Build 4 door Fj45 on 80 series chassis

[Mike Shull]

Matt is right. It’s best to just get our hands dirty and build from scratch. Someday AI will create the cad drawings and a 3D printer will make it.

On a side note, I couldn’t get AI to add 4 doors to an FJ40 so I gave up.

 

[Ditcherman]

On a side note, I couldn’t get AI to add 4 doors to an FJ40 so I gave up.

That probably is a sign that it shouldn’t be done.

 

[Blackknight1]

That probably is a sign that it shouldn’t be done.

Who needs signs ? We're crazy and act like it. I mean, I could have bought a brand new truck with what i spent on this thing and it's far from done

 

[Blackknight1]

I can't thank you guys enough for the help, support , knowledge that you have poured onto me during this build. I am forever grateful and hope to be able to one day return the blessings. So many have helped me whole-heartedly and even checked on me and my family during some very difficult time .
This project could not have reached this point without your collective input and participation.

Thank You !

 

[Mike Shull]

Who needs signs ? We're crazy and act like it. I mean, I could have bought a brand new truck with what i spent on this thing and it's far from done

Tell me about it! A brand new truck just wouldn’t have the same experience. Here is some motivation…watch for the new one. It’s just not the same.

 

[Blackknight1]

Tell me about it! A brand new truck just wouldn’t have the same experience. Here is some motivation…watch for the new one. It’s just not the same.

That's so cool ! I am certain that mine would not do well on those trails considering the type of suspension I have on it. I wish I had enough knowledge to design a 3 link with coil overs.

 

[Blackknight1]

I think i have chosen a color for it. This is an AI version of my truck

 

[Mike Shull]

That's so cool ! I am certain that mine would not do well on those trails considering the type of suspension I have on it. I wish I had enough knowledge to design a 3 link with coil overs.

Dennis in the 45 has 80 suspension with maybe a 3” lift? It does quite well. @Tank5

I think i have chosen a color for it. This is an AI version of my truck

View attachment 4012677

What AI program are you using? Gemini would have removed two of those doors if I were trying to make this.

 

[Broski]

That's so cool ! I am certain that mine would not do well on those trails considering the type of suspension I have on it. I wish I had enough knowledge to design a 3 link with coil overs.

But that's just not the case. The stock 80 series suspension work's incredibly well in fact I run the hardest trails the western united states has to offer with mine with a 3" lift and basic shocks.

 

[Ditcherman]

I can't thank you guys enough for the help, support , knowledge that you have poured onto me during this build. I am forever grateful and hope to be able to one day return the blessings. So many have helped me whole-heartedly and even checked on me and my family during some very difficult time .
This project could not have reached this point without your collective input and participation.

Thank You !

I feel the same, as a newb to building and wheeling the forum has been very helpful but the cool thing is it’s the same in real life.

Also, I’ve seen plenty of leaf spring 40’s and slightly built 80’s do awesome things. In the vid Mike posted the gray 45 you see is on an 80 frame. I’ve seen Broski wheel and he is a boss, no doubt.
IMO you also have a secret weapon, in that black box. Going slow leads to confidence and traction, both. Of course sometimes you need momentum but you know you have that control through that black box when you need it.

 

[peesalot]

Can AI make those bed sides line up with the cab ? the wheel openings are , well, not good.

 

[Blackknight1]

Can AI make those bed sides line up with the cab ? the wheel openings are , well, not good.

Here is what AI came up with

 

[Broski]

I can't thank you guys enough for the help, support , knowledge that you have poured onto me during this build. I am forever grateful and hope to be able to one day return the blessings. So many have helped me whole-heartedly and even checked on me and my family during some very difficult time .
This project could not have reached this point without your collective input and participation.

Thank You !

I feel the same, as a newb to building and wheeling the forum has been very helpful but the cool thing is it’s the same in real life.

Also, I’ve seen plenty of leaf spring 40’s and slightly built 80’s do awesome things. In the vid Mike posted the gray 45 you see is on an 80 frame. I’ve seen Broski wheel and he is a boss, no doubt.
IMO you also have a secret weapon, in that black box. Going slow leads to confidence and traction, both. Of course sometimes you need momentum but you know you have that control through that black box when you need it.

The Toyota/Land Cruiser family is like no other!!
Super great people/community

 

[Blackknight1]

I feel the same, as a newb to building and wheeling the forum has been very helpful but the cool thing is it’s the same in real life.

Also, I’ve seen plenty of leaf spring 40’s and slightly built 80’s do awesome things. In the vid Mike posted the gray 45 you see is on an 80 frame. I’ve seen Broski wheel and he is a boss, no doubt.
IMO you also have a secret weapon, in that black box. Going slow leads to confidence and traction, both. Of course sometimes you need momentum but you know you have that control through that black box when you need it.

Mine was not built to do any extreme rock crawling . As I said , I wish I had the knowledge and access to parts and materials to build those super flexible suspensions you legends build but I think mine will do great for the type of wheeling we do here in the mean time, I'll keep learning from you guys whenever possible.

 

[Blackknight1]

Dennis in the 45 has 80 suspension with maybe a 3” lift? It does quite well. @Tank5

What AI program are you using? Gemini would have removed two of those doors if I were trying to make this.

Gemini. I loaded a picture of it and basically told it what I wanted to see. That's a great tool especially when some people like me have a hard time choosing colors and such.
The first time I tried, it would not do a 4 door 45 but when I loaded the picture , it did it with no problems.

 

[Blackknight1]

Hurricane Melissa was ripping thru the Caribbean and while we were not directly affected, we had lots of rain for days, land slides and everything else that comes with that kind of weather. We still managed to get some things done when we had a chance .
We fabbed up the Hi-Lift jack mount and installed it on the front of the driver side rock slider. We replicated a bracket i had built for my FJ40 to bolt the upper part of the jack to the windshield frame hinge. It holds the jack in place very well and does not allow any clinking and rattling at all.
The jerry can carrier is also nearing completion. All I need to installon it now is the locking system. It's also a design I had used on my 40 build, but this time around, I made it a tandem carrier and used that tire carrier from the donor 80 series that we've been scavenging parts from.
I won't make this post too long. Here are some pics of the advancements.

 

[GLTHFJ60]

Glad to hear you didn't get too messed up by that hurricane. Looked like it sucked for those in the path.

Love the updates on the truck, keep it up man. The metalworking you're showing in this thread gives me a ton of motivation to get out of my comfort zone and do more.

 

[Blackknight1]

Guys, I'm seriously considering installing a roll cage into this thing. The pros are as follows :
1)Safety. That's always first. The center of gravity having been "somewhat " raised , this thing is at a hight risk of rolling.
2) It would definitely stiffen up the chassis and the cab .
3) Last and not least, it would look cool as hell
And of course, there are cons :
1) having extended the cab, it would take more materials to build.
2) It would take a good bit of money to by materials..... I am not even sure what kind of pipe you guys use to build your cages but one thing is for sure, it very likely isn't available here and it might have to be ordered. That will add to the total cost and I'll have to wait for i don't know how long to eventually receive it.
3) it will take up a heep of space inside the cab and might make passengers less comfortable.
3) We only have access to an old school manual hydrolic bender. And I am not certain that the man operating it will do it well enough. Would hate to go thru this whole process and end up not liking the thing in the end and not using it.
So, my questions to you guys are :
What kind of pipe should I use and what size?
How much does it cost ?
Can that old manual bender handle the job without kicking the pipe?
How much weight will it end up adding to the truck ?
My engine is only a stock 6 liter LS. I know this is by no means a race truck but i'd be embarrassed to be left behind by some bone stock Suzuki Jimny because mine would end up being overweight and under powered.

All advice will be appreciated. Thanks in advance

 

[peesalot]

i think you will enjoy the 80 suspension. All I can say on the cage is that you should take your time, do it right, fitment, welds, if a cage is to do its job it's gotta be right , otherwise if just throwing tubes in for a look, leave it alone.

 

[Ditcherman]

Guys, I'm seriously considering installing a roll cage into this thing. The pros are as follows :
1)Safety. That's always first. The center of gravity having been "somewhat " raised , this thing is at a hight risk of rolling.
2) It would definitely stiffen up the chassis and the cab .
3) Last and not least, it would look cool as hell
And of course, there are cons :
1) having extended the cab, it would take more materials to build.
2) It would take a good bit of money to by materials..... I am not even sure what kind of pipe you guys use to build your cages but one thing is for sure, it very likely isn't available here and it might have to be ordered. That will add to the total cost and I'll have to wait for i don't know how long to eventually receive it.
3) it will take up a heep of space inside the cab and might make passengers less comfortable.
3) We only have access to an old school manual hydrolic bender. And I am not certain that the man operating it will do it well enough. Would hate to go thru this whole process and end up not liking the thing in the end and not using it.
So, my questions to you guys are :
What kind of pipe should I use and what size?
How much does it cost ?
Can that old manual bender handle the job without kicking the pipe?
How much weight will it end up adding to the truck ?
My engine is only a stock 6 liter LS. I know this is by no means a race truck but i'd be embarrassed to be left behind by some bone stock Suzuki Jimny because mine would end up being overweight and under powered.

All advice will be appreciated. Thanks in advance

Like peesy said, do it right or don’t do it.

Very common in these trucks is 1.75” .188 wall 1020 DOM tube. Not pipe. .120 wall might be common too.
Every race federation has their own rule book, and a lot can be learned from these rule books, but the rules don’t apply to us just driving our trucks around looking for some extra protection. But the knowledge is there.

I don’t think the weight would be a factor.

You need to use a mandrel bender, one that pulls the tube around a die, not a hydraulic thing that pushes the tube into a shape. It’s going to kink or at least lose a lot of strength.
I have a JD Squared, Rogue Fabrication is also a very popular one.

In a 40 the best looking cages in my opinion are the ones that wrap tight around the dash lines and the roof curves. It takes a good bender and a lot of forethought to do that. A subscription to Bend-Tech software really helped me visualize and fit stuff.

If you can remove the roof easily enough and you’re not dead set on a cage right now, you could wait until later to do it.

Another thing that complicates proper cage mounting in my opinion is that it needs to not be mounted to the floor or tub, but through the floor, allowing for the same flex as the floor and tub but not depending on it for strength, but going to the frame. At least that’s how I wanted mine with my aluminum tub.