Build Stretched 1-Ton FJ40

[DangerNoodle]

I’m sure that it will all work out and I’ll be watching your post (or here) for updates.

I came to the senses that I need to cut out my 4-link cross brace and reconfigure it so that it bolts to the frame and it is removable. I will be able to get my transfer case out once the cross brace is off and I will clock my transfer case down a notch, then remake my transmission mount to clear the front driveshaft. Once this is done I will be able to have a new intermittent shaft made to length and create a new carrier mount.

This should only take 7-10 days given my toolset and ability so I may have this done by April. Ha. That gives me 3 months (~25 available working days) to finish the cage, sliders, bumpers, top and interior before SAS. I might be calling in for reinforcements, @DangerNoodle.

Lol, let me know. I can probably help out or at least do some stuff here and get it to you.

 

[Mike Shull]

You guys are doing work before trips? I grab the tape, cross my fingers, close one eye and hope for the best and ignore any new sounds

The tape method worked for a long time, but after 47 years of abuse, an overhaul was much needed. Had I to do it again, I may have rebuilt it in phases so that it would have been easier to test different components.

 

[Mike Shull]

You guys are doing work before trips? I grab the tape, cross my fingers, close one eye and hope for the best and ignore any new sounds

One more thing…I am installing some good speakers that should drown out any new sounds.

 

[Mike Shull]

I picked up some steel this weekend and I made two speaker boxes for the cage. I will need to kick it into high gear one of these weekends.

 

[Firemedic831]

I 100 percent agree do Stages and see if they work . Its hard when you do a complete build

 

[Mike Shull]

I 100 percent agree do Stages and see if they work . Its hard when you do a complete build

It’s a bit late for that.

 

[Zukrider]

Mike. Be sure to line the inside of the speaker boxes with some type of dyna mat. And some poly fill will help a lot to.

 

[Mike Shull]

Mike. Be sure to line the inside of the speaker boxes with some type of dyna mat. And some poly fill will help a lot to.

Good tip, Joe! I don’t know anything about making good sound. What will these products do? What I do know is that weld sparks burn right through the speaker in no time.

I was contemplating building the rear 6x9 speaker brackets with an open back but I am wondering how much better they would sound if they were in a full enclosure.

 

[matzell]

Something to think about. I used wake board speakers that simply bolt to the roll cage. Simple and easy.

 

[Mike Shull]

Something to think about. I used wake board speakers that simply bolt to the roll cage. Simple and easy.

I thought about that but I already have the other speakers. I’m definitely going the hard route here and it’s probably not a good use of time but I should still have time to finish everything needed to take wheeling by summertime.

 

[Mike Shull]

Thanks again for the tip, @DangerNoodle. I don’t know if I am more excited about the bender or the bench. Ha. Gotta love Facebook Marketplace. I’d have an ARB twin on the floor but it sold while I was on my way.

 

[DangerNoodle]

Thanks again for the tip, @DangerNoodle. I don’t know if I am more excited about the bender or the bench. Ha. Gotta love Facebook Marketplace. I’d have an ARB twin on the floor but it sold while I was on my way.

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"I am a marketplace fiend"

I also may or may not have a problem lol

 

[Mike Shull]

"I am a marketplace fiend"

I also may or may not have a problem lol

It’s a fun hobby, though the problem extends well beyond Marketplace at least for me. Ha.

More goodies arrived. I am way ahead of myself here…

 

[Zukrider]

Good tip, Joe! I don’t know anything about making good sound. What will these products do? What I do know is that weld sparks burn right through the speaker in no time.

I was contemplating building the rear 6x9 speaker brackets with an open back but I am wondering how much better they would sound if they were in a full enclosure.

They help keep the rattles down, and enhance the bass output. Open backs work do any good in this type of vehicle.

Nice score on the bender. Rogue has a great teaching set of web pages and YouTube videos. Highly recommend.

Tube and Pipe Bending 101 | Rogue Fabrication

This is currently being updated to add new offsets for the M601/605/625. Please let us know if you have any questions. This is our page where you can learn how to bend tubing accurately with...

www.roguefab.com

Design Index - Bent Tube Design Tools - Rogue Fabrication

Tube Design Index – No CAD software required! Bookmark this page! We have several calculators to help you design bent tube structures, and we’re frequently developing more of them! Feel free to share and post...

www.roguefab.com

 

[Mike Shull]

They help keep the rattles down, and enhance the bass output. Open backs work do any good in this type of vehicle.

Nice score on the bender. Rogue has a great teaching set of web pages and YouTube videos. Highly recommend.

Tube and Pipe Bending 101 | Rogue Fabrication

This is currently being updated to add new offsets for the M601/605/625. Please let us know if you have any questions. This is our page where you can learn how to bend tubing accurately with...

www.roguefab.com

Design Index - Bent Tube Design Tools - Rogue Fabrication

Tube Design Index – No CAD software required! Bookmark this page! We have several calculators to help you design bent tube structures, and we’re frequently developing more of them! Feel free to share and post...

www.roguefab.com

Awesome. I’ll check out those videos. I might still need to borrow some dies as the final pieces of this build are depleting my play finds quickly!

 

[DangerNoodle]

Awesome. I’ll check out those videos. I might still need to borrow some dies as the final pieces of this build are depleting my play finds quickly!

The bender is always the cheap part lol.

Dies get expensive quickly. I really want to get the mandrel attachment for mine.

I love that bender.

 

[Mike Shull]

The bender is always the cheap part lol.

Dies get expensive quickly. I really want to get the mandrel attachment for mine.

I love that bender.

Yeah, no doubt about that! The mandrel attachment would be cool, especially if they had a 2.5 and 2.25” die for exhaust work.

 

[DangerNoodle]

Yeah, no doubt about that! The mandrel attachment would be cool, especially if they had a 2.5 and 2.25” die for exhaust work.

Unfortunately this bender only goes to 2", but that would be super nice.

 

[Mike Shull]

Unfortunately this bender only goes to 2", but that would be super nice.

I knew that, but I didn’t know that Swag Offroad made a 2.5” die. There isn’t a description but it is listed under their press brakes. I can’t envision how this would work.

REV 2 Tube Bender Die - 2.50" Round Tube Dies - 120°, 7 inch CLR

Bender Dies for the SWAG Off Road Tubing Bender

www.swagoffroad.com

 

[Ditcherman]

I knew that, but I didn’t know that Swag Offroad made a 2.5” die. There isn’t a description but it is listed under their press brakes. I can’t envision how this would work.

REV 2 Tube Bender Die - 2.50" Round Tube Dies - 120°, 7 inch CLR

Bender Dies for the SWAG Off Road Tubing Bender

www.swagoffroad.com

Not sure why that's in their press brake section, it looks just like my dies for my Swag bender.
I bought a 2" before I knew what I really needed and not sure where I'll use it.