PROJECT FJ40 - a history

[FJ40LVR]

Finished off axle assembly, caliper mounted.

 

[FJ40LVR]

Steering was an especially challenging part of working around the new lift / ride height I am attempting to do. I set a mopar steering box into the newly boxed front frame / winch assembly, and dropped a pitman down to a overbuilt (hopefully) crossover set up using some original parts.

 

[FJ40LVR]

Here is a couple showing the tight quarters that the box is placed in. The whole front end was built AROUND the steering box, no the other way around.

 

[FJ40LVR]

One big problem I had with the steering was the geometry of the steering shaft, I had to run two seprate u joints to clear all the obstacles (radiator, headers, etc.) / match the Steering Box angle.

 

[FJ40LVR]

I will just say that the orginal measurments of the radiator mounts were a little off, so once the steering was complete, and driveshafts in, the first time moving under it's own power turned out great.....until.....

 

[FJ40LVR]

Everything works out for a reason, i was planning on replacing the stocker eventually to keep the V8 cool. I just had my timelind moved up considerably. After doing reasearch, and reading the 350,000 "cooling problems" threads in the 40 section, I replaced the original brass 20" x 20" x 2 3/4" with a 26" x 21" x 3" Aluminum Cross Flow radiator from Summit Racing.

It took some creative radiator mount fabricating to fit the new width within the framerail, but she now runs @ 187degree average.

 

[FJ40LVR]

I still have yet to build a shroud, and install my electric On-Demand pusher fan for emergencies. (thanks for the idea BMAN) Everything seems to fit pretty good. The only things that had to be cut / moved to accomodate the wider radiator was the batterry tray, and the lower mounting plate.

 

[FJ40LVR]

I have always liked the original dash layout of a 40 series, but unfortunately the P.O. had customized the dash extensively using what appeared to be a cutting torch, sawzall and angle iron (?).

At first I was going to cover it with plate / restore it, but then I decied to just start over. At that that point I just started cutting aluminum, going for a super clean, no frills look.

I still have to take the 'plate back off and give it a surface etching pattern, the original full mirror polished 'plate I used it WAY too blingy for my taste. (still looking for a glove box door)

 

[Blues Dawg]

Geez, Josh - what's the clearance from your fan clutch to the radiator? it looks pretty close.

No speedo? and I like that stout Jesus bar on the cage!

 

[FJ40LVR]

Geez, Josh - what's the clearance from your fan clutch to the radiator? it looks pretty close.quote]

Pictures are a little deceiving, it cleares by 1 1/2". After the temporary radiator was chewed up by the fan, (due to the PO under welding / measuring the mounts a little on one side, and myself failing to notice until it was too late and they cracked during frame flex) I made sure on this new one that when I made the radiator mount it was securely mounted onto tabs, that were welded to the frame rails, bolted securely to radiator mount, with stiffeners from the top sides going back to not allow rearward movement under any circumstances. (hopefully)

 

[FJ40LVR]

New Toy finnaly received

Got back my third front drive shaft today, this time the measurements and the test fittings have all come to the proper fit. Overall, a good job by the driveline guys, but poor measurments by third parties. (my own fault in the long run)
Will be putting it on for good this weekend, just need to pick up the right bolts, and ditch the temporary stuff....(grade 10 metric). I would love to have more bugs worked out by AZROCKS......

 

[FJ40LVR]

Overall full compression: 25.5" Full Extension 34.5 9 (with aprox 1"of splines left)

 

[Relix]

who did the drive shafts? They look beefy, and those joints(I know I am not calling them what they should be called) are very nice...

 

[FJ40LVR]

who did the drive shafts? They look beefy, and those joints(I know I am not calling them what they should be called) are very nice...

Relix - Since I do not believe in throwing anyone under the bus in a public forum (other driveline place) -PM Sent.

 

[FJ40LVR]

Drove the 40 home through Tempe and Chandler, aprox 17 miles from Truck Werks the other day, after the exhaust was completed by Josh and jason. I was pretty excited that the temp needle never got above 193, even in 112 degree weather, idling at stoplights, traffic etc.
I got to hand it to Jason, the exhaust performs BEAUTIFULLY, and sounds GREAT. It was a pretty big job, but jason was able to tuck it up against / over the frame, as well as stuff it above / alongside the suspension to protect it from start to finish.

 

[FJ40LVR]

...

 

[FJ40LVR]

A few more....

 

[FJ40LVR]

Since the exhaust is back on, I thought I should put my driveshaft (another new one) and try it all out......my neighbors must hate me.

 

[Cdaniel]

Looking good on the exhaust. I'll be curious to see if you get any smelly inside when at speed on the highway though. Have you had it over 50 for a few continuous miles yet?

 

[RHINO]

thats a destructive driveshaft angle there buddy, it'll prolly work ok since its the front, but also, since you spent all the money for a dbl carden you really should turn the pumpkin up.

but it all looks like its turning out pretty dang nice, since your not having issues with temps dont worry bout a fan shroud. i thought i was goin to be making one too but it looks like i'll be just fine.