Extended cab 45 SWB from a 40 (1 Viewer)

[afraptor22]

It's pretty far above the tie rod because of how high the diff is. This is full bump with the diff vent touching the frame. The bracket will be just in front of the diff cover bolts and the bolt will be at the lower inside corner of the frame in the highest hole on the bracket.

 

[afraptor22]

I was cleaning up at work and found a steering drag link from a JK that had some great bends in it. Chopped the ends off and weld bungs fit, so it became the new panhard bar.

I had wanted the bend at the axle side to go under the frame, but it wasn't gaining me any up travel because the bracket still hits the pumpkin. I flipped the bend to the frame side and then decided to move the bracket outboard of the frame to lengthen the panhard bar. I used the bend to get around the pumpkin.

The plan to move the steering gearbox back was a fail. As I was planning the coilover tower location I realized I had waaaaay too much caster in the front axle and the coilovers would need to be more upright. This ended up moving the towers forward and I ran out of real estate. I was able to tuck the bump cans inside the coilover towers and I like this arrangement much better.

Pulled the engine and transmission out, welded everything, sprayed with Steel-It and now its back together. Front end is still higher than I want but there are a ton of parts to bolt back on. Also the Aluminum block dropped some weight. It's a no-no but I'll probably go negative pre-load on the coilovers to drop it a bit.

 

[UZJ40]

Looking really good! I like the bumps inside of the towers. Nice packaging.

 

[Mike Shull]

I was cleaning up at work and found a steering drag link from a JK that had some great bends in it. Chopped the ends off and weld bungs fit, so it became the new panhard bar. View attachment 3641080I had wanted the bend at the axle side to go under the frame, but it wasn't gaining me any up travel because the bracket still hits the pumpkin. I flipped the bend to the frame side and then decided to move the bracket outboard of the frame to lengthen the panhard bar. I used the bend to get around the pumpkin.
View attachment 3641081
View attachment 3641083
The plan to move the steering gearbox back was a fail. As I was planning the coilover tower location I realized I had waaaaay too much caster in the front axle and the coilovers would need to be more upright. This ended up moving the towers forward and I ran out of real estate. I was able to tuck the bump cans inside the coilover towers and I like this arrangement much better.
View attachment 3641085
Pulled the engine and transmission out, welded everything, sprayed with Steel-It and now its back together. Front end is still higher than I want but there are a ton of parts to bolt back on. Also the Aluminum block dropped some weight. It's a no-no but I'll probably go negative pre-load on the coilovers to drop it a bit.
View attachment 3641086View attachment 3641093
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Are you planning to add a crossbar between your towers? Mine moved when I flexed the suspension before adding my crossbar.

 

[afraptor22]

Are you planning to add a crossbar between your towers? Mine moved when I flexed the suspension before adding my crossbar.

Ya I was thinking about adding one, especially with how tall they are. I want to get the intake in and figure out the filter before I build one though.

 

[Mike Shull]

Ya I was thinking about adding one, especially with how tall they are. I want to get the intake in and figure out the filter before I build one though.

That’s a great plan. I lucked out and didn’t think about my intake when I built mine. The intake has at least a millimeter of clearance to spare!

 

[afraptor22]

Haven't had much time lately but my family is out of town for a couple weeks so I need to hustle and get the body work done...maybe paint.

Little bit Frankenstein looking but it'll get some body filler and then sprayed with Raptor Liner, color and a clear coat. Fender flares turned out pretty good. Still need to cut and shorten the passenger side flare.

Took quite a few pieces of the old tub sills to make the rear door openings. The radius didn't line up perfectly with the Aqualu doors but I may weld some filler aluminum to the door and re-cut the lower radius...or not...I'm tired of welding!

 

[afraptor22]

Rough cuts on re-using the old cage. It would be nice to start from scratch with no extensions but 1. its a poser not a hardcore trail rig 2. the cage has to be removeable to get it out of my garage!

Cheap tailgate for now, will buy an Aqualu storage tailgate in the future.

 

[peesalot]

FWIW, that track bar hiem at frame doesnt need the misalignment so you could delete the front side and space the back which would give that bar a bit more diff clearance, may be a non issue but noticed that.

 

[afraptor22]

FWIW, that track bar hiem at frame doesnt need the misalignment so you could delete the front side and space the back which would give that bar a bit more diff clearance, may be a non issue but noticed that.

I'll check it out and see if it needs to come forward some. Good idea, thanks!

 

[clrussell]

I dig this build. Huge amounts of work has been put into it.

 

[REZARF]

Yeah man, keep it up! Crank while you have the time!

 

[Mike Shull]

Rough cuts on re-using the old cage. It would be nice to start from scratch with no extensions but 1. its a poser not a hardcore trail rig 2. the cage has to be removeable to get it out of my garage!

View attachment 3682829

Cheap tailgate for now, will buy an Aqualu storage tailgate in the future.

View attachment 3682830

Sweet!!! Keep going and don’t even think about getting distracted about how you are going to back it out of the garage. Ha! It’s looking good!!

 

[peesalot]

Just noticed the front drive line does not appear to have much slip ?

 

[afraptor22]

Just noticed the front drive line does not appear to have much slip ?

It's not connected to the transfer case now, just tied off to the side.

 

[afraptor22]

Sweet!!! Keep going and don’t even think about getting distracted about how you are going to back it out of the garage. Ha! It’s looking good!!

Thanks!

 

[afraptor22]

I dig this build. Huge amounts of work has been put into it.

Thanks!

 

[afraptor22]

Yeah man, keep it up! Crank while you have the time!

Thanks! Trying to get to the finish line...week and a half before kids return.

 

[afraptor22]

Body metal work is pretty ,much done. The rest can get done after paint. Cage is mostly done except for seat belt anchors and the frame ties. Then the cage will come out to get everything welded and painted. It'll stay out so I can spray Lizard Skin on the floor and then cover that with Raptor liner tinted to the new color. It will be a Toyota color this time.

 

[afraptor22]

Body work...not fun. Lots of repetitions of apply filler, sand and apply again.

Shot the tub and new doors with etch primer. I figured the Raptor liner that's on there might need some help for the new Raptor liner to adhere. I realized I didn't have a spray gun for the Lizard Skin so I had to change gears and do the outside first. Hopefully it will be here tomorrow and I can finish the interior.

After that dried I sprayed the exterior with the Raptor color tinted with the final color. I still plan to spray over the Raptor so it's a uniform color and I can get that in spray cans.

The Raptor tint doesn't look exactly right but it will make a good base color to spray over and hide any spots I miss. Then I played Tetris in my garage and sprayed etch primer on the rest of the pieces/parts.

Some will get a coat of Raptor and some will just get a quick spray so the texture matches. Tomorrow I'll bolt them back on the tub while I'm waiting for my spray gun. Then I'll spray the inside with Lizard, Raptor and then finally the single stage urethane final color outside and inside. It better look uniform!