Quad Cab - 4 door coil sprung shortened troopy/extended swb build

[andrews520]

Coming along well Lawrence..
Who fab'd this for you? Was it Stylerod? Looks very similar to a styleside tub floor and I need some patches for mine..

 

[Sporty Forty]

Coming along well Lawrence..
Who fab'd this for you? Was it Stylerod? Looks very similar to a styleside tub floor and I need some patches for mine..

View attachment 1165767

Yep, Joel from Stylerod did the work on the folder there. Copied the factory floor pattern and made to suit the 80 chassis and mounting points.

 

[diogenese]

While this was going on the front guards were widened 50mm each side. The indicator bracket location was also moved to give the same position across the guard as a % (40%). Was 110mm from vertical bit now 135mm. This should still keep the front looking in proportion rather than having a large amount of guard after the indicator. I will be using std 40 series indicators, not a huge fan of the 70 series ones on a 40, my personal view there.

I'm going to widen my guards by 50mm too. I can't be doing with the rubber flares! I'm just a bit curious of what you did with the inner brace. Did you stretch that too or just remove the end?
I was planning on cutting inboard of the indicator hole and moving it outwards as I'm using the smaller round early indicator lamps.

 

[Sporty Forty]

I'm going to widen my guards by 50mm too. I can't be doing with the rubber flares! I'm just a bit curious of what you did with the inner brace. Did you stretch that too or just remove the end?
I was planning on cutting inboard of the indicator hole and moving it outwards as I'm using the smaller round early indicator lamps.

The bracket was removed while we widened them and the plan is to put it back there. As I will be running the same type of brush bars as my yellow 40 I might add to extra metal there or something for strength and run a tab out to the barwork to keep it away from the guards, but will decide over the Christmas period, but will probably just run it lengthened.

 

[diogenese]

I made wider guards with steam pipe and chequer plate for my mud truck.
My 45 will be for shiny use only ! I'll have a go at making the bracket longer.

 

[Bj on roids]

Come on, more updates?!

 

[Sporty Forty]

Come on, more updates?!

Body and chassis are off to get the engine, gearbox, radiator and steering column put in from Monday or Tuesday on. Nothing much has been happening in the last month due to Christmas and work holidays.

Hoping to have this done within a few weeks then back to the panel beaters for welding then the fun part begins of putting things in there and finding out how much will need to be fabricated in order for those things to fit. Still hoping to have it on the road this year.

 

[Bj on roids]

Awesome. So towards the end of the year you think?!

 

[Sporty Forty]

yep. Plan is engine/box etc done by the end of feb. then body done by the end of april then electonics by may. then paint and fiddly things or fiddly things then paint.

spent the other day getting the box bolted onto the engine and gathering all the parts together that I took off the donor 79 in 2014. place is a bit of a mess and need a few days tidying it all up again so i can find the next bits required.

 

[Sporty Forty]

A few update pics.

Car is now at fabrication shop and should be in there by the end of the week. Have to cut some floor out, nothing to concerning there and some firewall mods, again no biggie. Trying to keep the box and transfer as high as possible for a better ramp over angle, 122" wheelbase here.

Had to make a few small mods but going well.

 

[Sporty Forty]

Some pics from today.

Easy access to work on the engine mounts etc....

Steering column in there.

6 speed auto sitting there nicely after some mods to the mods.

Engine in there roughly sitting in place with inter cooler on the top. Body will be lifted up a small bit to allow a better fit as the radiator is a bit high and intercooler to bonnet gap is 10mm or so. Luckily we mounted the body very low on the chassis.

 

[Sporty Forty]

Engine mounts have now been welded up and body is sitting on 30mm spacers. Will be moving the brackets on the chassis to suit this new location once were pleased with how it all looks. Having to move things that have already been moved is a pain, but sometimes must be done when you are working without the engine and then put the engine in only to find a few issues.

Over all, all the measurements have worked out well and as I expected. Measure twice cut once is my normal rule and the body has been pretty spot on.

Driveshafts and petrol tank are next on the list to do after the suspensions is welded in palce and while this is going on, I have to try and incorporate the 79 steering column and ignition barrel into a 40 looking column. The 79 dash sticks a bit further out than a 40 dash so I will have about 10"(250mm) between dash area and steering wheel to cover up.

The fun never stops.

 

[Sporty Forty]

Started work on the dash face today as I have to widen that by 50mm as well. I will run the 79 series speedo cluster as the computer needs some signals from it so to make that fit I had to widen the 40 speedo cluster area anyway. I will be running the front face of the 40 cluster, or something looking like it as I don't need the temp, petrol, oil pressure and ammeter gauge along the bottom so will open up the center of it to cover the new speedo cluster.

I had 50mm to put into the dash, 25mm each side to keep it all centered. As I wanted to widen the speedo area 25mm went straight into the top but as I didn't want to widen the bottom hump and keep it looking 40'ish I put 12.5mm in each side.

This is what the speedo cluster will look like. I will be removing the tabs for the old face to screw onto. Need to see how the hump part for the steering column will go, it might stay it might have to go. Ideally I would like it to stay but might make it a bit shallower.

I put the 25mm on this side straight through the glove box. Kept one side in the same position and created more space to the side of the car and hopefully the computer sill sit in there, fingers crossed.

 

[Sporty Forty]

Some pics from the install as it sits now.

We have had to move the body up a bit. It was sitting very low to keep the COG low, but had fitment issues around the gearbox and intercooler. Lifting it a bit allows it all to fit under there quite nicely including the radiator as it is quite large, but given the 1VD-FTV was designed to run with it, thought it best to use it if possible.

Using 79/80 series rubber mounts in there onto fabricated chassis brackets. Pipe from the intercooler will have to be routed differently due to the shock tower getting in the way.

80 Series Landcruiser double diaphram brake booster being used.

Car sitting at full bump with engine in. Now spring heights can be worked out and finally begin to see what it's going to look like going down the road.

A slightly larger cross over pipe in there. As it's a single turbo engine the exhaust from the RHS comes over the the LHS where the turbo is located. There isn't one on the RHS as the drive shaft needs this area for movement and the exhaust location would likely be an issue. The 200 has a IRS front so the drive shaft doesn't really move up and down as the diff is fixed. Can't run a twin turbo set up on this computer as well as it needs things for blow off pressure or something apparently.

 

[2fpower]

This thread (and your hard work) is simply awesome. You are motivating me to get this project started.

 

[Sporty Forty]

This thread (and your hard work) is simply awesome. You are motivating me to get this project started.

Thanks, trying to note everything down for those who want to do something as stupid as this. Most of the hard work is being done by people who know what they are doing. I'm doing bits around the edges at the moment. When the body and engine are in then I'll be very busy trying to remember how it all goes together again.

Still a way to go on it though.

 

[Sporty Forty]

As the car is being widened by the 50mm I also had to adjust the wiper actuator arms in length. As I moved the hole for the wiper closest to the passenger side over the 50mm I had to adjust the length of this bit. I am running the 3 wiper screen here and have moved the wiper location to give a bit more space to the windscreen frame as I thought it was a bit close.

As I had a spare screen here I used one of those arms and cut it down to the required length, being 298mm. (248mm is std length to the first wiper out of 3) Top is the original out of the screen that I will move onto another 3 wiper screen that I will make from a 2 wiper screen

Welded up and made to look nice again.

As I don't really trust my welding, I put a small brace on the back of it.

 

[2fpower]

Amazing how adding a few cm effects so many things.

 

[Sporty Forty]

Amazing how adding a few cm effects so many things.

Yes, there has been a knock on effect down the line a bit but hopefully nothing else pops up. But hopefully at the end of it it keeps it 40 proportions while sitting on a wider chassis.

I have had to;
widen the rear ambulance doors by 25mm each
widen the bit above the rear ambulance doors by 50mm
widen the windscreen by 50mm
widen the front floor by 25mm each side
widen the fire wall by 50mm
widen the bonnet by 25mm each side
widen the front bib by 25mm each side
widen the front bezel by 50mm
widen the front cowl by 50mm
widen the roof by 50mm (not done yet as were not ready for it)
widen the dash front by 25mm each side
widen the glove box hole area and glove box lid by 25mm
widen the speedo cluster area by 25mm
widen the rear ambulance door lower sill by 50mm

in narrowing the rear doors by 100mm I see

shortening the door latch rods by 100mm
narrowing the weathersrip both inner and outers
making some door cards to suit
making some glass to suit
making some rubber seal to suit

and probably a few other things.

 

[Sporty Forty]

Decided that I'm going to be using a current ARB 40 series bar for the front of the project. Had an 80 one here but the uprights went straight in front of the lights and I would have had to change that for an engineer to pass it for registration.

Will need some mounting work to be done as the brackets are slightly different but nothing that the current guy doing the engine, gearbox, suspension etc.... work can't handle. Needs to drop down about 35mm or so as well so it looks like a 40 at the front. Not worrying about the width difference as if I had to put 2" (50mm) into this, I would make one from scratch and don't really want that added expense as well. Will also be moved back a fraction as the front of the 80 chassis is 100mm longer than the front of the 40 chassis from center line of the axle.

While I was finishing off the wiper links I decided that the motor needed a bit of a clean and paint.