FatherSonSJ45 Troopy

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Well looks like I’m in the two steps forward one step back phase of the project. After studying the crossmember and frame brackets I received, looks like I simply got the wrong frame brackets. Waiting to hear back from McKinnons cruisers, but pretty sure that’s the case. Bummer since shipping from Australia takes so long.

Also looks like I need the HZJ75 transmission mount that positions the transmission a bit off to the side. Probably explains why I couldn’t get the front driveshaft in because it was a touch forward of where it should be.
 
I think one with the side offset bottom studs is what I need:

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Here’s another question- how compressed should the front driveshaft be at ride height? I had mine both retubed and even collapsed as much as I could push it, I couldn’t get it quite short enough to install. Granted I only tried installed at the transfer case side first, but still seems like there should be a touch more play than that.
 
Kmehr said:
Here’s another question- how compressed should the front driveshaft be at ride height? I had mine both retubed and even collapsed as much as I could push it, I couldn’t get it quite short enough to install. Granted I only tried installed at the transfer case side first, but still seems like there should be a touch more play than that.
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Crack open the zirk, that’ll relieve the pressure enough to get it on. Little mess.
 
Little more progress today-

Put the painted steering linkage on, steering box and shaft. Did a quick and dirty tape measure alignment.

Got a little overzealous on my cutting for the radiator notch, so had to add a chunk back in. Have it tacked in place for now and will finish weld and paint tomorrow. Probably going to need a whole flap disc to fix my screw up, but it’ll turn out ok.

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More progress today. Got the core support welded up and painted. Added some rivnuts for the power steering reservoir. Should be ready to plumb the radiator and power steering tomorrow.

Swapped out alternators for an externally regulated unit. Man I’m flush on 12ht 2h alternators. Have two 24v units and an internally regulated unit if anyone is in need.

Did some figuring and my cross member brackets are 5 degrees tilted the wrong way. Apparently I have “short wheelbase” brackets stock, but I ordered the “long wheel base” kit since, ya know, it is. I’m going to be able to redrill the frame side.

Hopefully the last two fab items are mounting the vacuum res and the throttle pedal. I’m all ears on ideas on how to turn my linkage style pedal to a cable style.

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one option on the throttle cable is to do something like Redline does with the 60 series, though If I went this way, I'd need a longer throttle cable so I could loop around towards the driver's side and avoid the exhaust.

My other idea is to weld a little clevis to my upright section of my pedal rod and then fab up a plate to run the cable through bolted to the firewall.

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The redline bracket is the way to go in my opinion. They make a bracket for the 40 series already, I've used them a few times. And you could probably walk in and buy one being local. :)

That is a very sexy steering setup if I do say so myself. I am really happy with the HZJ79 column fitment.. thanks for being the gunie pig on that. @Chamba, you're next
 
cruisermatt said:
The redline bracket is the way to go in my opinion. They make a bracket for the 40 series already, I've used them a few times. And you could probably walk in and buy one being local. :)

That is a very sexy steering setup if I do say so myself. I am really happy with the HZJ79 column fitment.. thanks for being the gunie pig on that. @Chamba, you're next
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Oh man, I didn’t see a 40 series one, that’s definitely the way to go!
 
Ticking a few more things off. Got the frame brackets redrilled and they match the OEM crossmember angle, now just waiting on the right transmission mount, which is scheduled for delivery tomorrow. I’ll be so glad to hopefully close out that saga. To the future swappers- follow @duncanrm s advice and just get the correct bellhousing!

Next up was the throttle cable bracket. Sadly redlines doesn’t work for 81+, so I made my own. Design number two worked, though not very sexy. The issue I’m having now though is even after removing some sound deadening and the floor mat, I can’t get full throttle at the injection pump. I’m thinking my best option is to bend the pedal a bit unless anyone has a better idea.

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Cross member is fully in. Had to drill more holes and actually use a mount I already had. So waited on the hzj mount for nothing.

Radiator is plumbed and filled with coolant, though now I see my rear heater lines are leaking, so maybe that was premature.

Power steering lines are all run except one high pressure side fitting. One of the two I had had some screwed up threads, so waiting on that overnight.

Need to finish installing the drive shafts, get the clutch master replaced, bled and adjusted. Need to trim the inner driver fender a touch, Then the vacuum resvoir mounted, some sort of temp exhaust and I think it’s ready for a test drive around the block.

Will have plenty of small things left, like massaging the throttle pedal, vacuum lines (really been dragging my feet as I’m dreading that task), and some minor wiring. Also need to find somewhere to make a nice 3in exhaust. But getting really close to finishing phase 1!

Next will be suspension and brakes. Will do those together and while I’m at it going to send my injectors off for a rebuild/test, and will do a compression test. Probably should have done all that earlier on, but so it goes

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Daily log update:

Power steering lines finalized and had my oldest help bleed the system, engine off. Not sure it did much, but I’m nervous running the engine very long with nothing coming off the turbo. Don’t want to melt my engine bay!

Got the rear drive shaft in and the clutch line drained. Going to replace the master tomorrow and get my 5 yo to help bleed it.

Also working on and exhaust flange out of scrap steel. At a minimum want to get a dump pipe a foot away from the turbo so I can do a few test drives and get it to a real exhaust spot
 
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why not just make the exhuast yourself?
 
Daily update

Vacuum lines are sorted. Wasn’t as bad as I thought. Waiting on new lines to plumb the reservoir tank and brake booster.

VSV is swapped out for a 12V version and it starts AND stops with the key.

Coolant temp and oil pressure senders swapped out and wired up.

Trimmed my fender to clear the steering box. Wish I’d have left a bit more, but someday I’ll box it back in.

Sadly the clutch master the PO ordered is the wrong one, didn’t realize till today. The one installed looks original, so the correct one is on the way. Waiting to install the front driveshaft till I get that bled and sorted.

Shifter boots and exhaust are really the only items left before it’s ready for some shake downs! Should have what I need for exhaust tomorrow. We’ll see how far I can get in an afternoon. Really need to get back to my day job next week…

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