workingdog
GOLD Star
So, this is going to be a build thread for my '66/'67 fj40. Currently on fj60 axles, 6.0l GM V8, 4L80, fj60 transfer case with AA 4.0 gear set. And, both rear quarter panels and wheel wells are trashed.
After following the Knorr Brothers @55guy on the Rubicon for Rubithon, I realized that I need/want to go to 40's with a longer wheel base and a little more height (as little as needed). And then on my next trip I blew up a birfield and that kind of sealed the deal for making some improvements.
We've reached a point where it does not appear there's any way to do this incrementally anymore, so we are committing to diving in for the next year. I'm going to restore the garage to a garage (it had been converted to an in-law unit by PO and the garage doors are now french doors), kick my son's band out, and move in there.
I've been told I can't run 40's on my fj60 axles, even with RCV shafts. That I HAVE to go to dana 60's. Okay, But, to accommodate 40's I also need to go up at least 2 to 3 inches (rig is currently sprung under). And, lengthening the wheelbase (I did a head stand on the way into the RTF property and had to be drug up on the way out) is hard to do with springs.
So, the plan is to stop doing half measures and jump in and do it all. Dana 60's front and rear, stretch the rear of the frame and modify it to accommodate links, 4 link rear, 3 link with track bar front, coil overs, built new tub as Ramination did here My '64 FJ40 Build - Cave Cricket. Build new front fenders. Have the tub off the rear and the fenders and aprons off the front, we'll have decent access to both axles.
It's going to be a while before the garage is ready. We can start by taking the roll cage off and doing the body tear down outside. But, for now, I'm just trying to work on the details like desired wheelbase, track width, ride height, link design, parts I'll need. Buy new or used axles, etc. etc.
Here is my beginning build plan right now
After following the Knorr Brothers @55guy on the Rubicon for Rubithon, I realized that I need/want to go to 40's with a longer wheel base and a little more height (as little as needed). And then on my next trip I blew up a birfield and that kind of sealed the deal for making some improvements.
We've reached a point where it does not appear there's any way to do this incrementally anymore, so we are committing to diving in for the next year. I'm going to restore the garage to a garage (it had been converted to an in-law unit by PO and the garage doors are now french doors), kick my son's band out, and move in there.
I've been told I can't run 40's on my fj60 axles, even with RCV shafts. That I HAVE to go to dana 60's. Okay, But, to accommodate 40's I also need to go up at least 2 to 3 inches (rig is currently sprung under). And, lengthening the wheelbase (I did a head stand on the way into the RTF property and had to be drug up on the way out) is hard to do with springs.
So, the plan is to stop doing half measures and jump in and do it all. Dana 60's front and rear, stretch the rear of the frame and modify it to accommodate links, 4 link rear, 3 link with track bar front, coil overs, built new tub as Ramination did here My '64 FJ40 Build - Cave Cricket. Build new front fenders. Have the tub off the rear and the fenders and aprons off the front, we'll have decent access to both axles.
It's going to be a while before the garage is ready. We can start by taking the roll cage off and doing the body tear down outside. But, for now, I'm just trying to work on the details like desired wheelbase, track width, ride height, link design, parts I'll need. Buy new or used axles, etc. etc.
Here is my beginning build plan right now
- Workspace/Garage
- Garage door
- How?
- Is it high enough? No, it’s not
- So, what has to be done to get it high enough?
- Gable end this end (both ends)? That is the least amount of work
- And it fixes everything else
- Need to fix the bowing walls
- Truly workable carport from back of garage to a car length in front of garage.
- Design
- Set track width goal
- What is the current track?
- What is the desired track?
- What wheels are we going to run?
- Set wheelbase goal
- Is a stretch required
- Set ride height goal
- 40” tires
- Preliminary link/coilover design
- Tear down
- Remove roll cage (outside with gantry)
- Remove the front fender, grill and aprons (and keep)
- Brace tub to locate B pillar
- Remove the tub, cut from body behind gas filler and gas tank
- Throw away quarter panels and wheel wells
- Keep existing floor and rear sill
- Remove fj60 axles and sell them
- Set rig on jack stands
- Remove all suspension mounting points on frame
- Frame work
- Clean, inspect, and repair the frame (at this point it’s accessible except for the middle)
- In rear, remove rear curve down and stretch 10* inches
- 2x5 or 2x4 0.188 wall box tube
- Figure out how to mount 4plus bumper at the right height.
- Box frame where necessary
- Optional - Remove 3 inches front frame to move front bumper in
- Axles, suspension, and steering
- Buy Dana 60 axles front and rear – buy new and rebuild or buy new?
- Used axles still need to be narrowed, new axle shafts, 4.88 gears, lockers, knuckles, truss
- Which is a lot of work and expense
- Buy coil-overs – 14” of travel, start with 150/150
- But link kit, hoops, and other parts for links coil-overs, steering and cross members
- Finalize wheel base and ride height
- Lay out four link in rear and three link with track bar in front including hoops for coil overs front and rear
- Coil overs in rear to fit inside new full height wheel wells
- Figure out steering
- Rear link mount cross member
- Front link mount cross member
- Finalize four link Including all mounting tabs and crossmembers
- Tack all mounts in, use PVC links and.
- Tack in in coil-over mounts to axle and hoop mounts to frame
- test cycle
- Once good, weld them in and weld up links
- Body
- Stretch floor 10 inches - in the middle or at the gas tank
- Storage where gas tank would be?
- Buy new quarter panels with top lip
- Extended quarter panels 10 inches as needed
- Fabricate new wheel wells that are full height (replicate stock texture or buy reproduction wheel wells and make them taller)
- Turn rear doors into tailgate
- Assemble quarter panels, lip, floor, wheel wells, to body including frame for tailgate
- Build (or buy) new front fenders, trim apron to fit for ride height
- Modify roll cage for new tub
- Don’t stretch, maybe add a kicker to the back.
- modify body mounts to work with new wheel well height
- Engine bay
- Relocate power steering cooler
- Reorganize engine bay
- Work on firewall as much as possible
- Fan and shroud on radiator
- New radiator?