Builds 75 Series cab on 80 series chassis with Cummins 6BT

Mr Cimarron

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Spent the morning tearing down front end. It went pretty easy. No broken fingers or toes this time. It had been done at some point before since I found Timken bearings and National seals. At some point this week I will get around to cleaning everything up for a paint touch up before it goes back together. Usually soak in some diesel for a day to help loosen all the crud.
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Mr Cimarron

DRIVE, BREAK, FIX, REPEAT
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I see you have a low tech parts washer setup like me :)
Yup. Here are the other items for my low tech setup. I don't know where I got this thing but it fits over the bus tub nicely to catch the grime. I probably stole it from the wife at some point. If only it was sunny today I would be cleaning.
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Mr Cimarron

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Garage day is over so back in the house for things to do while watching football. I traced out the 70 series gauge cluster so I can figure out measurements to cutout a new faceplate to use for gauges. I will be using Speed Hut gauges instead of OEM. Face plate will be cut out on the CNC table at work for a nice finish, hopefully. I plan to graft the 80 series lights onto it as well so I can know when the CDL, lockers, brake, high beams, are engaged. Only real things I care about. Should be easy enough to program in 5 squares to be cut in the plate and then add the labels behind it. I will need to cut out the bulb housing part to add behind them. I will figure that out another day.
I will be also adding EGT, boost, and fuel pressure gauge to the altimeter pod like others have done.
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Mr Cimarron

DRIVE, BREAK, FIX, REPEAT
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Dropped all the knuckle stuff into buckets of diesel so now I am waiting to clean this weekend.
Front end is freshly rattle canned.
I also managed to fix the non functional H4 switch which only needed to be blown apart and cleaned. Needed this to use to control the CDL motor. Works just like an 80 CDL switch!

I got tracking for my motor mounts also. That’s a big step so maybe, big maybe, I will have time to bring the engine home from work and drop it in over Thanksgiving.
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Mr Cimarron

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Picked up motor mounts from the mailbox this morning. Same as the ones I'm running in my 80. I need to replace the frame bushing before install. They look okay but probably should replace anyway. Odds are the engine won't go in until around Christmas as I have plenty to still do beforehand that I don't want to rush.
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Mr Cimarron

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Now that everything is clean and painted I started putting things back together.
I have my torque poster ready to go.
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I also did the martack mod to the axle shafts to do away with the inner c clip for the birfs.
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One thing I have noticed and have debated with others is whether the 80 series shafts require two c clips like the 40 and 60. I have tore down four different 80 front ends and never seen two but the @NLXTACY poster shows two. Anyone else have input here?
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NLXTACY

Wits' End
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I’m trying to remember why I kept it there because I’ve also only seen one. I’ll have to go thru my notes but there was a reason it’s there.

From the FSM:
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dogfishlake

"Go on a living spree"
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Killer build man. Glad I found this thread. I really want to make a low buck cruiser based utility vehicle for running around the property. I sold my Polaris Ranger (right at wood hauling time and the beginning of snow pushing time- not smart) and am planning something. Your truck will be a super cool and useful rig for you. Subscribed!

Ps- I usually grab my Wits End t-shirt and lay it out to have all those torque values when doing my 80 axle rebuilds!
 

Mr Cimarron

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From Cruiser Outfitters website. Looks like only one c clip on 80 series axle just like I thought.

Fits 67'-9/75' FJ40/45/55 - Drum Brake
At Free Hub/Drive Flange - Part# FACL28038
Inside Birf - Part# FACL27091
Birf Stop - Part# FACL28036

Fits 9/75'-90' 40/55/60/PU/4R - Disc Brake
At Free Hub/Drive Flange - Part# FACL31007
Inside Birf - Part# FACL27091
Birf Stop - Part# FACL28036

Fits 91'-97' FJ/FZJ80
At Free Hub/Drive Flange - Part# FACL31007
Inside Birf - Part# FACL34005
Birf Stop - Part# Not Required
 

dogfishlake

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I've only seen one clip. The only difference is the depth with the early 80 series having the deeper groove/shallow flange. Maybe that's why it shows 2? Like the 2 different clip positions. Just a guess
 

Mr Cimarron

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Over the weekend I managed to install my front brake lines. Then I did things which didn’t involve money which was cleaning and piecing together the dash. I almost have a usable dash at this point. Only need a radio bezel, right side vent bezel, and the piece that holds the locker dial. I also still need to paint the metal frame with a fresh coat of gray.
Next months budget will be the rear and then 1st of the year will be engine install.
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Mr Cimarron

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I got one side done on the front. My garage has really s***ty lighting so winter projects suck with the lack of daylight. No machining snap ring groove since I used early 80 series birfs. I will finish the other side this weekend and then tear into the rear.
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I still debate myself on how much body work is coming once I have the chassis done. I’m a big believer is making the drivetrain main priority and looks second. We will see. Once it’s drivable it will be driven regardless of what the body looks like. I am kinda looking forward to driving around with different color body parts.
I regualry watch this clip from Slap Shot and then it’s all good.
 

dogfishlake

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I got one side done on the front. My garage has really s***ty lighting so winter projects suck with the lack of daylight. No machining snap ring groove since I used early 80 series birfs. I will finish the other side this weekend and then tear into the rear. View attachment 1842884
I still debate myself on how much body work is coming once I have the chassis done. I’m a big believer is making the drivetrain main priority and looks second. We will see. Once it’s drivable it will be driven regardless of what the body looks like. I am kinda looking forward to driving around with different color body parts.
I regualry watch this clip from Slap Shot and then it’s all good.
That axle looks as nice as any paint job on the exterior.
 

Mr Cimarron

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Front end all done for now. Now onto the rear. This is where I start noticing things that are missing. A few years ago I dug into the parking brake to steel a few parts for the 80. Also noticed/remembered I stole some brake line retainers on the axle for the BJ40. Parts are already coming in and am giving myself the whole month of December to finish the rear.
Everything is broken done so the next week will be cleaning and painting before anything goes back together.
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Mr Cimarron

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Spent the weekend cleaning and painting. Also swapped all the guts from my locker to another. My rear locker was so corroded it wouldn’t work. I had found a locker at the pick n pull a few years ago literally laying on the ground. Whoever took the 3rd from the 80 left it. Probable due to breaking the housing while removing.
I managed to disasimble both locker which wasn’t bad at all. I even was able to get the bearing for the motor shaft out also.

Broken housing but looked brand new on the inside
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This is he Allen screw you will need to remove in order to bang out the bearing with a punch
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This was the hardest part. The wires are glued into the grommet. I used a pick to slide in to widen them a bit to remove wires.
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