere.
I definitely appeciate your inputand the knoledge you are sharing so graciously. Thank you !
Your pictures are definitely a great help. Would you , by any chance , have a few more shots of the way your crossmember mounts to the rear of your transfer case ?

 

[GLTHFJ60]

Thanks. That's exactly what i worried about looking at my setup. The transmission plus the doubler and the transfer case seem way too heavy to be supported by just that one cross member . It worried me that it would not be long before it would start breaking things.... i would hate for that to happen in the middle of nowhere.
I definitely appeciate your inputand the knoledge you are sharing so graciously. Thank you !
Your pictures are definitely a great help. Would you , by any chance , have a few more shots of the way your crossmember mounts to the rear of your transfer case ?

I do. I'll post some up later today, or you can check out my moonshine thread (link in signature).

 

[GLTHFJ60]

Here you go. Not a cruiser tcase, but you get the idea.