ROTW: Brokenparts FJ-60

[brokenparts]

 

[brokenparts]

Not too much to report...got my front ARB ordered and got a couple of the brackets off the frame to make room for the links. I actually have a free day tomorrow with no kids soccer so I'm hoping to get some actual work done. Hopefully I dont get bogged down with "Honey do-s".

 

[boots4]

I actually have a free day tomorrow with no kids soccer so I'm hoping to get some actual work done.

I hope you get more of those so it's on the ground for the christmas tree run.

 

[brokenparts]

me too!!!

 

[kling-on]

cool EXO wish I had done somthing like that on mine I miss the roof ... sometimes

 

[brokenparts]

not a ton to updates but here a few.... I got the ol' sawzall, plasma, and grinder out to start to remove the old brackets:

cutoff the old exhaust:

ThenI put some more work into swapping the front output shaft to the 32spline:

needle bearings are a pain:

buttoned up:

started putting the 203 doubler stuff together:

ARB came... Randy's ring and pinion is cheap and fast!

 

[brokenparts]

ran into a little problem... When I went to put the lock ring onto the mainshaft it seems that the either the mainshaft was machined just slightly off or the bearing isn't seating all the way down on it. In either case it is preventing the lock ring from fully engaging. If you look close enough at the crappy picture you can see that the bearing lip is raised over the "seat" of the mainshaft.

snap ring wont fully seat:

I was tempted just to hit it with a flap wheel but I decided to be patient and email Kyle at NWF. He literally responded within minutes! I ended up calling him today and we've got a couple things were are going to try before I ship the mainshaft back. It was great to get great customer support like that!!!

 

[brokenparts]

so this seems to be the problem... I knew my cheapo HF measuring device woud come handy some day.

(it says .977)

(it says 1.005)

so basically the thrust washer plus the bearing is bigger than distance on the mainshaft not allowing the lock ring to seat.

 

[cody c]

so take a little off the thrust washer?

 

[brokenparts]

so take a little off the thrust washer?

I think that's the easiest plan... gonna call Kyle @ NWF right now.

 

[brokenparts]

Hit it with the flapper tonight and BINGO!!!

 

[Dirtgypsy]

fer shizzle. this is going to be crazy!

exo looks good too bad its on a heep

I bet your yota will make it look good though.

Let me know if you need an extra hand some eve. it would be nice to get out of the house sometime.

clint

 

[brokenparts]

fer shizzle. this is going to be crazy!

exo looks good too bad its on a heep

I bet your yota will make it look good though.

Let me know if you need an extra hand some eve. it would be nice to get out of the house sometime.

clint

coolio, I'll take ya up on that here soon. I could use another set of eyes on the cruiser too. I always welcome criticism good or bad... give me a buzz and we'll try to figure it out. I know your schedule is as unpredictable as mine. Maybe we could even get boots over and set up my bender and let you guys go to town.

I should get my weekends and weekday nights back here for a month or two when my daughter's soccer season ends (then spring soccer starts). I was hoping to get this done by the Christmas tree run but I really dont think its going to happen.

 

[boots4]

I gots to find me some tube and try out that bender of yours!

 

[brokenparts]

shift rails got here today so I got some more done on the 205. Managed to get a little help too.

Kennedy feelin for the shift rail hole:

she got it!!!

She had more important things to do inside so she joined mama inside since the hard work was done.

Shift fork installed:

then I had to back up... forgot to install the short input shaft first:

then the fork and sliding gear:

together:

snap ring installed on other side:

then the shift rail pins by lining up the forks and the holes in the shafts:

then installed the bearing and snap ring on the output shaft:

the stuff for the output shaft:

it was easier to prop up the case to drop it in:

looking down:

then the thrust washer:

then the high gear:

then dropped in the shaft:

backside:

then I quit too..

 

[Dirtgypsy]

looking good zach!

clint

 

[brokenparts]

rear output bearings...

some paint:

doubler bearings for the 203:

 

[brokenparts]

finished up the doubler.

I didnt bolt it together yet because I'm not sure about how I'm going to clock it yet. I need to set the front end up first... this stuff should help with that.

 

[boots4]

I bet the other reason you haven't put the doubler together is because it's HEAVY. Sounds like a bench pressing party is coming up soon.

 

[brokenparts]

you better believe its heavy!!!! I believe the 205 is like a 140lbs itself! I had to move it over to my other work bench is separate parts. I'm either going to have to start eating more wheaties, get creative with some floor jacks, or just break down and buy a tranny jack to get it up in there... not to mention build a cross memeber for it.