Build Meet Ivy, 1976 FJ40 w/VW TDI, 2.8 CRD, OM606

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I apparently did the same theory at @fc187. I cut a triangle out of a piece of square tubing I had laying around. I think it was 4x4 so I couldn't get it any higher, or I would have also.

I went back and forth on whether or not to outboard. But the more vehicles I looked at they were outboarded from the factory. So I figured I would give it a shot.

I know this question had been beat to death, but..., what is everyone doing for rear brakes? I have a headache from over thinking it.. I would like rear discs, but I still want a good working parking brake... What do you guys think???
 
I had an older Superwinch laying around that came off an offroad tow truck I build years ago. It fit down between the rails really nice. So I made a mount for it and a front bumper. The front brush guard came off a 67 fj40 I have for parts. After the fact I realized that legally the bumper is too narrow. I am gonna leave it for now, if I don't get pulled over, I won't worry about it.


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And I added a light.



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Here is a better photo of the adapter plate.


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Curious - What car/era VW is the TDI out of? Always cool to see someone doing something different!
 
The donor car was a 2002 VW Jetta 1.9L TDI. It came with 90 hp and 155 ft lb torque. I have done some bolt on upgrades, turbo, intake & exhaust manifold, head studs, injector nozzles, bigger intercooler, and computer tune. Right now it should be at 180 hp and 330 ft lb torque. On paper it looks extremely impressive. Hopefully before long I will be able to tell you how the seat of the pants feel is.
 
Feels like a milestone has been made once the paint starts to go on!!





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At the same time I started working on the cowl. Made the front floor patches. A friend of mine had a roller also, was fun putting the lines in the panels.



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Cowl primed and painted.


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Fitted the 60 power steering gear box. I had to put a 1/2 in plate on to get the steering shaft to clear the serpentine belt.


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And I rebuilt the gearbox. Thanks to other write ups here on Mud! I had the shaft in the freezer, you can see it frosted up, to get it to slide in easier. Those teflon seals are a bit of a pain to get in!!


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Fast progress! Looking good.

Did you tap that 1/4" plate under the steering box or sleeve the frame and run thru-bolts?
 
Thanks! I put sleeves in to the other side of the frame and thru bolts.
 
This morning I put together my windshield hinges with the stainless steel pins I got. When I put them on should I use the serrated washer??? I think it is supposed to be a lock washer? Will the bolts stay tight without them? After painting the cowl and hinges I'm not too keen on letting these washers cut the paint all up....


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fjdiesel said:
This morning I put together my windshield hinges with the stainless steel pins I got. When I put them on should I use the serrated washer??? I think it is supposed to be a lock washer? Will the bolts stay tight without them? After painting the cowl and hinges I'm not too keen on letting these washers cut the paint all up....


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It is a lock washer. You could use a bit of thread locker instead.
 
@abtx4x4 Good idea! I will do that instead. Thanks.
 
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