Earl - my HJ47 Project

[SOOT]

I will be rebuilding this little beauty later this year. All gear teeth accounted for and intact. Nothing bad to report here.









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[SOOT]

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[SOOT]

I thought milling the pto hole in the mill was the shot so I took the transfer case to work and chucked it in the mill.

Milled out the necessary material to allow the one piece pto gearbox gears to fit with some clearance.

Also machined the spacer between the input shaft gear and the pto gear down 4mm and got a spare one from Aussie25, thanks again, and machined it to 4mm to take the total spacer width back to what was there. I actually surface ground the ends of the spacers so the are parallel and spot on size.








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[SOOT]

I cleaned up the pto gearbox, pulled out all the gears and shafts and TIG welded the old mounting holes up, probably didn't need to do that but hey I wanted to because I know later down the track I would have looked at it and wished i had. Then I used the split case pto cover plate as a template and drilled out the holes.










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[SOOT]

It fits! Had to file some of the flange down for clearance. Going to mount it with some high tensile plated socket head cap screws as pictured. Stuck my hand in a gave the gears a bit of a feel and it all lines up spot on and turns great. I love the idea of a mechanical winch coming from a mechanical background. Its awesome.
And cleaning transfer cases and pto gearboxes suck and takes forever.










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[SOOT]

I really want to get these doors sorted, so fire away with your suggestions and comments

 

[SOOT]

Awesome work!
I like to see your bare cab! with no paint at all. This is what we call cruiser fanatic. I'm one of them.

Thanks wongtsenhin, I find myself standing there sometimes just looking into the shininess, far too often i'd say. I won't be happy till all the old paint is off damn it. I keep giving it a spray with WD-40 to keep the surface rust at bay, probably should have stripped it and primed it when I had the chance, we are coming into winter here now so it will have to wait. It is nice to work on nice clean steel. I want to get this cab and some other pieces ready for primer by the time spring comes around. Lots to do before that happens though.

All the blokes at work think I am nuts for doing this and I think they are missing out on something awesome.

Man I am loving this build

 

[tornadoalleycruiser]

"Had to file some of the flange down for clearance"
The front output of the PTO? That is some NICE work on that.. Wow. you have some elbow grease in getting those cases clean..

 

[2fpower]

Doors..... they are a pain. It really comes down to how much they fit to your tub. think about it this way....

You wake up and get some coffee. You go to the shop and hang the doors on the hinges. there is three points of adjustment. top hinge, bottom hinge and then the striker. striker is really just in and out -- the hinges make all up and down movement. So, if your bottom corner below the striker is sticking in or out, you play with the hinges. Very quickly you just made the gasket on top of windshield not touch.


So, what you have to do is add some twist to the door. This quickly makes the center of the door suck in. You are working in three dimensions, so every change makes the door fitment change.

My .02 is to get it close enough for your preference but hang it on the door and make sure you get it all fitting before you paint.

Oh, and AWESOME work on the PTO. Amazing. It looks like you are taking all the paint off with grinder disks or paper. Is that right? If so that has to be days (not hours) of work....

 

[herbs]

Awesome work, especially with the pto, the Toyota winch is nice, can be engaged in either direction giving lots of options with line speed in forward and reverse, the Thomas pto drives only allow one speed with line out. Keeping the 4 speed I see? My 5 speed is being rebuilt in the next few days then it's going into my '81 FJ 45. Have to get it on the road asap since my 76 series has to go to the panel shop.

 

[SOOT]

"Had to file some of the flange down for clearance"
The front output of the PTO? That is some NICE work on that.. Wow. you have some elbow grease in getting those cases clean..

I cleaned up the pto gearbox, pulled out all the gears and shafts and TIG welded the old mounting holes up, probably didn't need to do that but hey I wanted to because I know later down the track I would have looked at it and wished i had. Then I used the split case pto cover plate as a template and drilled out the holes.

View attachment 760799


View attachment 760801



View attachment 760800

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tornadoalleycruiser,

Had to file the main pto gearbox mounting flange. The tabs that are on the left side in the pictures above. They needed about 4-5mm of material removed to enable clearance between the transfer case and the pto gearbox.

I measured everything about 10 times before I machined anything to make sure everything was going to line up, Aussie25 was right on the money with moving the pto gear forwards 4mm by machine the spacer down and putting another 4mm spacer in, my pto gears are inline.

And yes I spent some time on thoes cases getting them to where they are now, I used some soft wire brushes that go into a drill, they worked well, they still need more work to get them to where I want them then I will probably put some clear coat on them.

Here is the link to pto mod thread I used as a guide, you posted in it as did Aussie25 and I can always post up some more pics if you want. https://forum.ih8mud.com/fj45-owners-club/534115-earlier-pto-later-setup.html

 

[SOOT]

Doors..... they are a pain. It really comes down to how much they fit to your tub. think about it this way....

You wake up and get some coffee. You go to the shop and hang the doors on the hinges. there is three points of adjustment. top hinge, bottom hinge and then the striker. striker is really just in and out -- the hinges make all up and down movement. So, if your bottom corner below the striker is sticking in or out, you play with the hinges. Very quickly you just made the gasket on top of windshield not touch.


So, what you have to do is add some twist to the door. This quickly makes the center of the door suck in. You are working in three dimensions, so every change makes the door fitment change.

My .02 is to get it close enough for your preference but hang it on the door and make sure you get it all fitting before you paint.

Oh, and AWESOME work on the PTO. Amazing. It looks like you are taking all the paint off with grinder disks or paper. Is that right? If so that has to be days (not hours) of work....

Thanks 2fpower,

Something I didn't think of was putting the doors on to check, I will do that, sounds like fun and a good thing to do before paint.

I did remove the paint with a grinder, I have heaps of these 3M coating removal or stripping discs, I posted info on them in this thread on page 1 and 2 I think. They work very well to remove paint. It does take some time as does blasting them yourself but is less messy then sandblasting it in your yard. I will be blasting around the seams and areas where the discs don't reach to finish them off.

 

[SOOT]

Awesome work, especially with the pto, the Toyota winch is nice, can be engaged in either direction giving lots of options with line speed in forward and reverse, the Thomas pto drives only allow one speed with line out. Keeping the 4 speed I see? My 5 speed is being rebuilt in the next few days then it's going into my '81 FJ 45. Have to get it on the road asap since my 76 series has to go to the panel shop.

herbs,

Thanks for the comments, I am loving the idea of have a factory pto winch, its pretty sweet, in good condition and will look awesome rebuilt, blasted and painted.

I will be using the 4 speed for now, I don't intend on breaking any land speed records in this thing, but saying that I would love to have one and if I happen to stumble across one at the right price one day I will rebuild it and change it out. Not good to here about your 76 going to a panel shop with at the end of your post?

 

[Aussie 25]

Pto

Hay that is cheatig, having all those fancy machines to do the pto & t/case. Looks good. I see you surface ground the face on the pto case, just check you have some clearence between the two gears, i had to use 2 gaskets. Your project looks good.

 

[SOOT]

Hay that is cheatig, having all those fancy machines to do the pto & t/case. Looks good. I see you surface ground the face on the pto case, just check you have some clearence between the two gears, i had to use 2 gaskets. Your project looks good.

Hey hey I didn't cheat! It would have taken me longer to set it up and machine it then it would have with a cut off wheel but it looks great, not that anyone will ever see once its all bolted up and covered in mud!

I didn't surface grind the pto gearbox housing face/flange. That is just a quick hit with a stainless steel wire brush. They clean up aluminium really good.

I plan on making a gasket out of some gasket material from work, we have a selection of different sizes there and I'm sure they won't miss it too much. If I can't find the thickness I'm after I will buy the required thickness so the gears will mesh correctly. I will stick this on my ever so long to do list, thanks for the heads up Aussie25!

Soot

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[scrapdaddy]

herbs,

Thanks for the comments, I am loving the idea of have a factory pto winch, its pretty sweet, in good condition and will look awesome rebuilt, blasted and painted.

I will be using the 4 speed for now, I don't intend on breaking any land speed records in this thing, but saying that I would love to have one and if I happen to stumble across one at the right price one day I will rebuild it and change it out. Not good to here about your 76 going to a panel shop with at the end of your post?

I've been following along and liking your build. Thought you might like to see a color option,

 

[SOOT]

Thanks for posting your PTO. It is great to see what others have done, I haven't fully decided on a colour yet, I need to look at some more pto thread/pictures. I like how your support angle has been cut on that 45 degree. It looks heaps better like that. mine is just a straight cut at the moment, but before paint, cutty cutty.

I see you are sporting a SUA u bolt flip kit. How much more ground clearance did you gain from that. Me thinking me lik this idea!

 

[scrapdaddy]

Honestly, not much. It does protect the u-bolts from getting the nuts smashed. In my case, I'm not doing any rock crawling, so should have spent the money elsewhere.

Something to look at, is this thread on gear case protection. Keeps the winch case mounting feet from snapping, under load. I think this a great idea. https://forum.ih8mud.com/40-55-series-tech/208362-if-aint-broke-reinforce.html. This is what I did. All underneath, can't see them.

 

[SOOT]

Thanks for the heads up scrapdaddy, another very useful mod to add to my to do list, I will definately be doing something like that. Gotta love the info sharing on mud.

I haven't had a really good look/search yet but does anyone have the measurements of the PTO winch to chassis spacers/wegdes handy? My winch didn't come with them. Some side on installed pics would be awesome as well.

 

[doofus]

Hey SOOT, great work on the rust repairs. I'm in Canberra and this is motivating me to get my arse into gear with my own repairs. Great read. Let me know if you ever need some local help.