Rear FJ 40 Bumper Build.

[D'Animal]

I don't know if this goes here or the 40-55 area. I'll post it here and if the mods or supermods want to move it, thats OK with me.


My 76 FJ 40 needs a swing away tire carrier with fuel can provisions. The bottom of the rear quarter panel has the usual rust issue of a 31yo rig. The stock tire carrier does not like the 35"s.


Here is where I started. I build a rear panel and mounted the fuel can and the jack on it. The factory swing away is in use.

 

[D'Animal]

I removed the bumperettes and the tail light protectors.

 

[D'Animal]

I drilled the original holes out to accept the 1/2" grade 8 bolts.

I drilled some plate steel to line up with the holes.

I mounted the steel plates and spaced them out with thick 1/2 washers. I did this so water will not set in there and cause rust between the plate and the frame cross member.

 

[D'Animal]

Here are both plates mounted as well as the tail light protectors.

 

[D'Animal]

Here is the bottom part of the bumper that I had built a few years ago for the Wifes CJ-8.

I installed it on her CJ-8 but she did not like it after the install was done. It blocks her view when looking out the Rear View Mirror.

I took it back off and put the Smitty Built double tube bumper back on.

 

[D'Animal]

Here is the swing away closed.

 

[D'Animal]

Here is the bumper mount area. I flipped the receiver hitch as you will see in later pics.

 

[D'Animal]

Making the gussetts and adding them to the plates.

They are 4 7/8" on the long end.

 

[D'Animal]

Here are all the gussetts installed.

Don't flame my welds too bad, I don't claim to be a welder.

I set my Miller 175 at 6.5 and 55 to burn these in.


Welding upside down sucks.

 

[D'Animal]

Here is the bumper installed.

The top of the bumper is level with the floor in the cargo area.

 

[D'Animal]

Here is the swing away carrier installed.



Time to take the 5x5.5 wheel studs and replace them with the 6 lug pattern.

 

[D'Animal]

Replacing standard bolt with Metric wheel studs.

Also putting spacing where it needs to be.

 

[D'Animal]

Here is how it looks with the 35" tire installed.

 

[D'Animal]

As mentioned earlier, I flipped the receiver around.

I also added a second receiver.

 

[D'Animal]

Time for the removable top basket and fuel can holder.

 

[D'Animal]

Top basket installed for mock up.

 

[D'Animal]

Top rack installed along with fuel cans. The cans are sitting in thier location. I need to make the nuts to hold them on.

 

[D'Animal]

The top pic in Post 17 should be a good reminder to not weld near a trashcan. Keep all rags and flamables out of the work area.


Look to the left side of the picture.

 

[D'Animal]

I will take it out on the trail today and see how bad it rattles and squeks, etc.

I will also see how top heavy it became by moving the tire up to it's new location.

I also have to find a place to mount the Hi-Lift.

 

[D'Animal]

Here is a day time pic with it swung the other direction.