67 FJ45LPB build (6 Viewers)

[Cirbo]

The recommended fuel system configuration from Turnkey included a return line. I installed a 100-micron prefilter and 20-micron post filter. Filters and pump were mounted on another piece of diamond plate attached to the bottom of the bed.

A good friend who has long since passed always hated it when I used diamond plate on any project truck. All those years of wrapping our rusting rear quarters and rocker panels just set him off. In my defense, I try to keep them out of view when possible.

 

[Cirbo]

June 2012

Tic, tic, tic,

It took a little searching to find the right fittings and hoses to make the power steering lines. I ended up getting them locally from a Parker Hannifin supplier.

 

[Cirbo]

Speakers and radio wiring for the Tuffy console.

Line-X and bed mount for the spare tire. Northern Tool advertisement removed, and you can see the filler neck solution in the picture as well.

 

[Ditcherman]

June 2012

Tic, tic, tic,

It took a little searching to find the right fittings and hoses to make the power steering lines. I ended up getting them locally from a Parker Hannifin supplier.

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I just went through the same process, figuring out what the pump and gear fittings were, but I ordered adapters that fit but adapted to -6AN, so if something went wrong I could just replace the -6 hose instead of having to procure a whole hose assembly with the right fittings.

 

[clrussell]

Phenomenal build

 

[Cirbo]

I just went through the same process, figuring out what the pump and gear fittings were, but I ordered adapters that fit but adapted to -6AN, so if something went wrong I could just replace the -6 hose instead of having to procure a whole hose assembly with the right fittings.

I liked the Parker fittings because I could make up my own hoses without involving any special crimpers.

 

[Cirbo]

I had an exhaust bent that started with 2 1/4-inch tubing at the headers with the passenger's side routing around the front of the pan and joining the driver's side at a collector near the transmission. The shop ran 2 1/2-inch tubing through a single MagnaFlow muffler and out behind the rear driver's side tire. I was trying for relative quiet on the trail, with a little throaty response on the street when needed.

I ran out of time to add loom to the wiring harness. I also had a big issue in that the doors were not built yet. I ended up buying a set of soft doors that actually matched pretty well with the paint scheme.

 

[Cirbo]

July 2012

Without any more than a quick test-drive around the neighborhood, we loaded up and headed for Colorado. The group was comprised of a '79 FJ40, '07 FJC, and the untested 45. The plan was to dump trucks and trailers at a friend's house in Bailey and explore Southwest Colorado for a week.

 

[Cirbo]

Looking back now, our tour covered lots of great scenery. A Pass list as follows (derived from the pictures I saved):

Mosquito
Tincup
Hancock
Tomichi
Engineer
Black Bear
Imogene
Poughkeepsie
California

To name a few.....

It didn't take too long to start building a punch list. The first thing I noticed was the fact that the RPM's developed a mind of their own on some obstacles. I would roll over a rock or berm and the RPM's would start to climb on their own. I got good at knowing when it was going to happen and just putting the clutch in or letting it free run when the trail allowed. It would typically calm down in 15-20 feet. I later found that this is a documented symptom with fuel injection computers that don't incorporate a MAF sensor (like the Delphi unit that came from Turnkey).

Second thing was the previously mentioned pitman arm being too short. That would need fixed later.

The third problem was a little more serious. The truck began stalling at high altitudes and got progressively harder to start. I ended up using the starter to get over the obstacles and catching it in gear to get back underway. This led to a dead starter by the time we reached Silverton, followed by a push start on main street and a 60-mile trip to Montrose for a replacement unit. When I got home and leveraged internet access, it was found that the MAP sensor was bad as indicated by the MIL light code.

While at the Autoparts store in Montrose, we replaced the serpentine belt to cure a squeak that was getting a little unnerving. I later found that belts would start squeaking after a few hundred miles. A few minutes of checking showed that the pulleys on the front of the motor were not all on the same plane. Another thing to be fixed when I got home.

I'm beginning to wonder about Turnkey at this point in the adventure.

 

[Cirbo]

I did manage to get one ding while in SW Colorado. I had worked hard to protect the front and back of the truck but did nothing about the rockers. I ended up scraping one of my running boards on The Wall at Poughkeepsie Gulch. While I was attacking the punch list, I started toying with rocker panel protection. I wanted a solution that was strong enough to jack on or strap too and wanted something that followed the body lines as close as possible.

I knew it would be difficult to come up with the proper angles to hug the body lines, then make the correct rotations on the bender (x2). I opted for a two-piece main tube with a slug and plug welds.

 

[Cirbo]

I picked up an Iron Pig skid plate that was made for a 40. As always, it didn't fit a 45. Nothing a little plasma and MIG wire can't fix. It ended up hanging 1/4 inch lower than the transfer drain plug.

One of the other nagging issues was that poly tank. Finally dumped that for the Man-A-Fre alternative.

Observant readers will notice that the OME springs are installed in this shot. It looks like I had not yet pulled some of the leaf pack and replaced the front springs with the Alcan units.

 

[Cirbo]

November 2013

Finish truck with a fresh set of BFG 35x12.50's and Trail-Ready beadlocks.

Or so I thought. Not even close.

 

[Cirbo]

Things start to get spotty after 2013. I did see that we did GSMTR in 2015 to revisit Windrock. No big changes that I can see in the few shots I had saved. I guess it was Spanky's turn for excitement.

RIP Timmy.

 

[Cirbo]

Driving and tweaking.... tweaking and driving.

February 2017

Built a 4:1 Orion and swapped it in along with a twin stick kit from AA. This would eventually lead to the change to 3.70’s.

While I was at it, I changed out the cheap Grant wheel for a Momo.

I had watched a group of "old time wheelers" years ago at the Chili Challenge in Las Cruces. They all had their winches wired to momentary or push-button switches within reach of the driver. It appeared to be a nice option to have at your fingertips in a tight pinch, so I added one of those from 12VoltGuy.

 

[Cirbo]

January 2020

I wasn't liking the way the Corbeau seats were wearing and frankly found them a little uncomfortable getting in and out with their side bolsters. Did a lot of internet searching for a low back vintage looking replacement. Finally settled on a pair of PRP suspension seats.

While I was at it, I added a hand throttle built out of BMX bike parts ordered off the web. A piece of rubber floor runner with a 5-bar diamond plate pattern was sourced and cut to make floor mats.

Note the crushed side bolster on the seat. Mine was worse.

 

[Cirbo]

March 2020

I had been playing with a few different design ideas and decided to hatch a COVID fab project. First order was to fix that rear bumper so I could actually use a receiver hitch and tow a trailer when needed. I really wanted to add a swing-out tire carrier as well but could not get any designs to work well and look good with the full width tailgate. I ended up reusing my original design with a few additions.

The bumper was made from 1.75x.120 walled DOM and the side wings were 1.5x.090

It is hidden from view, but there are outriggers that attach to the frame rails behind the side hoops for added strength.

 

[Cirbo]

The other half of the project was to add a roll bar in the bed. At 6ft and 230, I had ruled out an internal roll cage in the cab years ago. I wanted a vintage look with real world functionality.

As before, the red tubes are 1.75x.120 DOM and blue 1.5x.090. Rear bed mount would attach very close to the rear body/bed mounts and capture the thicker C-channel used for that same purpose. Front mounts would plate on top and below the bed and connect to the rock sliders near where they welded to the frame. I added a poly bushing to that connection as well.

I played with different mounting solutions for the spare but ended up turning it 90 degrees behind the driver. I also added the horizontal bar behind the cab in case I wanted to use shoulder harnesses with the top off some day in the future.

 

[Cirbo]

Removal and powder coating.

Finished products installed.

 

[Cirbo]

Side support and spare tire mount.

 

[Cirbo]

Finish product with a Zarges case bolted in the bed acting as a toolbox and spare parts stash.

It was also nice to get more of the bed back for storage/cargo.