So I want an FJ 40 but... (1 Viewer)

[metalshaper]

***Disclaimer***

If you're a FJ 40 purest DONT READ BELOW!!

***END DISCLAIMER***

So I have really fallen in love with these FJ 40's and I have grown to love the shape, well almost. I've always been a Jeep guy more so than a Toyota guy. The more I look at pictures the more I wanted one. The problem was they were either in really bad shape and wanted top dollar or they were in really great shape and wanted top dollar, a kidney, left testicle, a lunch and while they were at it the other kidney. Honestly for what I wanted to do with it neither of these options worked for me. Well, they could have worked but what fun would that have been. So I happen to have a friend that bought an FJ 40 that I could pull some measurements from. After spending a little time measuring and researching, boy that thing was JACKED UP. It was a real struggle trying to pull anything constant from this FJ. However for what I was doing, it will work.

So the first step was to order some cold rolled sheet metal. I ordered some 16 and 18 ga sheet metal, about 10 sheets each. Then I went to the computer and try to draw the basic shapes. With my rough measurements I can cut some blanks to get started with.

 

[metalshaper]

So my thought was I would start with the smaller pieces. I started with the inner fenders on the back.

 

[wngrog]

Great. Bring it.

 

[metalshaper]

So now I needed to make a die for my Pullmax so I can make the same shape as the FJ40 upper body edge. I think it turned out pretty good.

 

[Bomar]

Like!

 

[MScruiser]

I'm interested

 

[metalshaper]

There is always a two step process on making a panel. The next part of this equation is to make a guide so I can run that die over edge of the panel.

 

[metalshaper]

I guess I should have stated my plans first. I have a 6.0 Chevy engine that I'm going to put in this with a Dana 60 front and 14 bolt. I already have them built with Detroit lockers chromoly shafts and OX joints. I also already have the DOM tubing for the tube chassis. I want it to look the FJ40 part (kinda) but I want a rock crawler. I also Have my Corbeu seats already. The picture is what I'm aiming for. Also, sorry it takes so long to post, I'm doing it with an iPhone.

 

[metalshaper]

I can't edit my posts so I'll add here that I am doing a comp cut rear. Drawn is more stock.

 

[metalshaper]

Front cowl section I cut. As you see I have the slot for the louvers. Well, crap I don't have a louver punch... Let's make one.

 

[metalshaper]

Basically I wanted a louver tool that I could cut any length louver. I'll just post the pictures. Basically I take a chuck of steel and face the pieces and then put on the index table and machine the shape into the edge with a ball end mill.

 

[metalshaper]

Dang picture limit...

So, fast forward...

Typically you make a few passes first cutting the metal then pressing the shape in. I used a short cut by cutting the 1/16" slit on the CNC.

 

[metalshaper]

So let's test this out...

Ok, so it works better than I thought and it's very similar to the louver cutter that you could buy in the 50-60's.

Let's actually use it.

 

[metalshaper]

Cut the other side and let's form it and the louvers. I'm really liking that. I think that will work just right.

 

[MScruiser]

Damn, man.

You have some major skills, and some awesome tools.

 

[metalshaper]

But wait! There's more!

 

[jynx]

This is gonna be good!

 

[metalshaper]

Here you can see I cut some MDF as my "hammer form" so I can fold the edges down.

 

[metalshaper]

I haven't 100% decided what to do with the vent hole on the front cowl piece. To me, it's an iconic piece that really defines the FJ40. On the other hand it's a vent and I don't know that I actually need it. So for now, I will leave that unfinished so I can either delete or do something cool/different. I did however leave enough meet to form what ever I want to form there, meaning the stock shape.

 

[metalshaper]

Here is basicly the "rear" comp cut sections. So I made another hammer form so I can fold the lip on the fender down and it served another purpose to be a guide for the edge die. In one of these pictures you can see the MDF under the sheet metal. I was in the process of removing it.