Build Georgia 1980 FJ40 Build Thread w/ Cummins R28 Diesel

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Which molle panels are they?
 
Polecat said:
Another vote for the Procar Rally, though I have the narrow, non-XL version. Everyone who sits in the them comments about how comfortable they are. (If you're an average or above width, I'd probably go with the XLs.)
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Do you have a tuffy center Cole box on your set up ? If so, why did you go with narrow vs. xl?? I am worried that since I have a tuffy box, the XL won’t fit.
 
Got the finished roll bar mounted. Not gonna lie, turned out better than I could have ever imagined.
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Troy Pusateri said:
Just spent an hour looking through your build….man, you have done A LOT OF WORK !! Well done sir. I am obviously going to be adjusting my time to completion from original 6 months to 2 years…that being said, I have about 8 months left, lol…we shall see. Or perhaps a new goal would be to have completed for my 50th birthday, which will be in Feb. 2026, lol.
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I too am targeting Feb. 2026 as that is also my 50th B Day !! Too funny. Where’s the thread for your build ??
 
Troy Pusateri said:
Do you have a tuffy center Cole box on your set up ? If so, why did you go with narrow vs. xl?? I am worried that since I have a tuffy box, the XL won’t fit.
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Yes - I have a universal 6 ½ in wide Tuffy center console. The sides of the seats touch the armrest, but it doesn’t feel too tight.

I went with the narrow because I don’t need that space. Worth noting - the outside dimensions of both the standard and XL seats are the same, so if one fits with a certain configuration, the other should too.

Hope that helps.
 
Troy Pusateri said:
I too am targeting Feb. 2026 as that is also my 50th B Day !! Too funny. Where’s the thread for your build ??
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My build thread is here:

forum.ih8mud.com

Builds - New Alaskan FJ40 intro thread

Greetings all. I've been lurking and stalking this forum for a couple of months since purchasing my first FJ40 and it's been incredible the amount of information and help that's available for those willing to ask and search. Thanks! As far as an introduction goes, I'm a mechanical engineer in...
forum.ih8mud.com forum.ih8mud.com

Enjoying seeing your cruiser come together! Would love that power train combo in my FJ40, but it's too spendy for me at this stage of life.
 
Got the custom made tool box / bear carrier that sits in the back of the tailgate. Super happy with how it came out. I tried pricing these out online, and they were a fortune…hit up a local fab shop, and the quality is excellent at about 1/4 the cost. Will be sprayed with the Raptor and modded a little to include tray system inside, etc.
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Got some Farkles added this weekend, and the front of the body. had to do a 1.5” body lift to accommodate the rock sliders, cause the front fenders were not fitting. Still, when I look at the photo from the front, I feel the fenders are drooping a tad bit, but everything has lined up perfectly. Anyone experience this? And if so, what was the issue/solution??

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Been a hot minute since ,my last post…been a hectic and crazy ass year…..some new pictures from last weekend…working out the final details on the complete and finished diffs, knuckles, disc brakes. Also, starting to work on the fuel tank, and seeing how to run a Dakota Dig dash to the OEM gas tank, with sending unit, etc. Hearing that there are issues with the Toyota OEM sending unit communications with Dakota’s gauges…Any insights would be greatly appreciated. Pictures for reference. Starting to get to the home stretch on this build, trying to have it finished NLT Feb. 18th…for my 50th. We shall see.
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Sharing the build progress videos here @Troy Pusateri .

I couldn't be more excited to get to build this for/with you, man!

Bummed I didn't film anything up to this point, but everything is getting filmed from here on out.

For those of you who read here, my name is Seb. I guess I'd call myself the "builder in crime" and assistant idea guy to help make this picture come together.

I'll be sure to share updates as I make new videos covering the build from now to when it's on the road. I am currently working on putting together some one-off suspension parts making Troy's dream FJ40 the only one in the world with said parts.

Feel free to roast me on the mediocre quality of these YouTube videos, it won't hurt my feelings because I've never done it before :)

 
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jim land said:
What is the modification to the suspension that make it special ?
Why is the tie rod upside down ?
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@jim land

Current dampers (shock absorbers) on the 40 are to get it dialed in, running and driving.... I am putting together a set of custom length dampers for the 40 once we have corner weights and total GVM; In addition we are replacing the OEM bump stops that one would typically run with a pair of hydraulic bump stops for secondary damping.

These dampers and bump stops in particular don't exist on the market as a readily available option for purchase.

Not pictured is an 80 series box that I own (we have decided to forego the OEM box and relay rod).... I have the tie rod ends oriented that way to play around with drag link angle and clearance to the tie rod that I will make as a replacement for the 80 series hardware.

This is all currently on there to figure out what height pitman arm I can get away with and getting that tie rod/drag link set accordingly.
 
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