Builds "Life Changer" FJ40 Build

[RockTactics]

I have been building 4x4's with my family and friends since I was little. I bought my first rig when I was 12 with my yard mowing job (1977 Scout). I spent 4 years building the scout until I got my license at 16. My Dad was an amazing teacher. That experience had me hooked. I have never left a rig alone after that.


Fast forward to 25 years old

This was the beginning! 1973 FJ40 sat for several years.

When I started I didnt have a good place to work on the FJ40, didnt have any money, and did things because it was cheap or easy not because its how I wanted it in my mind. I have always built everything with a grinder, hand tools, and in the gravel. I have always tried to think outside the box, and modify everything on a limited budget.

Things have changed for me. I still am on a pretty limited budget, but I have a pretty decent place to work, and I have access to a lot more tooling.

This will be a slow build. I am buying tools, and making tools in the process of this build. I am in no hurry I want this a certain way, and I want to make as much as possible.

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I comp cut it, spring over lift with dakota springs, dana 60's, H1 wheels and bald 39.5's

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I didnt get much work done on the Cruiser for a while because I was saving for a wedding. We got married and soon after bought our first house.

I finally got the garage I have always dreamed about. I collected some tooling and had to wait around until I could wire the garage.

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To make a long story short I started building a ton of stuff for other people. I always dreamed about selling off road parts when I retired. I read a quote one day that said "Instead of dreaming about what your gonna do when you retire figure out a way to do it now and make a living doing it" This was my Life Changer

My FJ sat like this for quit a while. I was building stuff for other people and developing a product line. I wanted my own products on my rig so I decided to tear the rear out and instal one of our adjustable leaf spring kits. Me and the wife started talking babies and I figured I would need to build another cage that is more family friendly.

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I kept looking at everything and decided I wouldnt be happy unless I started from scratch.

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"WE HAD A BABY BOY"

 

[RockTactics]

I started drawing up pieces to build the entire thing.

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On my way home from the shop!

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Started the front bumper! The bumper will also house the spring hangers. I am keeping this rig leaf sprung and full bodied.

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Building the spring hangers that will be frenched into the bumper. The tube section of the frame will also share the same mount.

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Front bumper with dual recover points!

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Starting the good stuff!

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Setting the body on to work on the rear section!

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Cage work!

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Doing the final welding on the main frame section.

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All strapped back down!

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Sneak in a shot of the new Helper!

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[RockTactics]

I got the body sitting back on the chassis. The Body will now become part of the chassis. The cage is part of the structure and I am using the body in some places for extra support to keep it as family friendly as possible.

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Starting the front!

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I am doing a little mock up with the LS!

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So I came to a stand still. I messed my wrist up really bad and had to have reconstructive surgery on it. So I started drawing pieces for the Cruiser so when the time came I would be able to make them.

All the pieces to my exhaust!

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I am gonna build my own Axle housings so this is just drawing everything up.

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Coming up with the LS alternator/power stearing relocator!

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[The Phoenician]

subscribed

 

[RockTactics]

When building this I wanted to keep everything as low as possible with the ability to clear 40's. I sat the body down over the frame 3 inches lower than stock. I need to run 14" travel shocks. with a low stance and need to run a 14" travel shock it puts me in a tight spot. I dont want anything coming into the cargo space in the rear. I dont want anything that my son can get his fingers pinched in.

I decided to run a cantilever setup. There is performance advantages to this as well as packaging advantages. I am gonna run a 1.5 to 1 ration cantilever so I can have a 10" stroke shock parallel to the ground with a total of 15" travel.

This is the design stages.

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I still need to finish machining the bearing housings and I will finish building the cantilevers.

I was given the opportunity to build my own shocks. My buddy Dave at DT Machine has been building some shocks and air bumps on a small scale. I talked him into letting me build my own in stages. I am gonna try a couple different things that will make tuning easier. This is the start. I will be finishing the rear shocks in the next few weeks.

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[RockTactics]

subscribed

Thanks! I am slow but I hope everyone enjoys this project.

 

[hman913]

You made it over here too huh? Always enjoy watching your work progress.

 

[RockTactics]

You made it over here too huh? Always enjoy watching your work progress.

Yea, I have been lurking for a while and know a bunch of people dont go to pirate. I figured I would put both projects over here and see if I get any feedback for my FJ45 build. Im building a complete line of parts that are for the closer to stock crowd. I started tearing it down yesterday and I am making some stuff as we speak.

Looks like we have a few guys on both!

 

[hman913]

Looks like we have a few guys on both!

Like you said, different crowds

 

[CreeperSleeper]

Good to see you over here, RockTactics! I really should get off my butt and start working on my 40...

 

[GLTHFJ60]

"Instead of dreaming about what your gonna do when you retire figure out a way to do it now and make a living doing it"

Well s***. How am I going to do that?

Good work man, keep it up!! Looking forward to what else you come up with.

 

[Tapage]

Well s***. How am I going to do that?.

I was thinking exactly the same plus .. that level of fab .. well I guess I will have another chance ( in another life ) to do that ..

 

[RockTactics]

Good to see you over here, RockTactics! I really should get off my butt and start working on my 40...

Well s***. How am I going to do that?

Good work man, keep it up!! Looking forward to what else you come up with.

I was thinking exactly the same plus .. that level of fab .. well I guess I will have another chance ( in another life ) to do that ..

Thanks guys. I am happy to be here. My heart is in Toyotas and this sight sure seems the same.

 

[RockTactics]

I have been working on something for a while and havent shared it with many people until today. There is a mid road need in the 4x4 industry for bump stops. It seems that everyone wants air bumps but not everyone can afford them. The rubber and poly tear and break down easy in hard wheeling. No one has offered anything in a variable rate similar to air bumps at a low cost.

There is many higher speed advantages to air bumps. I wanted to create something that acted the same and could be mounted in a bump can, that could be mounted in the exact location and survive until someone wanted to spend the coin on air bumps. The other nice thing about bump cans is you can have spacers to tune heights.

I have found a place that is one of 2 in the world that cold forge a molecular structure "Thermoplastic Elastomer Maximized". this material delivers load capacities of up to 10 times that of rubber bumps and elastomer while significantly prolonging operational life spans up to 5 times longer than steel coil springs, 10 times longer than rubber bumps and 20 times longer than urethane bumps.


So today the first pieces are ready for real live testing on a vehicle. 2.25" compression bump stop. The first 1.75" of compression starts at zero and goes to 600 pounds allowing the axle to slow before bottoming out. The last .5" increases beyond what a 5000 pound vehicle would achieve in any terrain. The slowing of the axle makes it easier to control the vehicle at speed because there is no longer a sudden change in handling due to hard impact .

I will have the tested numbers on the other rubber and poly stops in the next couple weeks to compare.

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[UZJ40]

Awesome build! Are you going to blast and powder the frame and body as one unit?

 

[RockTactics]

Awesome build! Are you going to blast and powder the frame and body as one unit?

Thank You!
I am gonna have it blasted and painted as one unit. My buddy is a painter so he treats me right. I am gonna do a stealthy metallic charcoal grey with flatener in the clear. Then the chassis will be sprayed with a glossy finish. I hope it looks good when done.

 

[GLTHFJ60]

I have been working on something for a while and havent shared it with many people until today. There is a mid road need in the 4x4 industry for bump stops. It seems that everyone wants air bumps but not everyone can afford them. The rubber and poly tear and break down easy in hard wheeling. No one has offered anything in a variable rate similar to air bumps at a low cost.

There is many higher speed advantages to air bumps. I wanted to create something that acted the same and could be mounted in a bump can, that could be mounted in the exact location and survive until someone wanted to spend the coin on air bumps. The other nice thing about bump cans is you can have spacers to tune heights.

I have found a place that is one of 2 in the world that cold forge a molecular structure "Thermoplastic Elastomer Maximized". this material delivers load capacities of up to 10 times that of rubber bumps and elastomer while significantly prolonging operational life spans up to 5 times longer than steel coil springs, 10 times longer than rubber bumps and 20 times longer than urethane bumps.


So today the first pieces are ready for real live testing on a vehicle. 2.25" compression bump stop. The first 1.75" of compression starts at zero and goes to 600 pounds allowing the axle to slow before bottoming out. The last .5" increases beyond what a 5000 pound vehicle would achieve in any terrain. The slowing of the axle makes it easier to control the vehicle at speed because there is no longer a sudden change in handling due to hard impact .

I will have the tested numbers on the other rubber and poly stops in the next couple weeks to compare.

That is very interesting. Looks to be a pretty robust material you've got there.

I know this is the first run, but what do you think your price range is going to be? Inbetween air bumps and regular poly bumps or closer to one end?

 

[RockTactics]

That is very interesting. Looks to be a pretty robust material you've got there.

I know this is the first run, but what do you think your price range is going to be? In between air bumps and regular poly bumps or closer to one end?

I am gonna try and keep them around higher end poly bumps. The quantity I can afford to start with will probably be in the $75.00-$90.00 a set. I want to include hardware and a landing . The standard solid poly bump is in the $25 set range. The poly bumps that allow compression generally are in the $40-$70 range a set . I can make all those poly bumps on the market in my garage with a mold. If these work the way they are engineered than we may have something special at a great bargain.

 

[CreeperSleeper]

I like those bump stops a lot!

 

[Tapage]

guess those will work like Daystars ...

http://daystarweb.com/productlisting.php?make=all&prodcat=Stinger+Bump+Stops