just another 60 series with an 80 series frame .. (1 Viewer)

[4runner2FJ60]

Just watched this the other night. Stated and shown. But they also say they add some to the rear of the frame for the extra length on the 60 rear.
interview link at OVERLAND WEST

 

[cruiserpilot]

@TRAIL TAILOR do you offer kit for cutting 80 frame down? How many inches does it need?

 

[4runner2FJ60]

This is just one of many on MUD.
Thread 'Mad Max - Another 60 on 80 (plus diesel goodness)' Mad Max - Another 60 on 80 (plus diesel goodness) - https://forum.ih8mud.com/threads/mad-max-another-60-on-80-plus-diesel-goodness.1347721/

 

[4runner2FJ60]

Thread 'Another FJ68 Build' Builds - Another FJ68 Build - https://forum.ih8mud.com/threads/another-fj68-build.912980/

 

[Swissmat]

This is just one of many on MUD.
Thread 'Mad Max - Another 60 on 80 (plus diesel goodness)' Mad Max - Another 60 on 80 (plus diesel goodness) - https://forum.ih8mud.com/threads/mad-max-another-60-on-80-plus-diesel-goodness.1347721/

thanks for sharing! great build

 

[Swissmat]

Next floor panel is in, here are the steps I take:

.

1. Measure existing contour --> 2. create 3d model to 3d print a press die

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3. figure out where the beads have to go --> 4. mark and drill holes for press die alignment pins

.
5. use a 20t press to squish metal into submission (to create the longer beads I reversed my press die)

 

[Swissmat]

6. one side pressed, now locate other two holes and go again --> 7. use clecos to place new panel

8. and 9. keep adding smaller bead pieces or wider bead pieces (using TIG to weld it all together)

10. two finished panels with overlapping seam (seems to be what was original in my 1985 BJ60)

 

[Swissmat]

11. final placement, scribing --> 12. fitting and welding

13. coat of paint .. good (enough) as new ..

 

[tmxmotorsports]

Uhhh that's dope ass hell one day I'm gonna get smart enough to work a 3d printer awesome work!

 

[Rabrownmkiv]

Beautiful work, definitely inspiring. Loving this thread.

 

[JamesR]

I'm in awe!!

 

[mongoose2231]

 

[lelandEOD]

Am I to understand you are making sheet metal dies from 3D printed forms?

If Canadian's are actually this smart, I'm going to have to jump on Signal and let SECDEF know we should call off the invasion.

 

[Swissmat]

Quick update .. as mentioned before I've been working my way forward .. read @lelandEOD's thread and too note of how the 80 series frame interferes with the BJ60's tub .. I am not entirely sure but the depressions where the seat belts bolt in maybe? Anyways, they had to go .. so I decided to do that now .. I've been scavenging body parts from a donor FJ62 so could graft in bits and pieces and make up some of the pieces that were missing ..

 

[Swissmat]

 

[Swissmat]

time for the floor pan ..

turned up a couple of locator pins, used a strip of the original floor to locate the patch panel .. worked a treat ..

mostly stitched in .. lots of work left to do yet tho ..

 

[Swissmat]

also realized I had some work to do on the rear seat belts .. my donor FJ62 came with three point harnesses for the back .. I had never bothered to check whether the BJ body had the necessary cutouts .. well, it did not .. thankfully there are many great threads on here that show what requires doing ..

I just roughly held the seat belt reel in place and cut crudely around it .. will go back with a file to blend corners and sharp edges later ..

on the right side I'll have to come up with an alternate routing for the gas tank release cable .. I believe it went through that angled opening with a grommet (if memory serves) ..

 

[Swissmat]

I turned up an M12 nut, welded it to a washer and drilled holes from the outside through which I welded the nut to the body .. seems to have worked okay-ish

final-ish product for now ..

 

[lelandEOD]

Unbelievably awesome work. Thank you so much for documenting your efforts so well with these photos. They will really come in handy when I get to several decision points.

 

[Swissmat]

ok update time .. I apologize (in true Canadian fashion) for not providing you guys with more entertainingly diverse content, but all we have again is more rust removal and metal replacing .. I promise it'll eventually progress to other stuff .. Anyways, enjoy the pictures ..

Used my laser cleaner to clean up the area where the support beam goes and then used self-tappers to pin it in place (did paint underneath)

Plug welded top and bottom .. still miles of grinding needed .. although I am not going overboard with the 'blending in' as it'll get epoxy primed and bedlined underneath and epoxy primed and sound insulated up top ..