Putting the 80 Series Suspension onto the 40 Chassis is not the best option and you will find it a compromise and a PITA. The one linked above that belongs to Watrob was a huge compromise and he did non of it himself. It was based on an 77 FJ 40 Chassis that I had hot dipped for another project. The limitations are that the 80 Series stuff is designed around the 80 series stuff lol and if you don't have the constraints then why restrain.
I have been through this a number of times and my opinion is that the 80 Series chassis and Suspension is best left on the 80 series chassis. I have no limitations in regards to Fab and Engineering and when it came to my own forever build it was a no brainer to go with cut and shut 80 series chassis over a custom setup for one simple reason ...... on road handling and behavior . For anyone who has ever built a linked , coil over truck / buggy you will know what I am talking about and know damn well that they are a compromise and not the best use for Dual Purpose and are better suited to Heavier Offroad use as opposed to Daily Duties.
Not to mention the strength of the 80 series chassis and the usually rust free nature of it over the 40 ...
Now don't get me wrong there is nothing wrong with custom stuff I am just saying for a great dual use truck setup you are hard pushed to go past an stock 80 series setup and design. I have done a few swerve, land change, torsion and beaming and brake test under controlled conditions as required by several countries for DOT compliance and it is very eye opening how badly some stuff goes when you have a "New" driver in your truck who is out to test it not cover up shortfalls by talking up their modifications.
Anyway, enough dribble feel free to check out my build thread which is an 80 series chassis with FJ 43 body .
Happy to answer any questions you may have the 80 series conversion is very popular in Australia due to engineering and compliance limitations
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