Builds rocks and rolls

[mrqtipp]

Rocks & Rolls - FJ40 Build Up

Started a fj4o project awhile ago after catistrophic trail failure. Ultimate objective to make a truck that can handle the rocks and can handle the road. I will try to keep the build in proper sequence but I did a horrible job of documenting the build. Repair and despair. Pictured is the truck prior to build and is a 1969 FJ40 nothing special to mention.

Pre build pic

 

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pulled engine and drive train

 

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pic of engine and drive train removal

 

[mrqtipp]

Moved to body work. Cut cancer from rear quarters

 

[mrqtipp]

Replaced sill/channel (cool cruiser) and welded scab plates to the rear of the sill (not picutred) for drop down tailgate I had to fabricate, pictured later in build

 

[mrqtipp]

welded new quarters very rough. hammered out wrinkles and grinded down welds. I unfortuntly did not take pictures of the finsihed product but they did come out very well

 

[mrqtipp]

I took my ambulance doors and removed the hinges on both sides and welded the two doors together. Welding the two doors together was trickey because I was to lazy to build a simple jig as a result when welding the ambulance doors together a slight warp occured but not enough to notice with the naked eye. I welded scab plates on the bottom of the doors so I could drill and tap them for hindge stock. I immediatly went way from the hindge stock when I came accross OEM hinges. I only took pictures of the finished work. Welding the doors together was much more cost effective then purchasing the (hard to find and cost prohibitive) OEM drop down tailgate

 

[mrqtipp]

fabricated some removable 3/8 plate hangers on sides of tailgate and made cable limiters. Pictured on sides are spare full floater axles for the rear and spares for the front. Will discuss later in the build

 

[mrqtipp]

I plan on posting the whole build. First pictures are pre catistrophic failure that started the build. Very stock

 

[mrqtipp]

I was originally going to fabricate flat fenders but then decided to cut 3 inches off the fenders and weld a small piece of pipe to the lip. Let me know what you guys think

 

[mrqtipp]

best way to get fabrication done faster
hand the grinder to your bro

 

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more fender pics

 

[mrqtipp]

Passenger side fender

 

[mrqtipp]

Had the fenders sprayed with a polyurethane linings.

 

[mrqtipp]

Made half doors and sprayed the inside with a polyurethane linings

 

[mrqtipp]

Pic of exterior of the doors. used all OEM hindges and door latches. no rattles

 

[mrqtipp]

Had to modify the transmission hump and again the key to fabrication is to get your bro to cut chop and rebuild

 

[mrqtipp]

Cut the transmission hump so the drive train could be removed without removing the transmission hump which as you all know sometimes requires gas tank removal and or seat removal.

Fabricated a removeable section that attaches to the hump with several quarter twenty bolts with nuts welded on the transmission hump for quick removal. I found out the hard way that I had to remove the drive train several times. I then had the hump sprayed with polyurethane linings.

 

[mrqtipp]

I decided to put a 22 gallon gas tank in the rear. Decided not to use the passenger side filler that came with the tank. Welded the hole up and cut a new hole in the rear of the tank and fabricated a fill spout. The rear tank will be the main tank and the OEM tank will be used to fill the rear tank via a toggle switch that operates an aux fuel pump. Additionally, I put a toggle switch that operates both fuel tank sending units so I can see fuel levels in both tanks on one autometer gauge. I then fabricated to the OEM fill spout which splits thru the floor board and attahces to the 22 gal tank. Now when I fill up the tanks I use the same fill spout and just turn the gas nozzle to right or the left

 

[mrqtipp]

I then gutted the 40's wiring harness and installed a 12 circuit wiring harness I picked up at the swap meet for half the price of painless harness. Installed the fuse panel on the firewall completely out of the way and accessable. So much better then the OEM buzz fuse box. The installation of the wiring harness was time consuming. Lots of solder and shrink tube.

I fabricated a panel for the gauges then installed autometers gauges. Fuel, temp, oil press, tach, speedo.

A series of toggle switches.
* KC lights
* reverse light
* under carage lights
* compressor (york) w/ storage tank (quick disconnect at the front bib)
* aux fuel tank transfer pump
* fuel tank sending unit (1 toggle operates both sending units)

ARB swtiches mounted in the ashtray

Chevy tilt steering