Build Rockcod’s final ride, Morty the Forty

[rockcod]

I sourced an FJ62 front disc axle, from Craigslist, for the disc brake conversion, rear disc rotors and brackets (Thanks Poser!), knuckle rebuild kits (Georg), rebuilt brake booster, gm steering box is going to get rebuilt and modified for hydro-assist and last but not least the Warn 8274.

We have removed the “so-called” roll cage, dash pads and mounting flange, so FC can do his magic on a new family cage.

 

[rockcod]

Out with the old and waiting for the new.

 

[Buttons]

Parts are starting to pile up!View attachment 2596179

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Niiiice. Disc brakes???? Did they come with a Monocle and top hat? HAHA

 

[whitey45]

Nice solid platform Tony, I have a Dana 60/ 14 bolt here with your name on it, ditch the silly little toy axles

 

[rockcod]

Nice solid platform Tony, I have a Dana 60/ 14 bolt here with your name on it, ditch the silly little toy axles

Nothing better than 1 tons!!!

 

[rockcod]

Bare front housing is getting sent out for sand blast and a dip, the stops, shock mounts and spring perches will be cut off in preparation for the SOA and cut/turn. FJ55 rear springs will be reworked and replace the stock 40 rear springs, the upper shackle mount will need to be moved for proper shackle angle. New to me doors will require a little attention but are solid.
Now I need to find the time to dive into this project.

 

[rockcod]

Scored this gem locally yesterday, gotta love the Mud community!!!

 

[rockcod]

I really hate cleaning parts, but then again clean parts make re-assembly so enjoyable! Waiting for the knuckle housing to come out of the solvent and then time for a little paint. Tomorrow, the other side, then start shaving the front housing of mounts, brackets and stops, prepping for SOA and cut and turn.

 

[rockcod]

Slow progress, work and life interject and de-rail the cruiser rebuild train. Today I had a couple of hours and was spent cleaning more parts, some re-assembly of hubs and a little paint. Since I don’t like running disc dust shields, I cut the centers out of them, they act as spacers for the knuckles and dust seals. A little finish grinding on the edges and some paint, they are good to go!
Next on the list to do are to clean the spindle hubs, replace bearings and races, inner dust seals. The rotors are in good shape, I am simply going to have them turned and they will be good to go!

 

[rockcod]

Knuckles cleaned and painted, hubs cleaned, painted and rebuilt, birfields cleaned, disassembled, inspected and re-assembled.

 

[rockcod]

Since I was going to 4 wheel power disc, I had to modify a few things. Cut the re-enforcement rib on the firewall (still need to weld the top back on it to finish it off), enlarge the pushrod opening and drill the mounting holes.
The old accelerator cable had seen better days, ordered a new one and found it needed to be modified a little to clear the new booster, the wiring harness had to be re-routed and the clutch master needed a little clearance grinding to fit the booster, the proverbial snowball effect! A lot of work that can’t be seen but had to be done. Now to replace the old 9mm fitting with a new 10mm fitting on the existing front brake line and then make a new rear brake line and replace a fitting on the frame to split the front brakes from the rear.

 

[rockcod]

A few more parts sourced, seats from a KIA Soul and soft top bows from real steel cruiser parts.

 

[rockcod]

Got the plugged up heater core, fan motor, 4 wheel drive vacuum lines and lever removed, as well as the front fenders and bib. Trans tunnel removed to drop out the 3 speed trans and t case.

 

[rockcod]

Replaced the intake/exhaust gasket with a remflex gasket, accelerator pump plunger bellow fell apart, landcrusher909 had a new factory part. The quality is much better than the part included in the rebuild kit.

 

[rockcod]

And just like that the project has made an abrupt turn, talking with FC, he convinced me to replace the old f motor with a 5.3L LS motor. After looking at many engines I found this one with an ECU and stand alone wire harness. The old 3 speed trans is getting replaced with a sm420 and I just received the mounting plate to mate the trans to the t case (Thanks KT40) and will be picking up my Orion transfer case in a couple of weeks (Thanks Georg).

 

[rockcod]

So, part of this build that will be different from anything I have done before is hydro assist steering. I want something that will turn 37” tires with ease, especially in rocks or when the front end is weighted. I have watched many how to videos and figured what the heck, I’ll give it a try.

I sourced a used GM 500, 4 bolt, steering box, bought a rebuild kit, a new drill bit and tap as well as the necessary fittings.

Items needed:
Gm steering box
Rebuild kit
7/16” drill bit
1/4-18 NPT tap
(2) 1/4 NPT TO 6 AN steel fitting
(2) 6AN steel cap, optional

I measured 2.850 from the end of the housing and using the casting center line as my reference. Step drilled the hole up to 7/16”, tapped the hole and threaded in the fitting, this port is for left hand turning.

The lower port, for right hand turning, location is inline with the machined galley in the casting (you can see where the passage goes), there is a small galley plug on the end of the housing. Distance from the end is not critical for this one, it is critical you drill into the galley passage. I chose a spot where there was plenty of meat around the hole. Be careful not to drill past the galley, bottom your drill on the opposite side of the galley and no farther. This hole is not as deep, so you are limited on how deep the tap will go and how many threads you get.

I did mine with a hand drill, it can be done, but a drill press is the way to go. Just take your time and double measure everything for best results.

**The steel AN6 caps are needed, if you burst a hose going to the steering ram, on the trail. Just cap the ports and you are good to go, assuming you brought extra power steering fluid!

 

[rockcod]

The factory brackets have been removed to aid cleaning the motor, I ordered a new P/S pump and alternator bracket from G.O.A.T Built. Found a set of Sanderson block hugger headers, KT40 hooked me up with the SM420 to Land Cruiser adaptor plate and Georg built me an Orion 4 to 1 t case and supplied me with a bell housing. Dave, at Clutches Unlimited in Midway City, provided me with an LS billet flywheel, pressure plate, clutch, throw out bearing, clutch fork, pilot bushing and bolts. The plan for the next few days is finish cleaning and painting, then slap everything together and get it up to FC Fabrication.

 

[landcrusher909]

This is going to be one Hell of a Build and Adventure. Glad your back Brother

 

[whitey45]

I think a reunion is in the future, I have a rock crawler build revival in the works. Actually headed to the rubicon thursday with my best friend in his 40 we built in high school!

 

[rockcod]

I have a little over 2 weeks before the 40 goes under the knife at FC Fabrication and still waiting for parts to come and plenty of things to get done. Today I spent the better part of the day in wrecking yards looking for a couple column parts. Finding older GM columns is more and more difficult. I have to make another trip on Wednesday to remove a horn contact ring from a square body GM truck, didn’t have the correct tools with me .

I did make some progress though, I was able install the column I rebuilt, minus the part I couldn’t get from the donor vehicle. I had to modify both the GM and Toyota upper steering column mounts. I cut off the mounting ears of both mounts, and welded the Toyota mounting flanges to the GM cradle mount.

Wednesday morning after work I will hit the wrecking yard and then a trip to the metal yard for some 1/8 sheet metal to make a column firewall mount.