Builds Aussie 1978 FJ40 Buildup

[brooksy]

Bit lazy & tired to do a write-up but here are some pics, basically all done except tailgate/wheel carrier as I am still waiting for parts from USA. I have a little more work on tank bashplate too.
Twisty has some more detailed shots but here are the cage pics.

brooksy

 

[brooksy]

Back in the 40

brooksy

 

[brooksy]

Rear mounted 57L fuel cell with bashplate & fully removable cell mount
I have done a very trick dimple effect on the bashplate but haven't taken pics, Dave has some.
I still have to do the same effect on the rear vertical section but time was getting away from us so I will do it during the week.

brooksy

 

[brooksy]

A lot of other stuff was done things like finish all welding, die grind out cage footings in floor, the fuel cell/bashplate assembly, battery box intergrated into seat mounting bracket, fuel filler in rear floor, run new fuel lines & refit wiring.
I still have to put in seat belt mounts in B-pillar & do cross brace. May while I am there do harness mounts for added safety when driving the more risking tracks.

brooksy

 

[brooksy]

Here are a couple pics of the bashplate covering fuel cell.
The dimples are located where the X bracing isn't so the dimpling strengthens those points.
I still need to do the vertical return to the bumper section, I will do it this week.

brooksy

 

[Davs]

Sooooooooooooooo jealous!!!

 

[Twisty]

Copying some updates from Brooksy across from another forum.

Couple more from this arvo as the wife wanted to have a look

brooksy

 

[Twisty]

and another

Dave asked me to post up some more progress pics as 4wdlinks is still down

Here is a quick couple pics of the battery mount that is fixed on seat rail tube. I have a dimpled bracket that is going over the top to mount Daves Waeco fridge console on top which I will have done by this arvo

Here is a couple of the 57L fuel cell mounting, very strong & pretty easy to remove as one complete unit with hose lengths allowing to sit on ground.

brooksy

 

[Twisty]

and another

Here is the doors. Dave is having 2 sets of doors. These are the daily set which will be used for the Scenic Rim trip at the end of this month.
I am making a tube set but they are going to take some time as they will be pretty detailed with removable sections. They will be done at the same time when I do the tailgate carrier & roof rack.

Marked out doors to a height that is same as rear tube ontop of the tub. Dave will be painting the cage the same as the body so this works great. If He was painting the cage a different colour the doors would need to be cut lower to match the body line as it wouldn't look right.

brooksy

 

[Twisty]

and another one

The cage fouled on the doors (which I knew would happen) so I did a bit of panel work to follow the tube cage lines.

And the result, pretty good I thought.

Top skins

brooksy

 

[Twisty]

another one.

Started mounting checking for fit & clearances.

Tac'd into position

Height is awesome & you feel comfortable

brooksy

 

[Twisty]

and another

took both doors off & fully welded interior skin but only did spot tac's roughly every 1" on outside to minimise warping although on each end & at the point where the door angles up I run a weld to eliminate cracking.

brooksy

 

[Twisty]

another one

Finished & the doors outer skin is pretty damn flat with next to no warping at all

Some pics outside

brooksy

 

[Twisty]

and another

x8

Onto seat belt mounts.


Had the belt cartridge mount on 8mm plate welded to just above B-pillar mount

Next was the shoulder mount which needed to be drilled through the cage & welded both sides to pass regs

brooksy

 

[Twisty]

last one.

Finished, but I didn't have a 7/16 UNF tap so will need to buy one so I can use factory HT Bolts that allow seatbelt mount to rotate.

brooksy

 

[brooksy]

OK, finished for the day so progress for today was bashplate/fuel cell guard is complete & battery/Waeco centre console done.

Console first:
Front

Rear

45mm clearance to battery terminals so should be fine.

With seats back in place

brooksy

 

[brooksy]

Rear Fuel cell guard.

Looks good combined with rear barwork. Lot of dimpling but just enough without being over the top.

brooksy

 

[brooksy]

Couple outside pics

brooksy

 

[Twisty]

Some more updates by Brooksy (copied from another forum)

Well basic outline of Tyre gate is done although I am going to be lowering the stinger height so I can bring it in closer to the back as currently it needs to be out that far to get tyre off.
I was going to just cut the stinger off halfway up the lower radius & angle cap the ends of the tube to give it the KOH look but as Dave mentioned don't think the Police or DOT would approve :crazy:


I am using factory points to simplify the mounting & maybe make it easier for other 40's to be done.

I folded some 6mm plate to fit on the radius corner.

I will be doing some dimple infills on the bush brackets

You can see in this pic how I have used a larger tube slipped over & cut to use as a stop on both sides for the tailgate

brooksy

 

[Twisty]

number 2

With wheel mount & latch.
I am however having some issues with the latch holding correctly but hopefully will have that sorted over the weekend along with all the bracing tubes & gussets

brooksy