Daystar FJ40 body mounts, late model

[jgeoffr]

@Bambi Girl - For those body bushings, did you turn inserts or purchase? If turned, what was the material - if purchased do you have an item you can point to?

I am looking at having those turned to enlarge like you did to insert a metal washer that is recessed enough to recess both the washer and the screw head.

Here is the underside of the original bumper - Toyota vulcanized a washer onto the bushing.

For the middle bushing, it does appear that Toyota intended the hole to be larger than the bushing crush tube, perhaps to allow for the bushing assembly to be able to move, or perhaps to facilitate manufacturing tolerances.

The original appears to have had a fabric disc as part of the bushing, perhaps on both the top and bottom (but I cannot be sure).

Regarding the daystar middle bushings, daystar M02388 for the upper and M02850 for the lower, I did decide to have my machinist make new crush tubes to fit the M02388, with a larger OD while keeping the same ID. The length will match the other crush tubes in the set. I am also having the M02850 turned to fit the new larger crush tube. I'll post pics of that when I get them back.

-Geoff

 

[Usernametaken]

That's awesome mate, thank you

 

[gcrump01]

After reading this thread I opened by Daystar kit to check it out. I'm having the same problems described by the OP. Guess I'll call Daystar & see if I can get a few extra pieces. Ugh!!

@Usernametaken - can you list the Daystar part numbers and quantity of the extra parts Daystar is sending you? Keep us posted if it works out the way you planned.

 

[Bambi Girl]

@Bambi Girl - For those body bushings, did you turn inserts or purchase? If turned, what was the material - if purchased do you have an item you can point to?
Hi
Used nothing special just a piece of black nylon.
The job simple took me less than an hour to machine.
I ended up using stainless screws and not the black as in the photo.
Cheers


...via IH8MUD app

 

[gcrump01]

Emailed Daystar technical support. I'll let you know if I get a response.

 

[Usernametaken]

Emailed Daystar technical support. I'll let you know if I get a response.

See if you can get onto a guy called Ralph Sheeler.
rsheeler@daystarweb.com

 

[jgeoffr]

As promised, here is the new crush tube to fit the M02388 as well as the enlarged M02850. Material is solid stainless steel versus the rolled steel crush tube from daystar. They are so nice I am thinking of having four more made to replace the remaining crush tubes...

-Geoff

 

[gcrump01]

I emailed the general tech support email address. A quick response said they would look into it & get back to me. That was about a week ago.

 

[gcrump01]

Been emailing this evening with Daystar tech support. Very helpful. They asked where my truck was from & I told them US, as far as I know. Anyone know if there are frame differences for various countries? Anyway to verify that I have a US truck? with vin numbers or frame numbers?

 

[Usernametaken]

Frames are all the same as far as I'm aware.

 

[gcrump01]

Now the rep thinks I have the wrong kit so he's sending me the one he thinks I need. To be continued.

 

[gcrump01]

OK, so I had the right kit - at least according to the description. Still having same fitment problems as OP.

Has anyone actually used this kit with success? Without having to modify the bushings, etc.????

 

[Superfj40]

I to have a daystar kit for my 1981 FJ40 but have had the same issues as Usernametaken has, I have been in contact with Daystar via email but after the 2nd or 3rd email I get no reply and this has happened 3 times, Has anyone had any luck with their tech support?

 

[gcrump01]

I've been emailing with Kelly Herring (kherring@daystarweb.com) and Ralph (email above) and they've been pretty responsive but no real resolution. Please email both of them & reference this thread (I gave each of them a link to it).

I'm still looking for anyone who has used this without modification.. anyone, anyone, Bueller, Bueller...

 

[Usernametaken]

OK, so I had the right kit - at least according to the description. Still having same fitment problems as OP.

Has anyone actually used this kit with success? Without having to modify the bushings, etc.????

I modified my front lower bushings by boring them out until they fit.
Needed to get the body on so improvised.

 

[gcrump01]

Daystar is supposed to be sending me a few extra pieces to make this work. Waiting to see.

Still looking to someone who has used this kit without any modifications. Anyone?

 

[gcrump01]

does anyone know what these fabric discs/washers are called or how to find them? What are they made of?
(Pic from jgeoffr above)

 

[gcrump01]

Thought I'd bump this one last time before I let it die. Still don't have extra parts from Daystar, still hoping. They suggested I call CCOT. CCOT said they had not done a frame off in years and didn't have those people around any longer. No help.

Anyone used the Daystar kit without modification? Anyone?

 

[Usernametaken]

No but the modification I made took about 3 minutes with a Dremel.

 

[shipmag]

Where did you guys get the kit from? Will it work on a usa 76 FJ40?