Builds FJ40 buggy re-fresh (1 Viewer)

[too tall]

I love how that looks.

Why the multiple bolt patterns in the winch plate? Changes over time or are you future proofing?

I found that plate in my junk steel pile. The holes were from previous projects/ideas. I was going to make a new piece, but It didn't look too bad for what I wanted so I used it.
I have quite a steel collection and hang onto odd/what you might think would come in handy in the future type scrap pile. Bad habit and kind of like hoarding in a sense but I end up using most of it or throw it eventually. I hate collecting it but the cost of steel and the amount of things I build that require special pieces of steel outweighs the inconvenience.
I often have friends stop by and peruse my collection or outright just ask and most of the time I have something that will work for what they need.

 

[too tall]

Got the rad inlet changed and started putting some stuff together. Thinking about aesthetics now, made the expanded steel grill fit the narrowed cowl and re-centered the toyota emblem. Also added the safety hook for the hood to the inside of the cowl. still have to decide how I'm going to hold the hood down. the hooks on the side would get ripped off immediately so whatever it is it'll have to be inside.

 

[cruisermatt]

That’s looking really good. Are those 2.0 or 2.5 air shocks? Interested to see how they do with 3FE on them.

 

[too tall]

The Air shocks are 2.5's x 16" . They ended up at 5.25" showing at purposed ride height. Hopefully get the steering stuff worked out in the next week or so, then nitrogen and I should have a roller. I am interested to see how they'll hold it all up as well.

 

[too tall]

Mounted and plumbed the radiator. Used T-bolt hose clamps for everything. Motor on the winch wasn't working. Swapped it out for another I had and got it working before I installed it. Have to figure out where I want to mount the contactor, I'm leaning toward mounting it to the motor itself just to keep it simple and close for wiring.

Going to pick up some 1/2" fine thread bolts and nylocks for the air shocks. Also have to grab the heims and material to build the steering links from the arms to the ram.

 

[too tall]

Came up with an idea to mount the orbital. Ended up the steering column was too short but the lines from the orbital were getting into the intake so pushing the orbital itself out from under the dash seemed like a good way to achieve better steering wheel position. You can adjust the tilt with tools. It's pretty comfy now, still gotta bend the shifter a bit. I can get a better pic of the orbital mount if anyone wants to see it.

 

[too tall]

Got the steering links made. Still have to make the double shear tabs for the steering arms. Then I have to build the UHMW pucks to limit the ram and plumb it all. There is an event at the end of march that I'm going to try to make so I'm going to have to get a bit more serious about getting finished. Setting up the new gear set for the rear end tomorrow and hopefully finishing off the rest of the steering stuff. Almost time to make a list of stuff yet to do. Up until this point there was too much to do to start a list but It's getting closer.

 

[too tall]

Been pretty busy but got a few things off the list.( I actually have one now) Not many pictures though. I'll try to get some more up later. I got the brake master and clutch master worked out. I'm going to run an 80 series non abs brake master in manual form. I managed to increase the pedal ratio to 7:1 Hoping it'll be enough. I had to reinforce (replace) the firewall where the booster used to mount and lengthen the pedal while increasing the ratio. I think its going to work. There is not as much foot room on the drivers side as the engine takes up some of that space now so the pedals are closer together. More pics later of the setup.
I also worked out the intermediate shaft for the front. I used an old pinion and cut the gears off then machined it to fit inside a piece of 2".250 wall DOM so I could make the flange removable. I had to machine the outside to fit into a pillow block bearing and the tail down to fit inside the casting of an early cruiser u-joint housing. It fits and spins nicely . I made it an interference fit and pressed it into the DOM after I cut 3 slots 120* out from each other in order to plug weld it in. The oil seal surface on the flange fits the inside of the DOM perfectly I set the depth so that its all sandwiched together when bolted up. I'll remove it and get some pics of the finished shaft for later.
I am trying to get stuff done quickly now so pictures aren't my biggest concern but I'll try to keep taking some.

 

[too tall]

More pics of the shaft and bearing in place. Still have to weld out the holes and the base of the u-joint. Going to drill and tap the crossmember for the bearing and add nuts to the underside to lock the bolts in.

 

[GLTHFJ60]

That's sexy.

 

[too tall]

Too Busy to take pictures lately. Only got this one. Got the battery tray made/painted/installed, made a rear d-shaft and found one that will work in the front. I'm using early minitruck slips on late model cruiser shafts so I get the bigger u-joints at the diff but get more angle out of the early mini truck joints at the t-case ends. I'll try to get more pics of it. I'm going to skip painting anymore body stuff at this point as I might be able to finish enough to wheel it next weekend. Not sure just yet, but with a bit of help and some good luck it might happen. Glad to have big push regardless.

 

[Ditcherman]

Too Busy to take pictures lately. Only got this one. Got the battery tray made/painted/installed, made a rear d-shaft and found one that will work in the front. I'm using early minitruck slips on late model cruiser shafts so I get the bigger u-joints at the diff but get more angle out of the early mini truck joints at the t-case ends. I'll try to get more pics of it. I'm going to skip painting anymore body stuff at this point as I might be able to finish enough to wheel it next weekend. Not sure just yet, but with a bit of help and some good luck it might happen. Glad to have big push regardless.

View attachment 3865844

That’s a trip to see a battery mounted like that.
AGM for the win.

 

[too tall]

Got it running today. 3 days left before I'm hoping to wheel it. Gotta drive it around and see what's up but the motor sounds pretty good without the exhaust on . My sons helped me on the weekend with door skins and floors and a new fuel cell. Also got the centre windshield bar modified . Spent the last two days mostly wiring. Need an exhaust and a skid plate are the majors. Still need to plumb the brakes. Steering feels good, turns very sharp. Stoked to drive it.

 

[Gimme a 60]

Got it running today. 3 days left before I'm hoping to wheel it. Gotta drive it around and see what's up but the motor sounds pretty good without the exhaust on . My sons helped me on the weekend with door skins and floors and a new fuel cell. Also got the centre windshield bar modified . Spent the last two days mostly wiring. Need an exhaust and a skid plate are the majors. Still need to plumb the brakes. Steering feels good, turns very sharp. Stoked to drive it.

View attachment 3869798

I’m super impressed with the rig, and what you have done with it. It makes me smile to hear that my 3Fe is running again.

Post up some wheeling videos when you can. I wanna see that thing work.

 

[EWheeler]

The internet makes a big world feel small. How'd she do?

 

[too tall]

Ha Ha , it did pretty good. I lost my brakes just before that flop. Was pretty steep and I was trying to keep momentum then all of a sudden... on my side almost falling off that rock. As far as shakedown runs go, it was pretty successful. Feels more stable and climbs pretty good. I'll try to get some video next time I'm out. I usually just stick my phone in the glovebox of my tow rig. Also hard to video myself while driving. Might go wheel this weekend up some trails that we can drive from my house to without towing. Still haven't had time to finish sheet metal and paint but glad to be out wheeling.