Build Rustynailjustin's Baja FJ45

[RustyNailJustin]

This is a build I started and completed a few years ago. I get quite a few questions and interest so I thought I would share rebuild thread as it happened with you. This is not what I would classify as "hardcore" but it's not your standard issue 45 and it was a challenge here and there for me to finish, even have built several Land Cruisers. I hope you enjoy...............



Finally starting the Baja 45 project! Little background. After years of looking for the right one I bought a 63 FJ45 SWB from a guy in Sacramento. I had big ideas from the get go but I was not sure what way to take this little truck. I knew what I was going to be using the rig for and that it had to be very dependable, store a fair amount of gear and be fun to drive. My original thought was 5.3 Chevy, 4L60E, Atlas. To be honest I have done a fair amount of fuel injected conversions and wanted a new challenge. Why not keep it Toyota? Not a week after this revelation a buddy of mine wrecked his 98 Taco with a 3.4 and a stick. I took this as a sign and bought the truck from the insurance a couple days later.
This truck will be taking my Wife (Kelly) and I on many camping trips, and the trip it is really being built for, spending at least a month at a time on the Baja.
Here are some pictures of the 45 and the Taco.

 

[RustyNailJustin]

Tuning a rear end into a front end.

Front end I am building. I got a bunch of Cruiser axles so why not give it a try.

 

[RustyNailJustin]

Using the whole mess including the Tacoma in tank fuel pump.

 

[RustyNailJustin]

test fitting

 

[RustyNailJustin]

Chassis cleaning and modifications.

 

[RustyNailJustin]

The easiest solution turned out to be taking a 60 housing flipping it over notching the flange, building a cover and spinning the knuckles.

 

[cwwfj60]

So the axle build was for width? Genius! And the rear?

Can't wait to hear about the Baja part

 

[RustyNailJustin]

Well its out of luck that this fits! I have been thinking about the exhaust from the get but with so many other things to make fit/work I thought I can get the exhaust later. Well the factory crossover works, I may have to trim the flange a 1/8" but its gonna work just fine!

 

[RustyNailJustin]

I used an drilled and tapped FJ60 steering box, it's plumed to a Howe ram.

 

[RustyNailJustin]

The Tcase is not offset any longer so the cross member is in the way. I was going to cut the stock one out and just use some DOM but decided to try this.
Cut the stock one at lengths that once removed and flipped around it would be centered. Once I had it where I wanted it I tacked it in place and sleeved it from the outside in with 2" tube.

 

[RustyNailJustin]

It seems like one area that needs some beefing up on this chassis is the rear spring hangers. Not that this rig is going to see hard trail use but some insurance in these areas is a good stroke of business.

 

[RustyNailJustin]

Buying the wrecked Tacoma is paying off. I took the Taco rear 2 piece driveshaft and split it. I knew it would be close when I mounted the motor but today I test fit it. The CV shaft from the 2 piece fits perfect just need to clock the holes on the Tcase flange. As for the front, I am using the carrier bearing from the 2 piece to get by the cross member. From there it will be a regular Tacoma front shaft.

 

[RustyNailJustin]

Using the Tacoma Transfer case has a down fall. Because it went to an IFS front in the Tacoma and the front shaft did not have to move at all the drive shaftshaft was super close to the crossmember. Because I did not to make some goofy crossmember, I need to make a 2 piece shaft to get it by the crossmember.
I took the carrier bearing half of the Tacoma rear shaft and cut it up and flipped it around to put it on the front of the Tcase.
From here It will be Toyota truck shaft to the Land Cruiser flange on the 3rd.

 

[RustyNailJustin]

The painful start to body work. Good news is there is very little rust or damage to this 45. The second to last pic shows how good of shape the steel is under the dirt mat, and the bed is nearly flawless. Lots of scraping the 43 years of dirt and grease caked to the bottom of the tub.

 

[RustyNailJustin]

 

[RustyNailJustin]

Wire wheelathon

 

[RustyNailJustin]

A good friend of mine helped me make an aluminum tank, 30 gallons and uses the Tacoma in tank pump.

 

[RustyNailJustin]

Whoever cut this roof off back in the day did a pretty darn good job and for that I thank them.
My plan from day one was just to clean up their cut job and keep it removable top. I worked on the cage and the mounting flange for the hardtop.

Here is what I am working with on the tub side, the top side looks pretty much the same and I am basically doing the same thing there.

 

[RustyNailJustin]

Fitting a cage in an already tight can was not to bad with a little planning. I was able to keep the wiper motors in the stock location.

 

[RustyNailJustin]

At this point the chassis was pretty much finished up and I got serious about body work.