Build Project Boomerang

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ok so scratched my head a bit and decided to pull the lower bolts from the bellhousing. This solved the gap issue completely. The lower bolts that thread from inside the bell were pushing the trans away from the bell creating all the weird gaps. I ran a tap as far in as I could on the drivers side lower bolt hole but it stops about halfway. Holes must be misaligned just enough to cause a issue. Only thing I can think of is to pull the trans and and remove the bellhousing threads so that hole is just a pass through and then the bolt will go straight into the trans threads.
 
Are the lower holes in the old b/h threaded? I don't think mine are.
 
I would probably drill out the lower bellhousing holes. I'm not sure you would be able to thread in the lower bolts from the outside.
 
Picked away at getting the interior installed this weekend. Still have a ways to go

1000003756.webp
 
badsamaritan said:
Pulled the trans and drilled out the lower bellhousing bolt holes and then reassembled. Big thanks to @Boston Mangler for helping me heave that thing back in there. Starting to slowly reassemble everything.
Click to expand...

Good times man! 💪🏼
 
Buttoned some more things up and spent a lot of time working on getting the clutch to adjust. Which the new bell I have a little bit of adjustment that I can make to the pivot ball stud. I backed it out a few turns and the fork ended up in a good spot.

I got the battery charged and did a quick back and forth on my driveway. Shifted ok but had a odd whine. I checked tcase fluid and it was pretty low. Today I flushed the trans and tcase and went for another drive. Much better this time and shifting great. I heard the whine a couple of times, at low speed. I think it's the parking drum. I'll need to take a look at it again
 
Adjusted the drum last night and went for a few more drives. Seems nice and quiet now. Updated to-do list:

Install batwing rear crossmember
Re-work AA clutch slave bracket for better alignment and so the clutch slave can be mounted correctly with the bleeder on top.
Re-work Tcase linkage so that it's farther away from the floor.
 
went down the rabbit hole of trying to get some music in my FJ40. I just wrapped it up and so far I am pretty happy with the setup. I bought a cheap Alpine media only (bluetooth and USB) to put into my tuffy console

PXL_20260426_021151583.webp


Kick panels from SOR with some Polk Audio 5 1/4's off of Amazon. I wasn't sure how to install these because I couldn't access behind the door frame for the upper bolt. I ended up installing a M6 Rivnut for the top bolt on both sides and a M6 nut and bolt for the lower bolt.


PXL_20260426_021050146.webp


Wrapped all the power and front audio cable in painless brand power braid that I had left over from my Chevelle and then used Pclamps to mount it to the trans tunnel.

PXL_20260426_021127868.webp


I used Magdaddy magnets to help hide the speaker wires in the kickpanel and under the lip of the tub for the rear speakers. They hold pretty well and have a loop for a ziptie
PXL_20260426_021221308.webp
 
badsamaritan said:
went down the rabbit hole of trying to get some music in my FJ40. I just wrapped it up and so far I am pretty happy with the setup. I bought a cheap Alpine media only (bluetooth and USB) to put into my tuffy console

View attachment 4129273

Kick panels from SOR with some Polk Audio 5 1/4's off of Amazon. I wasn't sure how to install these because I couldn't access behind the door frame for the upper bolt. I ended up installing a M6 Rivnut for the top bolt on both sides and a M6 nut and bolt for the lower bolt.


View attachment 4129274

Wrapped all the power and front audio cable in painless brand power braid that I had left over from my Chevelle and then used Pclamps to mount it to the trans tunnel.

View attachment 4129275

I used Magdaddy magnets to help hide the speaker wires in the kickpanel and under the lip of the tub for the rear speakers. They hold pretty well and have a loop for a ziptie
View attachment 4129276
Click to expand...
Nice work. The magnets are a great idea
 
Thanks! I really didn't want any holes or for the wires to be visible. I'm almost done hiding them. I'll post a pic of the finished product. Magdaddy makes all kinds of magnets, I've thought of some other projects I could use them on
 
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