Builds 79 Aussie BJ55 build

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Jan 9, 2005
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knocked up a work bench over the last few days. still a few more things to do to finish it off but its not far off. i added 50mmx50mmx4mm box section as receivers under the bench. allows 40x40x3mm to slide in so i can mount a brake or vice i various spots.


i'm still struggling to see where to weld but think ive got plenty of heat and penetration in the welds.




Once done and i've finished drilling holes for bolting the gearbox and engine mounts, time to start on making a sheet metal brake and get back into the body work.
 
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had a stab at a brake tonight using what I had. m16 and 15nb tube for a hinge. I accidentily tac'd both sides of the hinge together and when i tried again i didnt get both pieces straight so will probably have to have another go at the hinge on one end. but looks like in principle it should work.


 
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Langley
My dad home built a small brake years ago, had to truss it to keep it from flexing, but it did work on thin enough tin...yours looks very similar so don’t be surprised if it flex’s a bit.
 
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My dad home built a small brake years ago, had to truss it to keep it from flexing, but it did work on thin enough tin...yours looks very similar so don’t be surprised if it flex’s a bit.
That 50mmx50mm angle is 8mm thick. Im hoping thatll mean it wont flex.
 
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Been spending more time on the brake but not sure if it will cut it. Im finding its still deflecting about 3 to 5mm in the centre when trying to bend a wide (~50cm) 10mm thick edge. Ive tried to sharpen the top clamping angle and its really clamped down but i struggle to bend it.

Made some handles (the vertical ones are an interference fit over the top of m16 bolts so they can be removed easily, and dont slide off when in that position)..

Some of the bracing I've added (finger is where it flexes)


This was massaged with a hammer


Radius is a bit tighter on the bend..


oh and i got a vice which inserts into the receivers under the top


Anyway i'm getting a bit bummed out at not being able to find a method to reproduce those roof sections with yet... still thinking about other ways to tackle it
 
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Joined
Oct 12, 2015
Messages
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Langley
Thinner guage tin?

Or get some 10mm round bar and truss the brake, but still be super tough to physically run the brake with the thick sheet...:hmm:
 
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Happy new year!




Still got parts to replace on the other side of this channel (the bit that the window seal fits into) but this is not nearly as hard as trying to form the same shape consistently over that length. Theres just a bit of minor tweaking to improve the fit.. I'm going to try and get out into the shed a bit more of an evening now I have an approach I can work with..
 
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Unfortunately no progress on the pig...

So in March I picked up the 80 and drove it home, and have now got it registered, and on daily duties allowing us to sell our Prado to recoup some cash.. Since then I've been doing a few mods to try and get it ready to take the family out camping at Easter.. This includes Tuffy Console, 8.25R16's, Rear swing-out, pintle hook and tow hooks for recovery, wiring to support our 40L engel for camping trips..





And we were able to get out camping for the first time in 5yrs with 3 kids (and 2 dogs!)..




Plans are to get all my turbo parts together allowing for a relatively quick diesel conversion using my 15B-FT and H55F into the 80 replacing the 1FZ-FE and auto. With the drive train sorted I can then focus work back on the 55 at my own speed and get the body panel and paint done with plans to throw this onto the 80 chassis.

I've just finished up with one job, and start a new one in 3 weeks so that's another hit to our savings but the 3 weeks will give me a chance to get some things sorted and in order for the conversion. I've sold a heap of my goodies from my leaf sprung 55 like Man-a-fre ubolt flip kit, bilstiens, and other misc bits.. so no going back now..

Thanks for enquiring too.. its been a while since I've stuck my head in here with everything else going on.

 
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