Builds Stretched 1-Ton FJ40 (2 Viewers)

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Done for now. The rear sway bar is next, then the fuel system. I am very happy with the fenders.

FYI, the tube caps (one pictured) came from here: https://utvdistribution.com/

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Rear sway bar
I got the rear sway bar setting in place (no welds yet). I tried to leave enough clearance for a fuel tank and to access the bolts on the rear frame cross member. I will need to center the rear axle, bend the sway arms, position the axle tabs and weld. Before I do that, I will measure and order the fuel tank.

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I have a feeling you will be notching the rear frame for coilover clearance. How long of coilovers did you get?
 
I have a feeling you will be notching the rear frame for coilover clearance. How long of coilovers did you get?
I had the same thought, as I had to on mine when I did mine. I tilted mine back as well, as I had tire-coilover interference on bump, and coilover-frame interference at full extension.
 
I have a feeling you will be notching the rear frame for coilover clearance. How long of coilovers did you get?

I haven’t purchased the coilovers yet and I hadn’t thought about that clearance. I’ll have to check the front, too.

It is built to have 16” front and 14” rear.

I had the same thought, as I had to on mine when I did mine. I tilted mine back as well, as I had tire-coilover interference on bump, and coilover-frame interference at full extension.

Can you post a few pictures of your frame notch and coilover placement?
 
Man, building all that without mocking up coilovers is going to be risky. Hopefully, it all works out.
 
I haven’t purchased the coilovers yet and I hadn’t thought about that clearance. I’ll have to check the front, too.

It is built to have 16” front and 14” rear.

Can you post a few pictures of your frame notch and coilover placement?
Shocks are angled back, and the floor was narrowed to make more room. I don't have photos of the notch, If I remember correctly, at the top its 1/2 the depth of the frame, at the bottom, its the full depth. Diameter of the shocks will be important as well. In the back, I started with 60 series axles and 2.5" coil-overs and ended up going to one-tons and 2" coil-overs to make everything clear, and even then, at the very limits everything touches. I have 16" front and back, 2.5" coil-overs in the front, and 2" coil-overs in the back. I can use all of the travel in the back, but the front is limited by the front pinion angle, so I need to adjust some link geometry to make the pinion tilt upwards as it droops. Lots of time in the 4-link calculator, and even then, I am on iteration 2 and there needs to be at least one more.

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Shocks are angled back, and the floor was narrowed to make more room. I don't have photos of the notch, If I remember correctly, at the top its 1/2 the depth of the frame, at the bottom, its the full depth. Diameter of the shocks will be important as well. In the back, I started with 60 series axles and 2.5" coil-overs and ended up going to one-tons and 2" coil-overs to make everything clear, and even then, at the very limits everything touches. I have 16" front and back, 2.5" coil-overs in the front, and 2" coil-overs in the back. I can use all of the travel in the back, but the front is limited by the front pinion angle, so I need to adjust some link geometry to make the pinion tilt upwards as it droops. Lots of time in the 4-link calculator, and even then, I am on iteration 2 and there needs to be at least one more.

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Damn, 16" front and rear? I've never seen that before. Most I've heard is 14", almost everything is 8" - 12" at work.
 
Damn, 16" front and rear? I've never seen that before. Most I've heard is 14", almost everything is 8" - 12" at work.
Yeah, like I said, I can't currently use all of the travel up front.
I started out with the 16x2.5s in the rear, and when that didn't fit, I moved them to the front and bought the 16x2s for the rear.
 
@DangerNoodle, It’s been fun mocking this up with string and 2.5” pvc tube. It will work out. I have tools to cut steel if something needs to be moved. I don’t have much of a choice as the shocks that I want were on major back order. I am also very limited on space so it is a bit fun trying to get things coming as I need it.

Thanks for the pictures, @mano002. Your Cruiser looks awesome! My front looks pretty close to your truck so hopefully that will be fine. The back will be fine, too, even if I have to notch.

@Firemedic831 , I was aiming for 14” in the front but I needed to limit the front up travel due to other clearance issues that entered the scene after the fact so I figured that I might as well add the 16’s.

I will wait to order the tank though. You are all an amazing help!
 
I spoke to Oakley when he was selling it for 30k. Old school coolness. Need a few people to go in on it and pass it around. Old original crawler new be persevered and wheeled. I watch it walk up Pritchett Canyon.
 
Old school coolness, ha! Now I am feeling a bit experienced. I’d love to take that thing through Pritchett. I can’t wait to take mine through again. The first time that I did Pritchett was in the mid 1990s. We had three somewhat stock Cruisers and we made it all of the way using a tow strap hooked to ten people, pulling my Cruiser up so that we could winch the others. No lockers. No power steering. Just a set of long shackles and Con-ferr nerf bars that did more damage than they were worth.

Edit: I am reminded that we camped out at Behind the Rocks that night and we ran Pritchett backwards the next day. I have a picture somewhere. Everyone coming up the right way thought that we had no idea what we were doing and they told us that we wouldn’t make it out. Ha!

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