Family haulin' FJ60 ********************************************************************************************************** These are the main points of a group of posts. (NOTE: These no longer work due to the forum software update) posts 1-30... FJ60 tear down and 2F engine pull, cut up stepvan and cummins 4bta engine pull posts 31-60... rear frame channel removal and boxing, hydroboost adapting, rear disc idea, 203 tcase disassembly, leaf spring painting and mock-up posts 61-90... Transgo 4L80E-3 manual shift kit install, rear spring hanger welded, 203 GRB to 4L80e adapted posts 91-120... Jerry Nichols No. for 203 doubler to splitcase adapter and assembly, front spring placement, tcase rebuild, drivetrain mock-up (4l80e to 203 to splitcase) posts 121-150... front and rear springs mounted, fix 4BT killer dowel pin (KDP), 4BT cleaning and painting, turbo repair and pyro probe placement, LED dash lights, 4L80e to 203 mated, spectrum coating posts 151-180... rear axle mock up, 203 drilled/tapped, 4BT and 4L80 connected, 4BT placement, clearance and engine side mounts, downpipe start posts 181-210... frame side engine mounts, tranny crossmember and mounts, Art Carr shifter mount, intercooler mock-up posts 211-240... Tranny cable connected, intercooler to radiator mounts, doubler/tcase operation and install, rear axle perch welded, front/rear ubolt plates, front axle mock-up posts 241-270... front axle mounted, dual battery mock-up and trays, bum turbo, mech water temp gauge placement, dual fuel filters, rear disc brake install, AC compressor placement idea, fixed and improved turbo with link, throttle cable hook-up, front axle caster adjustment, front diff guard and axle truss, hydroboost and brake MC install, power steering box tap for ram assist posts 271-300... Wheel spacers, front axle shims installed, Aussie locker in front 3rd, completed downpipe, front axle assembly and longfield super 30 set installed, Marlin High Steer, hydroboost and power steering hoses converted to AN, overflow and PS fluid reservoir mount, brake lines, heater hose routing, lower radiator hose, alignment, intercooler routing posts 301-330… rear weather strip lip fixed, 4l80 rebuild posts 331-360… rear shackles lengthened, doubler/tcase shifters, rear shocks, front shocks and hoops posts 361-390… fender skirts, electric vacuum pump and regulator for tranny modulator, sound deadening engine bay. posts 391-420… doubler/tcase shifter linkage, vacuum regulator install, LED dash lights glowing posts 421-450… 38's mounted, rear quarters trimmed, reconfigured front packs, minor flex posts 451-480… fuel pump and cut-off solenoid, wired up t.converter lock-up, spiral baffle in downpipe, reworked lower radiator hose adapter, tranny cooler installed posts 481-510… first major trip report, contour fan installed using spal controller, baffle removed from downpipe and downpipe heat wrapped, exhaust routed out back, 366 (3200rpm) govenor spring installed, intercooler pulled and cleaned, rig ramped for flex, front drive shaft started posts 511-540… rig gets named, front long spline driveshaft finished, new water temp sender, rear body mount cut for clearance, rear bump stops, first wheeling pics @ TSF, new amsoil air filter with 4" intake. posts 541-570… Modify Hydroboost for 1 1/4" master cylinder, bench bleed MC, heat shield for air filter, 8 groove pully alignment on CS-144alternator install, high mount rear speakers, hydroboost with 1 1/8" MC install from chevy astrovan, front fender trim posts 571-600… lower body line textured and painted, gutter reseal and paint, boost gauge signal line moved, battery straps, hydroassist ram install posts 601-630… wastegate signal line capped, beach wheeling pics and vid, mountain wheeling pics and vids, broke front driveshaft, posts 631-660… removeable rear mud flaps, rebuilt front driveshaft with stronger slip-spline, Hilift demount plate for breaking tire bead from rim, tried out BB for internal tire balance, Coretrax tie down strips from rear cargo area, TSF Cruise the Woods pics, posts 661-690… rear seat back painted, went back to 44mm inducer on my turbo, wastegate tied shut, made 3" intake for turbo mod, extended front/rear bump stops posts 691-720… intercooler and tubing pressure test for leaks, replace passenger side motor mount, made new tcase shifters and extended the levers, console 10" sub box, heater core replacement and duct cleaning, interior firewall insulation, posts 721-750… boost leak troubleshooting (gaskets and o-rings), tire grooving, fabbed steering stops, custom intake horn, snow wheeling pics, front shock repositioning, posts 751-780… 42's (yeah right!), rear shock repositioning, reworked hydro assist mount and clamp, reseal hydrobooster, initial rocker cut and slider mock up posts 781-810… tube bending for sliders, pics of inside of rockers, posts 811-840… sliders mounted on the frame, car crushing pics and vid, smaller lower steering joint for shock clearance, rear bumper 1/4 sliders, posts 841-870… rear bumper mounted, mudflaps fix and remounted, radio flyer welding cart, bilstein 5150s leaking seal, posts 871-900… skid plate frame brackets, CB radio info, TSF wheeling testing out Dirtgypsy's SOA, bending tube for front bumper, posts 901-930… front drive shaft lengthened/retubed, johnny joint and antiwrap bar links, antiwrap bar axle brackets, Poly performance rear axles installed, aussie locker installed in rear, new front axle shock mounts, posts 931-960… Bilstein 7100s mounted, Brokenparts front bumper mounted, rear 1/4 protection bent and mocked, line lock swagelok ball valve and brake line routing, skid plate slapped together, posts 960-990… Rubicon 2009 trip report, Antiwrap bar, posts 991-1020… Front bumper phase 1, massive tire failure, posts 1021-1050… TinyTach install, better boost line fitting, HE351 Holset VGT turbo cleaning, H1 double beadlock rims with pressed centers and rock rings, Cobra 18 WX ST II CB install in dash, posts 1051-1080… H1 rims mounted, posts 1081-1110… Junction block for power, pic of Dora in 4WD Toyota Owners Mag, posts 1111-1140… CB antenna mounted on front fender, skidplate mods, CTW'09 pics and video, Rubicon Part 1 video, sloppy windshield wipers fix, resealed heater core, aluminum rear interior 1/4 panel, posts 1141-1170… Rubicon Part 2, Rubicon Part 3, lower coolant intake port moded, Rubicon Part 4, Rubicon Part 5, posts 1171-1200… Rubicon Part 6, Rubicon Part 7, Rubicon Part 8, Rubicon Part 9, posts 1201-1230… Reworked T.converter, fatigued crossmember, revised crossmember and mounts, revised shifter linkage, tranny failure and replacement, Rubicon Part 10, posts 1231-1260… Electronic tranny control box and circuit board, line-lock leak fix, new belt tensioner, posts 1261-1290… ********************************************************************************************************** Alright fellow forumonians, I've got a project underway and it's time to start sharing. I've lurked here for a while and have absorbed much knowledge, so now it's time for me to show what I've done with that collective knowledge and put it to good use. So here's the plan, and like all good plans the important part will be adapting to what comes my way. Cummins 4bta (intercooled) manual 4L80e 203 to splitcase doubler SOA 38s hydroboost hydroassist larger fuel tank ***decided to run the cruiser tank instead 10/07*** and some other stuff like: some kind of insulation/liner for interior floor/firewall custom bumpers fender trimming marlin hysteer arp knuckle studs longfield super 30 set Intended use is a capable all-rounder for trips, DD activities, some towing, and a whole lot of wheelin! It's been almost a year since I sold my last truck/wheeler and the offroad videos on youtube just aren't satisfying my need for the great outdoors, so I'm pushing forward on this project. I've got another kid coming soon so having more room to haul the family became a necessity since my wheelin' "photographer" pulls double duty as a mom. So lets get some pics in here since all of us seemed to be into the picture books as kids rather than the story books. I'll have a bunch of pics to start with until I get caught up to where I'm at. That's what I started with. rear axle out grill and headlight out Front axle out Yup, my seals were shot, bearing grease should be thicker than that. It's being rebuilt anyways. the brakes still worked fine with that line smashed (wasn't me) looks good inside it's floating now prepped for cut n' turn this is where I'm at with the front axle so far goodbye bumper brackets and spring hangers starting to collect some scrap next I started working on the springs I'm planning on using. The rears will be the chevy 63 inchers and the fronts will be a hybrid pack using a ford ranger rear main leaf. I used a 3 leaf plus overload on a ford ranger I built up and I was happy with the results so I'm going to do it with the cruiser since it's got such a big butt (plenty of room to mount). I have a 4 leaf pack that I'll thinking I'll add one more leaf to start out with and tune from there. The ranger main leaf is 58 inches long so I have a little work to get them under the front, but those flexed pretty well too. I'll just have to build up the pack since the 4bta is heavy in the mid section. I wire brushed and painted each leaf. The chevys are in the front and the ranger main leafs are the furthest away. front spring mock up. The plum is the original center and since the holes are offset on the ranger springs I figure the axle will move forward 1-3 inches. I wanted to move the axle forward so this is good. I'm doing a shackle reversal so I don't snag a shackle when approaching obstacles and the long springs will push the mounting point out to the very front. the rear mount will be tricky since I plan on going through the frame to keep the SO low and that point of the frame just starts to curve out. The crossmember will be removed and relocated. burned in a front channel and mocked up the spring hangers. So I bought a stepvan for the 4bta and have found that the frame has a lot of steel I can use for fabbing parts. Those hangers were made from that frame. Not bad for living in the recycling age. you can see the plate I put in there to distribute the weight to both crossmembers on the front of the cruiser. Probably over kill but diesels do produce some good torque. decided to commit and burn the hangers in. I'm using flux core since I'm doing this outside and am newer to welding than some of you so I usually end up touch-up grinding/flapper wheeling my welds since they aren't the nicest to look at. Paint usually improves the appearace some, or hides it in my case. I'm using a Ready welder II and really like it. Great for portability since I built a little cart to haul my batteries around with. Future plans include dual batteries in the cruiser and a connector wired in for my welder for trail repairs. I'm out of time so I'll get more pics up tomorrow. Once I'm caught up, pics will probably come more on a weekly basis. I usually get 2 solid days to work on the cruiser on the weekend and after that I upload the pics. Glad to finally join the ranks and build something I hope to be proud of.