Most excellent! Hope to check it out more in person. I'm out of town until the end of the month but would like to give you a holler when my summer fieldwork is done. Very inspiring to hear of all the help you got on putting it all together. Learning how to weld and understanding how everything goes together is something I aspire to. Thanks for the great write up.
Sure--Remember, I am running FJ60 axles. FJ60 drum brakes integrate the brake adjuster into the e-brake mechanism. Every time you pull the e-brake, it adjusts the brakes. So in the 40, I didn't hook up the e-brake cable but the rest of the hardware is there. So to adjust the rear brakes, I pul a small lever under the bellcrank, crank it up and down until it stops clicking-perfect rear brake adjustment. Unfortunately, there is no way to retrofit this mechanism into an older FJ40. Sometime around 80 or 81, FJ40's adopted the same setup, but it would require a total axle swap-the attachment of the backing plate is completely different and axle specific.
Editorial--There is nothing inherently wrong with drum brakes. I think the later drum brakes have some significant advantages over the older style. I did not see the need to go to rear discs, and my truck stops straight and with good power.
I've never driven a SOA on standard FJ40 axles, so no real basis for comparison. The stability issue was one that had me a bit worried, and honestly it was a non-problem. Even on the road it was stable. The real test was the slabs at Rubicon and I was glad to have every bit of available width. Plus I have relatively stiff springs, and I run my shocks almost as stiff as they will go.