Builds Lynchburg Lemonade, matzell's STW

matzell

 
Joined
Feb 4, 2005
Messages
2,686
Location
Richmond, VA
So I was very impressed in what I could do with this little 40. It worked as well as expected. I will be upgrading the seat to something more along the lines of suspension seats. I think I also need to upgrade the power steering pump. I am not sure I have enough flow for the big bore box but it still had plenty of power. I think this was the most it has driven in about 20 years. The smoke cleared up but I need to wire up the electric choke and make sure it is set properly, it was running a little rich but always started well and quick. I can not say enough about the tires, Maxxis did it right with these, they just grip and go, they also side hill very well, rocks, loose gravel, mud, they just kept me moving. I need to get the cage in and do the body work so I can put the top on it.

The H41 was geared well but I am on the fence about an Orion. Looks like they only make the 4:1, but I know I saw the 3:1 option before?

I am hoping to take this out the Rubithon in 2020, so I have some work to do. I do not plan on busting my but like this first phase but I have some plans for it.

Thanks for reading,
Rob
 
Last edited:

matzell

 
Joined
Feb 4, 2005
Messages
2,686
Location
Richmond, VA
I have decided to work on the tub. I picked up a trail tub that has already been reworked but has some dings. After straightening it up enough to get a top on I am going to install the 3/16" quarters and then cut it to fit the other tub. Then I will install the new rockers. Hopefully this will be less work than rebuilding my current tub.

E7EAE60D-3702-4EBF-8B06-45CFC0FE8651.jpeg


4DA57B70-9011-4AB1-BE6F-BDFB603525DE.jpeg


2F39F786-EA37-4665-BDE5-06CA58E080D9.jpeg


051EC4D4-6520-493B-A423-C46C946102CC.jpeg


6EC4E4A2-21D7-4E2E-BB97-54753C638B94.jpeg
 

matzell

 
Joined
Feb 4, 2005
Messages
2,686
Location
Richmond, VA
I have sold a few sets of these quarters and I have gotten some feedback on how they fit or do not fit. I found if I just set them on they came up about 3/4" too short towards the "B" pilar. These were based off the CCOT quarters that I bought and still have. They are exactly like them in shape-length- curve. I think these really should be a two person installation. I managed to wrestle them on by myself tonight but it was a hassle. I started at the front and put a clamp on them, then another clamp. Once I had it where I wanted it I put a few tack welds on it and worked my way to the back and around the corner, moving the clamps and tack welding as I went. I found that it hit the custom rear sill but I was still able to get it within 1/8" at the rear opening. I am confident that if everyone else does this the same way they should be able to get a good fit. If they are laying them over existing panels rather than cutting them out I still think this should work. I laid mine about the same space as laying it over the old ones.

The custom inner wheel wells in this tub are 3" lower than stock. I cut them out and am going to make new ones 1" taller than stock to allow more up travel or larger tires in the future without lifting the truck, just have to cut the quarters.

I hope all this makes sense. Feel free to send me pm if you have any questions. I had about 2 hours and 15 min in the work tonight, cutting the old ones out and tacking these in place. It would have gone a lot quicker if I had an extra hand.
 

matzell

 
Joined
Feb 4, 2005
Messages
2,686
Location
Richmond, VA
Pass side in place. I learned a little on the first one. This one came out spot on! I really happy with the corners. Remember this tub was beat to crap before. I only had 1 1/2 hours on this side.

0B7BBD9E-CDFA-446B-81DA-7C478978C602.jpeg


22CB896B-A0EF-4657-BC7D-779C114703E5.jpeg


BF1588CC-7B81-40C8-80B1-66AAEA835894.jpeg


21494CCC-A649-4370-B28C-543FACD58C1E.jpeg


DC0312AC-89FC-4064-B19F-0F225C1A3CC3.jpeg
 

RWBeringer4x4

Mechanically Challenged
SILVER Star
Joined
Jul 11, 2012
Messages
4,491
Location
The People's Republik of Maryland
This might be a dumb question but I’ve never done body work - is there any reason you can’t butt-weld the extra thick quarter panels in so they’re flush on the outside and the extra “lip” is hidden under the tub?
 

matzell

 
Joined
Feb 4, 2005
Messages
2,686
Location
Richmond, VA
This might be a dumb question but I’ve never done body work - is there any reason you can’t butt-weld the extra thick quarter panels in so they’re flush on the outside and the extra “lip” is hidden under the tub?
Yes you can. You need to completely cut out the old ones like CCOT shows. The pass side could have been tucked under as that side was cut to size but I did overlap some areas in the front and back. It was easier for me to clamp being by myself. On the drivers side I cut them with 1/2" extra overlap. I did it this way because people where having problems with fitting them. I wanted to make sure they would overlay over existing panels if someone wanted that. It was a little easier to clamp it this way too. After I have them all welded up I will sand down the edges to make it more of a roll rather than the 90 deg edge. Give me another week and these should be finished up.
 

RWBeringer4x4

Mechanically Challenged
SILVER Star
Joined
Jul 11, 2012
Messages
4,491
Location
The People's Republik of Maryland
Yes you can. You need to completely cut out the old ones like CCOT shows. The pass side could have been tucked under as that side was cut to size but I did overlap some areas in the front and back. It was easier for me to clamp being by myself. On the drivers side I cut them with 1/2" extra overlap. I did it this way because people where having problems with fitting them. I wanted to make sure they would overlay over existing panels if someone wanted that. It was a little easier to clamp it this way too. After I have them all welded up I will sand down the edges to make it more of a roll rather than the 90 deg edge. Give me another week and these should be finished up.
Nice - When my rear sill finally rots out or I do enough damage to the quarters off road (already well on my way after this summer) these might be a good replacement option. Definitely heavy duty, and I, like you, plan to keep my truck looking like a FJ40 as best I can. What do those quarters weigh? How does it compare to a stock 16 gauge panel?
 
Joined
Apr 28, 2018
Messages
241
Location
Coopersburg Pa
I have really enjoyed this thread so far! Looking forward to seeing how the quarters look once they are finished up. These seem so much easier to repair than the aircooled vws that I'm used to!
 
Top Bottom