Builds 76 Project Silver Back

[SMG]

Finally all of the engine is back together and cleaned up. Had to make some custom radiator stay rods.

Should be starting real soon. I need to finish the exhaust and figure out a good way to mount the battery under the passenger seat.

Fuel tank going back in. Hopefully for the last and final time.

 

[SMG]

Today I welded up my battery mount.
This cradle design keeps the battery fully suspended below the passenger seat frame.

I picked up this AGM battery from Rural King for around $129 bucks. This will allow me to run the battery on its side.

For wire, I am running 2/0 gauge to the engine compartment.

 

[SMG]

Finally finished fabricating a 2 into 1 exhaust. For a home garage job, I think it turned out really nice. I was able to tuck it up nice and tight to the drivers side inside frame rail.

This is 2,1/4" from the manifolds and then 2,1/2" from the Y-pipe back.


Here's how I did the Y- pipe.

 

[SMG]

More pictures,

 

[SMG]

Wrapped the whole exhaust back to the muffler.
Used an old Christmas tree stand to hold the pipes while wrapping. Worked great!

 

[Geezer Cruzzer]

I just went through every page. I am not worthy of owning an FJ40. Your skills and workmanship are beyond anything I could envision. You make me feel guilty for buying the wife a garage queen.

 

[SMG]

I just went through every page. I am not worthy of owning an FJ40. Your skills and workmanship are beyond anything I could envision. You make me feel guilty for buying the wife a garage queen.

Thanks for the nice compliment. Honestly my build isn't nearly as nice as some of the others here on MUD. If it wasn't for this great community I really wouldn't know what I was doing. Just enough to be dangerous!!

I know it's taken a long time due to budget/time/space restraints, but I really enjoy every minute I spend working on it.
Thankfully I'm starting to see the light at the end of the tunnel. Looking forward to driving it someday. LOL!!!

 

[SMG]

Installed some Hummer 3 point seat belts over the weekend.

Fabricated some brackets out of stainless steel to bolt to the roll bar.

 

[White Stripe]

Did those lower 90 degree brackets that you bolted to the rear roll bar mount come with the hummer kit or did you make those? I like the upper stainless mounts, those are nice. How did you cut them out so cleanly?

 

[velillen]

The exhaust looks nice! Id love more details if you don't mind sharing (since Ill be doing pretty much the same as you). Where ya got the pipes, what you put over the welds (some sort of putty?), and how much heat tape you used.

 

[SMG]

Did those lower 90 degree brackets that you bolted to the rear roll bar mount come with the hummer kit or did you make those? I like the upper stainless mounts, those are nice. How did you cut them out so cleanly?

The lower brackets came from CCOT for $2.63 a piece. I made the upper brackets out of a 4" piece of 3/16" plate that I had laying around. Basically made two 90deg triangles out of the square piece using a bandsaw. Rounded the corners with the disc sander.

Oh yeah, one thing that's kinda cool is; the brackets can be flipped 180 so if your taller, the shoulder belt rides a little higher.

 

[SMG]

The exhaust looks nice! Id love more details if you don't mind sharing (since Ill be doing pretty much the same as you). Where ya got the pipes, what you put over the welds (some sort of putty?), and how much heat tape you used.

Thanks!

The manifolds are 2.5" early model Corvette cast iron manifolds.
From there I used 2.25" header buddies connectors.
From the manifolds I ran 2.25" mandrel
bent aluminized exhaust tube to the Y-pipe. From the Y-pipe I ran 2.5" all the way back. I have a total of 4, V-band exhaust clamps throughout the system for easy removal/access. Everything tucks up super nice to the forward edge of the oil pan and inner drivers side frame rail. The reason I didn't take it somewhere is because I knew it would be hard to find a shop that would fit it as good as doing it myself.

I painted all welds with KBS's high temp primer and paint before I applied the DEI lava rock exhaust wrap. I used just under 100' of 2" exhaust wrap.

All the pipe elbows/clamps/hangers were purchased from Summit Racing.

If you would like, I can compile a list of elbows you would need to complete the job. At least back to the tranny area where I'm sure your muffler would be different since I'm running an aux tank.

 

[SMG]

Finally got it running again. Still need to set the timing and fix a rattle on one of the pulleys.

Overall it's running great!

 

[velillen]

Thanks!

The manifolds are 2.5" early model Corvette cast iron manifolds.
From there I used 2.25" header buddies connectors.
From the manifolds I ran 2.25" mandrel
bent aluminized exhaust tube to the Y-pipe. From the Y-pipe I ran 2.5" all the way back. I have a total of 4, V-band exhaust clamps throughout the system for easy removal/access. Everything tucks up super nice to the forward edge of the oil pan and inner drivers side frame rail. The reason I didn't take it somewhere is because I knew it would be hard to find a shop that would fit it as good as doing it myself.

I painted all welds with KBS's high temp primer and paint before I applied the DEI lava rock exhaust wrap. I used just under 100' of 2" exhaust wrap.

All the pipe elbows/clamps/hangers were purchased from Summit Racing.

If you would like, I can compile a list of elbows you would need to complete the job. At least back to the tranny area where I'm sure your muffler would be different since I'm running an aux tank.

View attachment 1535970
View attachment 1535971
View attachment 1535972

Would love to have the shopping list. Sorry it took so long to get back to you too, for some reason I didn't see that you had responded back. Yours sounds like exactly how I plan to do mine....aux fuel tank and all (I plan to get the marks off road one)

 

[SMG]

Would love to have the shopping list. Sorry it took so long to get back to you too, for some reason I didn't see that you had responded back. Yours sounds like exactly how I plan to do mine....aux fuel tank and all (I plan to get the marks off road one)

Here's my exhaust shopping list.

1. Corvette style cast iron manifolds (center dump)

2. 2,1/4" Header Buddies.

3. 2,1/4" 90 degree mandrel bent elbows (3 each).

4. 2,1/4 45 degree mandrel bent elbows (1 each).

5. 2,1/2" 90 degree mandrel bent elbow.
(1 each)

6. 2,1/2" 45 degree mandrel bent elbow.
(3 each)

7. 2,1/2" 10 inch flex pipe.

8. 10 feet or so, of 2,1/2" straight pipe.

9. 2,1/4" v-band clamp. (1 each)

10. 2,1/2" v-band clamp. (3 each)

11. Dynomax 17676 muffler.

12. DEI exhaust wrap 2"x 50' (2 each)

13. DEI Muffer Sheild 010455.

14. 4 exhaust hangers.


That should be everything.

 

[velillen]

Much appreciated! be a good list to start with at least!

 

[Rigger]

Really doing a great job on this! Nice going!

 

[77HesterSue]

Wow! Good work. What color will the body be?

 

[SMG]

Wow! Good work. What color will the body be?

Just started painting it today. Kinda blueish grey. I plan on painting it piece by piece. It will take me a long time doing it this way, but I can’t afford taking it to a professional.

The paint is a 2 part epoxy single stage.


My neighbors love me....

This is the look I’m going for. (Not my pic).

 

[77HesterSue]

Nice. Love that color! Keep up the good work