Builds My 1981 HJ45 Troopy build

[RufusTheDufus]

That is surprising to me. What are the changes? I assumed the only real change from HJ45 to HJ47 was the engine itself. Can't imagine having a different frame for the HJ47 from the FJ45 of the same year, as it seems all 3 engines are pretty interchangeable, and why else would they vary?

HJ/FJ/BJ models of the same year share the same frame. (A BJ45 was available in some markets.) The HJ45 and HJ47 are different models that were produced in different model years for different markets. The transition from 45 to 47 was right around 7/80 and 8/80. (The HJ45 ended production in 7/80 which is when mine was manufactured.) The most obvious change is in the spring hangers. The 45 used the older style cast spring hangers with the smaller pins. The body mounts and locations are different too, at least for the Troopy.

I sometimes see people referring to their trucks as a 1979 HJ47 as an example. Toyota never made one of those. I assume they are calling it a 47 because someone swapped a 2H in for the H it originally came with.

 

[Awl_TEQ]

Just dawned on me that if I ever want to remove anything aft of the engine for whatever reason the tube would totally be in the way. I would have to pull the whole enchilada or at least tilt it all downward at the rear. That would make a clutch job a real PITA.

On further reflection.... the cab floor would be in the way also. That means tilting the rear down is the only way to get the transmissions off.

 

[RufusTheDufus]

For my application I think I'm just going to remove the tube completely and not simply move it back further. I bought one of IPOR's skid plates. I think I'll add gussets to it to make it a more integrated/structural portion of the frame. I'll also put a transmission mount on the front of it. I haven't quit figured this all out yet. I will soon after I have the transmission in place.

 

[RufusTheDufus]

Some more progress

I was able to cut up most of the sheet metal parts that I need for the body work and frame fixing.

My friend's brake can't handle something as large as my tank so we had to improvise. Four of the bends that were supposed to be in the bottom perimeter of the fuel tank have been pulled out of the flat part and switched to separate weld-in panels. This is what it looks like after tonight's welding:

It's made from 3/16" steel. I'll most likely do the internal baffles from 1/8" material. I wanted to be sure the thing won't crumble if the full weight of the truck is dragged over a rock on the tank.

My TIG welding skills need some work. I assume there will be leaks. I plan to seal it with a tank seal kit instead of trying to weld every pin hole.

It's nice to make some major progress on something for a change. Maybe I'll have it running in time for the Yankee Toys Fall Gathering but I kinda doubt it.

 

[MOTOV8R]

Looks like mine
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With the slots along the top of the tank, I wonder if you will be able to fill your tank all the way due to trapped air at the top. Seems like each of those sections would need a bleed line to your filler neck.

 

[fogblanket]

nice work i hope it makes it to the FG so I can crawl under and take a look
Jason

 

[Awl_TEQ]

With the slots along the top of the tank, I wonder if you will be able to fill your tank all the way due to trapped air at the top. Seems like each of those sections would need a bleed line to your filler neck.

They were for expansion during temperature change. Only the front/ widest one will get filled because that is where the filler neck will be. The tank will be vented as well so I'm sure it doesn't matter any more unless I connect them with a small hose to get a couple more gallons in . I did that a year ago and it's one of those "why did I do that" kinda things.

 

[RufusTheDufus]

A bunch of progress the past few days. I didn't have the camera handy but I'll post photos soon.

The frame repair is almost done. The inner plate is cut and in place. Now I need to fit the section that replaces the inner C-channel section. It was too hot to be welding under the car today so I hope to get to it later this week.

The H55+Toybox+Splitcase is installed. I'm working on modifying the IPOR skid plate to be a crossmember/mounting point to take some of the weight off of the bellhousing rear mounts. I think I'm going to go with the stock Toyota Hilux style mount that bolts to the Toybox.

The fuel tank fits great, as long as I don't install the rear leaf springs . I screwed up when measuring the size of the tank. It will work but I'd like more clearance between the spring and the tank in case the shackles flex side to side. At the moment it's 35" wide along the front edge of the tank and it clears the springs with 1/4" on each side. I'm going to cut an inch (or more) off of each side of the tank tomorrow and weld it up again. That will make it fit a little better.

Next is the rear ARB locker install so I can get the axle back under the truck and sitting on all 4 tires for the first time in many months. I'm looking forward to measuring lengths for new drive shafts so I can get them ordered in time for the Fall Gathering.

 

[Awl_TEQ]

Get that camera going!

 

[RufusTheDufus]

New photos

Hacking up the tank to make extra room for the rear leaf springs and the exhaust pipe.

This is the wedge I took out for the exhaust side of the tank.

And a new plate welded in its place

Cutting the other side for leaf spring clearance.

That's an H55 with a 40 series shifter. Still need to cut a hole for the Toybox shifter and install the twin stick kit from orangefj45.

This is one of the body support pieces I bent up to fix the rusted ones. Bent them by hand in a vice so they aren't perfect.

When I install the body mount pads it will line up properly.

Views of the tank up under the back end.

Plenty of clearance for the leaf springs now.

Trans mounted with IPOR skid plate held up by vices. Had to cut the torque tube and remove the stock fuel tank to make room for the H55+Toybox+splitcase. I ordered a mount for the Toybox and I'll modify the IPOR skidplate to work as a supporting cross member.

Part of the frame repair. Most of those bolts were frame rivets. Real fun grinding and drilling them out.

The inner plate was rosette welded through the frame in addition to stitch welds around the perimeter. And additional plate will be welded on the inside to box in the frame section in that area.

The IPOR plate hangs down a bit.

I'm going to come up with a way to tie in the IPOR plate to the vertical inner frame C-channel much like a stock cross member. The idea is to tie the IPOR plate into the frame in both horizontal and vertical planes.

 

[Mad Jack]

Awesome work Rufus! Looks great!

 

[Awl_TEQ]

looks great - much more progress than me lately.

one thing tho - I assume the buckets are full of concrete?!

 

[1tontoy]

I was thinking the same thing when I saw that. Still, you wouldn't catch me trusting those with my life...concrete can 'explode' instantly - i.e. NO WARNING. I hope its steel reinforced concrete. Better off using solid wood.

Not to mention they are tall and narrow. Are the jacks resting on the buckets? Or cemented in (assuming it's cement)?

Please be careful Rufus.

one thing tho - I assume the buckets are full of concrete?!

 

[RufusTheDufus]

It's concrete. I think 7500 PSI fiber reinforced. I've got 6 of them. A friend of mine locally is in the concrete business. Those buckets were filled from excess from a bridge he was pouring for the state a couple of years ago. I think this was the material used in the piers. It's not a sack of ready mix from the local hardware store. I'm pretty sure they can handle the load of the Troopy. They have had a lot heavier stuff on them but I do appreciate the concern.

 

[RufusTheDufus]

A little more progress

The progress is a little slower lately. I picked up a consulting gig that's going to keep me busy through the election in November. Looks like I won't be taking the Troopy to the Yankee Toys Fall Gathering. I just won't have the time this month.

I started working on a second fuel tank. This one will mount between the frame rails and straddle the rear driveshaft. It's about 20 gallons. I'm leak testing my welding job in these photos.

I'm also working on a rear swing out tire carrier.

Anyone looking for one of these? My wife would love to see it go away.

 

[fluffybunnysui]

Anyone looking for one of these? My wife would love to see it go away.

Dont toy with me like that....

 

[Christian]

Anyone looking for one of these? My wife would love to see it go away.

My wife would love to see it here!
Mustangs have been her favourite forever, when I met her I thought she had a thing for Nicholas Cage, but it was Eleanor she wanted!

Nice to see another 45 in progress!

 

[calfj60]

This is very cool build...really want a troopy someday!!

 

[RufusTheDufus]

Haven't had a chance to do much on it recently. I've been sidetracked working on my BJ42 getting it ready for the Yankee Toys Fall Gathering.

 

[82cruiser]

Great work and thanks for detailing it here. Good info and ideas as I work on mine.