The objective.
To build a bj40 converted to a hd-t or hd-fte driven dual case four door on a fzj-80 chassis.
I am posting this here as I am hoping to do a fairly significant build and am looking for tech help and process help as it goes along.
To do so in a class setting with three students who are incredibly apt and un-experienced.
We need to make a scomprehensive as possible of a list of supplies needed as most get shipped here from the USA and take six months to arrive. There is no Auto Zone to run to for the missing bolt...
To create a off-road rig that is built for these roads on a limited budget.
The back story....
I am originally from Michigan but lived in Dallas, TX for 9 years where I met my wife. We recently moved to Papua New Guinea where I work for a mission organization. If any of you are familiar with this country you can understand the insanity that is our roads. I will post some pics of my travels here later when the internet bandwidth is better.
One of my jobs here is teaching the citizens from various churches in the country technical skills. The main class I am responsible for at the moment is mechanics along side of maintaining and repairing the various mission vehicles and generators etc.
I have been teaching the guys here how to repair and maintain the assundried vehicles that come through the gate, most of which are Patrols or Land Cruisers. We have also been doing basic mods to them using available parts and pieces so that they come back to us less often than every time driven. Insurance companies say the average lifespan of a vehicle in 17 months (up from 8 months two years ago), and they attribute this to the quality of roads.
With the roads here being what they are I have been hatching a plan to do a build that would be demo of what the guys in the class are capable of as well as provide a show and tell of sorts for them as a way to get work modding vehicles for others here. In the end we would sell the vehicle as a fundraiser for the class as we are a non-profit- donation based organization.
In my head what is coming out is a bj40 converted to a hd-t or hd-fte driven dual case four door on a fzj-80 chasis.
Over time I have accumulated a variety of un-fixables, want to fixables, wrecks parts and pieces. I currently have in various forms of condition the following available to the class.
2006 fj-79 troopy frame new
1999 hdj-100 hd-fte auto ifs 44k km rolled and body ruined but complete running drivetrain
1995 hzj-80 5spd in good running condition, tree fell on it
1993 hdj-80 5psd non running repairable condition
1991 fj75 troopy frame and body, no interior or drive train. with two rolled tubs and a good tub needing some roof repair.
1987 hj60 with the 12-ht 5spd in a tired but running condition
1984 bj40 2h 5spd in a rusty but good running condition
1981 bj40 body tub
1979 fj45 2f 4 spd in a rust free but non running condition
1979 bj45 body and chassis.
1977 bj40 body and frame
1974 bj40 3b 4spd in excellent running rust free condition.
These are the ones sitting here at my disposal ( i own most of them from trades for work I have done for people who did not have funds so I took something they had in exchange for what they needed. I have more than this but most is probably not worth mentioning.
So what I am thinking of doing is taking my three best students and beginning a build that will teach them body work, welding , fabrication, repair, and off-road modification.
the parameters that are mandatory are the following
It must be.....
Maintainable with parts found here.
Built out of what we already have for the most part.
As bullet proof as possible.
As cheap as possible as this is all donation based.
Not a cheap junker but solid!
Some of those things may not seem to fit together but they need to. This is not a show truck but rather a functional truck. I do order supplies from the USA and there is a shipping container coming her mid August so I can get some stuff from the USA as it is available and needed ie lift kit, rims, tires, weather striping etc. Cost here is insane ie a used in medium condition diff is about $3000., which is why I have the stack I do, people cannot afford to buy parts.) So I will be ordering stuff from the US as I get the list together.
I will be posting my thoughts and questions here and hope for some solid feedback. I am excited to see this going forward and have read many builds, topics, rants and raves here and appreciate any help that can be given. As it takes me six months to get supplies please help me make a complete list of all needed items for the build before hand as after is going to be a bit late.
Next post, the build ideas.
Thanks for reading and for your help ahead of time.
To build a bj40 converted to a hd-t or hd-fte driven dual case four door on a fzj-80 chassis.
I am posting this here as I am hoping to do a fairly significant build and am looking for tech help and process help as it goes along.
To do so in a class setting with three students who are incredibly apt and un-experienced.
We need to make a scomprehensive as possible of a list of supplies needed as most get shipped here from the USA and take six months to arrive. There is no Auto Zone to run to for the missing bolt...
To create a off-road rig that is built for these roads on a limited budget.
The back story....
I am originally from Michigan but lived in Dallas, TX for 9 years where I met my wife. We recently moved to Papua New Guinea where I work for a mission organization. If any of you are familiar with this country you can understand the insanity that is our roads. I will post some pics of my travels here later when the internet bandwidth is better.
One of my jobs here is teaching the citizens from various churches in the country technical skills. The main class I am responsible for at the moment is mechanics along side of maintaining and repairing the various mission vehicles and generators etc.
I have been teaching the guys here how to repair and maintain the assundried vehicles that come through the gate, most of which are Patrols or Land Cruisers. We have also been doing basic mods to them using available parts and pieces so that they come back to us less often than every time driven. Insurance companies say the average lifespan of a vehicle in 17 months (up from 8 months two years ago), and they attribute this to the quality of roads.
With the roads here being what they are I have been hatching a plan to do a build that would be demo of what the guys in the class are capable of as well as provide a show and tell of sorts for them as a way to get work modding vehicles for others here. In the end we would sell the vehicle as a fundraiser for the class as we are a non-profit- donation based organization.
In my head what is coming out is a bj40 converted to a hd-t or hd-fte driven dual case four door on a fzj-80 chasis.
Over time I have accumulated a variety of un-fixables, want to fixables, wrecks parts and pieces. I currently have in various forms of condition the following available to the class.
2006 fj-79 troopy frame new
1999 hdj-100 hd-fte auto ifs 44k km rolled and body ruined but complete running drivetrain
1995 hzj-80 5spd in good running condition, tree fell on it
1993 hdj-80 5psd non running repairable condition
1991 fj75 troopy frame and body, no interior or drive train. with two rolled tubs and a good tub needing some roof repair.
1987 hj60 with the 12-ht 5spd in a tired but running condition
1984 bj40 2h 5spd in a rusty but good running condition
1981 bj40 body tub
1979 fj45 2f 4 spd in a rust free but non running condition
1979 bj45 body and chassis.
1977 bj40 body and frame
1974 bj40 3b 4spd in excellent running rust free condition.
These are the ones sitting here at my disposal ( i own most of them from trades for work I have done for people who did not have funds so I took something they had in exchange for what they needed. I have more than this but most is probably not worth mentioning.
So what I am thinking of doing is taking my three best students and beginning a build that will teach them body work, welding , fabrication, repair, and off-road modification.
the parameters that are mandatory are the following
It must be.....
Maintainable with parts found here.
Built out of what we already have for the most part.
As bullet proof as possible.
As cheap as possible as this is all donation based.
Not a cheap junker but solid!
Some of those things may not seem to fit together but they need to. This is not a show truck but rather a functional truck. I do order supplies from the USA and there is a shipping container coming her mid August so I can get some stuff from the USA as it is available and needed ie lift kit, rims, tires, weather striping etc. Cost here is insane ie a used in medium condition diff is about $3000., which is why I have the stack I do, people cannot afford to buy parts.) So I will be ordering stuff from the US as I get the list together.
I will be posting my thoughts and questions here and hope for some solid feedback. I am excited to see this going forward and have read many builds, topics, rants and raves here and appreciate any help that can be given. As it takes me six months to get supplies please help me make a complete list of all needed items for the build before hand as after is going to be a bit late.
Next post, the build ideas.
Thanks for reading and for your help ahead of time.
