71FJ40 Chevota

[71FJnick]

The ebrake handle will most likely mount on the trans tunnel, so I might as well sort out the shifter holes.

installed t-case saver from BTB (I think) and the twin stick setup from Advance Adapters.

I also had to pickup AA’s bracket kit for the SM420 because the PO had cobbled some stuff together. For others the AA twin stick does need the factory bracket (or at least the threads from the factory shifter mount).

 

[71FJnick]

Also noting this here if I need it later.
There are 2 bushings presses in on the pivot shaft 5/8ID x 47/64OD that are press fit into a 23/32 hole in the shift pivot block

 

[71FJnick]

Started working on the tunnel.
First cut out all the old patches, then made the holes larger to clear the new linkage.
Finished with CAD templates, not sure how the steel version will look, but I’ll get to try out my sheet metal skills

 

[71FJnick]

Started converting cardboard to sheet metal. Not perfect but happy with it so far.

 

[JAG666]

Started converting cardboard to sheet metal. Not perfect but happy with it so far.
View attachment 2754008View attachment 2754009View attachment 2754010

"Homemade Tunnel" looks pretty damn good, if ya ask me!!
Charles 1974 FJ40

 

[71FJnick]

Finished the patches and extension on the tunnel. I’ll have to massage the top section and add some body filler, it warped a bit with the heat. Overall pretty happy so far.

 

[71FJnick]

Got the ebrake handle mocked up and started welding in the nuts for the shifter boots.

 

[71FJnick]

E-brake works!
Used the factory FJ40 tcase drum brake and cable, then a lokar floor mounted handle, adjuster, and cable end.

 

[05CTD]

E-brake works!
Used the factory FJ40 tcase drum brake and cable, then a lokar floor mounted handle, adjuster, and cable end.
View attachment 2803794View attachment 2803795View attachment 2803796View attachment 2803797

Looking really good...

 

[71FJnick]

Finished the tunnel project today. Pretty happy with it overall.
Next up is to put the driveshafts back in.

 

[71FJnick]

Tested the ebrake this weekend, it works ok on flat ground
I can stall in 3rd gear but lower than that I can drive through it.
Also got the floor plates and main hoop tacked in for the MetalTech Jackson roll cage. I cut the main hoop .75” shorter to fit in the garage door a bit better.

 

[71FJnick]

Got the A-Pillars tacked in this weekend.
I took .250 off the length, then fit them 5” in from the B-pillar (toward the middle of the truck).
At the windshield I shot for ~.5” gap
And at the floor I’m 0.5” from the rocker panel (toward the middle of the truck) and 1.25” back from the tub support post.
I don’t have doors so hoping I left enough clearance if I want to add them later.
The tub is early so I have latches and put the tube on the outside of the latches, just so they barely clear.

 

[71FJnick]

Notched and placed a few more tubes..
I put the overhead bars in this orientation to keep the top under a max height. There is some debate about putting the bend toward the back to allow for more headroom. Since I’m short and will be adding toolbar padding this seems like it will work.

 

[71FJnick]

Waiting on paint to dry for the rollcage, I decided to work on the dash. I the PO cut out everything but he original glove box so there wasn’t much to work with. I made a 1x1 box frame and plugged the holes.
Around the glovebox I carried the body line down to finish it out.
Next will be to make some flat plates for gages and switches. Cardboard test looks ok

 

[kbahus]

Looking good Nick!

 

[71FJnick]

Got the dash finished up

 

[71FJnick]

Got the rollbar painted and installed.
Still need to do the frame tie in, but the main section is all done

 

[71FJnick]

Got mirror and mirror mounts from @kartek_off_road
The “current” plan is to make half doors and keep the ability to flip the windshield down, so these rollbar mounts are a great fit and price.

 

[EWheeler]

Got mirror and mirror mounts from @kartek_off_road
The “current” plan is to make half doors and keep the ability to flip the windshield down, so these rollbar mounts are a great fit and price.
View attachment 2946952View attachment 2946953

Those mirrors look really good!

 

[71FJnick]

Since it’s winter, I put a new bikini top (bestop) on and started the front bumper.
Just like the rear the shackle mounts pass thru the bumper and mount to the frame with a 1/2” bolt. I’ll add some top and bottom supports with mounting bolts and cap the ends.