Stevo's Unofficial Build Thread, FJ60 + FJ62 + FJ80 Axle = FJ68?

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I know it doesn't help you since you are on the other side of the country but these are the guys I have used and I have been super happy with them....

Page Brake | Locations
 
not sure what your getting quoted...but there are a ton of driveline shops here in Utah and they are very reasonable...Just had a dc shaft built for $150 I can always ship to you too.
Same guy lengthened one 4 inches for me as well for $45
 
Just to clarify, we are talking about the splined section, not the tube correct? Extending the tube is easy and can be at home at a cheap price, but the spline is more tricky. Typically something like this is a better way to go to extend the splines (just an example): Toyota, Suzuki Samurai, and Jeep Off Road Parts or Long Spline Drive Shaft Kit | Marlin Crawler, Inc.

This is what I think you are trying to do:

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Thanks for all the help guys, Boots that looks great, did you do that?
RMP&0 that looks like a good resource to have, too bad I'm not in that part of the country.
Tom, If I can't find a good place in trenton by the time I get around to the diesel swap I might take you up on that.

I took the measurements I needed from the front, and as it turns out I should be ok with the stock amount of slip.

I received my rear driveline from marlin today, but they forgot to send the 10mm driveshaft bolts I ordered. :mad: I got some free spares from them and they should be here tuesday.

Thats the way things go.
In the process of pulling out all the driveshafts I had around, I found out that if I put a front shaft slip on my stock fj60 shaft I had a shaft I could use temporarily. Its got around an inch of spline engagement enough at least to drive it into and out of the shop.

Man does it feel good to be able to drive the truck again. And I even managed to redo the clutch line so I can shift through my gears.

I am so happy with the way it rides, so smooth, takes turns nice without any real body roll. And the saginaw pump helps me turn the 35's easier than I used to turn the stock 29" tires I had on there.

I still need to put the rockers on, but I have them ready to go. Then once the interior is in and I get the engine 100%, plus slap an exhaust on, I should be ready to get it inspected and road legal.
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I have that same sticker on my beer cooler :cool:
 
StevoJonesFJ60 said:
Thanks for all the help guys, Boots that looks great, did you do that?
Click to expand...

Yup, that's also the one that broke. It was the male spline section that broke so maybe if you only extended the female part and clearanced some on the male you could get another inch or two of engagement. On that first pic I slid both female sections on the original spline to line them up. Then I sleeved it.

I salvaged the CV joint by cutting off that end and put on a proper long slip that brokenparts gave to me and it's been in service ever since.
 
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Extending the female portion is what I had in mind.
What I'm gonna do is mix and match some shafts, get it tacked really well and then flex out the truck. If it slips out I'll worry about extending the slip sections.

Also, does anyone happen to have a gas tank filler neck laying around? While flexing out there is a gas leak coming from it.
 
Marlin came through big time today.
I got my driveshaft bolts in the mail and drilled out my front and rear transfercase flanges. I also modified my transfercase crossmember to allow for more angle in the front driveshaft. It came out pretty well.

Took the truck for a couple laps around the property and was smiling from ear to ear. I love the ride and I can't express how nice it is to be able to drive the truck around.

Tomorrow I'm going to pull the belts and get the correct sized one for my WP-ford alt-Crank loop. It slips pretty bad and I have the adjustment all the way.
Also I hope to get the front driveshaft made, once those things are done its off for some "field testing" if ya know what I mean.
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Romped on my friend seans f-350 a little bit today, started mapping out some new trials too.

On the Cruiser I replaced that squealing belt, and just for my own personal reference I'm gonna post the belt that fits that loop here.

I also made my front driveshaft. It came out pretty nice, it might be a few degrees out of phase but hopefully it won't vibrate too bad. I figured I would try some dynamic balancing for it so I drilled a hole in it and poured in some ATF. Hopefully that helps some.

Also a note for people when doing a brake test, make sure all your junk is either out of your truck or well secured. I tested mine out and made a mess when I locked up all 4 tires on some concrete inside.
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Yesterday I installed the front shaft and took the cruiser out.

Performance is great, I can easily walk up things I would need to throttle through before. I can't say enough about the steering, easily turns those 35's. It does put a load on the engine, but nothing terrible.
The suspension is smooth too, and as the front springs soften up its only going to get nicer.

Tomorrow morning I plan on taking it out and testing what it is capable of for a few hours. After that I'm off for some camping so there won't be any work on the cruiser for a while.

I'll be sure to get some pictures of what I take it though.
 
Sorry about taking so long to post up, but in case anyone wanted to know wheeling went great.

A few things did go wrong, but nothing major.

First thing that happened was I forgot to gas up and ran out of fuel, so I hopped out and snagged a shot of that.

Second, the pulley on my power steering pump was loose and starting hitting my fan and destroyed a fitting on my upper radiator hose. In the picture you can see how far it had slid from being flush.

That pretty much ended wheeling for that day.
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Yesterday I fixed the pulley with a tack weld and the upper hose.
Took it out to wheel with my buddy Sean, and ended up blowing my upper radiator hose off dumping hot antifreeze all over my engine bay.
Turns out the plastic fittings I was using for the 90* bends weren't rated for high temperature.

You can see how deformed they got as I attempted to tighten them up to keep them from leaking.
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So today after work I took the time to buy a new hose and replace the old setup.

Out with the old, and in with the new.
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Not too much work done on the cruiser lately, been wheeling it too much.
The unfortunate part about night wheeling is that is pretty difficult to get pics.

I still only have 1 seat in the truck. hopefully tomorrow I can get the interior reinstalled and possibly get those sliders on.

Its leaking some gas, I'm going to need to replace the fuel pump. But other than that no issues.
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