Build The adventures of Otis the '76 FJ40

[drooartz]

Check out Stainless Steel Battery Trays for TOYOTA LANDCRUISER - https://stainlesstrays.com/?cat=1

Noel does great work and many on Mud are happy customers, including myself.

Thanks for that link. That looks like a great option.

 

[R.K.]

Finally had some time to knock a few small projects off of the Otis list. While I was waiting for some help to get the clutch slave installed and bled, I tackled a few small issues. First up was the dome light — the old one barely worked if you wiggled the switch just right, and the lens was cracked. A new LED one from City Racer and one item checked off the list.

From this:
View attachment 4004643

To this:
View attachment 4004644

I also got the wiper blades replaced with correct ones. Small victories are sometimes what we get.
View attachment 4004646

Is that a Morris Minor?

 

[drooartz]

Is that a Morris Minor?

It is indeed. 1966 Morris Minor 4-door named Maggie. Not really a hot rod, but more of a warm rod with a later, larger 1275 engine, Datsun 5-speed, and front disc brakes. Will even cruise at 70! More fun than she has any right to be.

 

[drooartz]

Here's the two sizes for OEM battery trays:

12" p/n 64403-70050 supercedes to 74403-60050
10.75" p/n 64403-70011 supercedes to 74403-60011

The longer version should fit just fine in your 1976, it bolted right up to my 1978.

If you have any interest in selling your extra set of jack rods to a fellow smurf blue FJ40 owner, let me know!

I just measured my old tray and it is the 12" version, so there you go. Will either do factory longer one or the stainless one mentioned in the thread.

I did check my parts pile, and I do still have the hooked rod (other rod already found a home). I'm going to hold onto it for now, but if I do decide to pass it on I'll let you know.

 

[drooartz]

Battery tray and assorted parts ordered. Also ordered the Koito headlight kit while I was at it.

For posterity:

81110-60P70 1 Koito headlights
74403-60050 1 Battery tray
74404-60060 1 Battery tray hold down
90950-04010 4 Shim
91631-40825 4 Bolt
90175-08003 2 nut
94511-00800 2 spring washer
94611-10800 2 washer

 

[drooartz]

Battery tray and assorted parts have arrived, as have the Koito headlights. Should be able to get the battery stuff installed this weeked, just waiting on the @cruisermatt brackets for the headlight swap to arrive next week. Less rush there, that may be a winter project. It’s already snowed at my place twice in the last week, so I guess winter projects are coming soon!

After 20 years of playing with British cars from long since defunct manufacturers, it sure is something to be able to order OEM parts right from a dealer.

 

[drooartz]

Battery tray and new battery installed. Otis is back on the road!

I also crossed 500 miles with Otis since the purchase back at the end of July. Starting to work on my winter projects list as the driving season is coming to a close here soon and the road salt season is about to begin.

 

[drooartz]

Snuck in one last mini adventure with Otis before he gets put into winter sleep. Went up to the Duchesne Ridge and explored around a bit. Just under 10k’ elevation. A little further on I ran into snow and mud in the shady bits. Otis got through it well for a stock truck on 9 year old tires, but I did have to spend some time at the car wash cleaning off the mud chunks. I’m really happy to have a 40 again.

About 650 miles on Otis this summer since I brought him home at the end of July. Not bad for shakedown testing, now it’s time to check a few more things off the repairs/updates list and plan for a full service and new tires in the spring. Was lovely to get him up doing what he was built to do.

 

[drooartz]

With winter approaching here in the UT mountains it's time to start planning the first major projects for Otis. There are a few small thing like the temp sensor and a basic full service that I will do before spring, but it's time to commit to an overall plan.

My ultimate goal for Otis is to make improvements for camping and travel. I've got great mountains and desert to explore here in UT, and I love camping and hiking. Not looking to build a hard core trail rig, but do want to have enough capability to get to neat places.

Given that Otis is essentially stock, these are the items I think I need to improve eventually for this vision:

• Ground clearance -- but just a bit? I go back and forth it I really need it
• Fuel range -- aux tank or 4Plus carrier?
• Cruising speed -- would like an easy 60mph with ability to cruise at 65 for a stretch when needed

My immediate need is to replace the tires. Otis currently has 9 year old KO2's in 30x9.5 on stock 15" wheels. I put about 650 miles on them this year since I bought the 40, all local just to get a feel. Upside of this setup is that the speedo is accurate which I do like. Downside is cruising speed is stock 40 with 4.22 gearing. So 60 is doable but 65 seems a bit much.

As I don't want to spend twice, this gets me thinking about suspension and gearing and where I want to wind up. Stay stock size and go to 3.70 gears? Mild lift, 16" wheels (City Racer) and 235/85R16 tires? Maybe 255/85R16? Big wide tires aren't right for my needs, but the move to 16" wheels (cost aside) does seem to open up options. New suspension also might help level out Otis' cruiser lean and larger tires gives a bit of rubber overdrive.

So with the need to do tires a given, the question is now do I also save up and go suspension and new wheels as well?

 

[drooartz]

Two options I’m playing with. Have to get new tires before spring, so that’s a cost no matter what.

#1 stay stock with a regear

• 30x9.5 tires (KO2 or KM3) on stock wheels
• regear to 3.70
• Keep stock springs as is (shocks are relatively new)

#2 bit of lift for rubber overdrive

• 235/85R16 (or maybe 255/85R16, though I like the skinnier option with the 235)
• CityRacer 16” wheels
• Terrain Tamer parabolic or Dobinsons or ? for a mild lift to handle the taller tires
• Keep stock 4.22 gears

#1 is easily 1/2 the price, even less if I can find a used set of 3.70’s to install instead of regearing my existing diffs with new gears. Gets the cruising speed I need, but no more ground clearance and still on old springs/bushings/etc.

#2 is close to the same final gearing as #1, but so much more expensive. Gain ground clearance and also new suspension all around. I can see the value, but boy is that price tag making me consider. This option also might drive me to a 4Plus tire carrier to take that extra weight for the spare off the tub. Slippery slope.

Probably need to call @orangefj45 and talk options to get my thinking more clear. And take a few more gigs to build up that budget!

 

[Andrew S]

I vote for #2. That is exactly what I have planned for my '78, but haven't made it there either due to funding concerns. You're not alone!

 

[drooartz]

I vote for #2. That is exactly what I have planned for my '78, but haven't made it there either due to funding concerns. You're not alone!

Good to know It's not just me!

#2 keeps the classic look but adds some functionality. The cost though, is going to take a bit of getting used to. I do believe in the spend it once rather than spend it twice. Still, it's quite the spend.

 

[cstav86]

For your tires this is the way. City racer 16’s with 235/85r16 white letter out BFG’s. Perfect for these trucks and looks very stock. I have a 2” old man emu for reference below. They also wheel just fine, ran them all over the San Juans.

The Holy Grail of FJ40 wheels and tires? — Exploring Overland

I’ve owned my FJ40 long enough to have gone through several generations of tire and wheel combinations. When I bought it it still had the factory steel 15 x 5.5-inch rims (with hubcaps), and absurdly skinny and short 215-series tires of a brand I do not recall, but which were genuinely tiny enough t

www.exploringoverland.com

 

[drooartz]

For your tires this is the way. City racer 16’s with 235/85r16 white letter out BFG’s. Perfect for these trucks and looks very stock. I have a 2” old man emu for reference below. They also wheel just fine, ran them all over the San Juans.

The Holy Grail of FJ40 wheels and tires? — Exploring Overland

I’ve owned my FJ40 long enough to have gone through several generations of tire and wheel combinations. When I bought it it still had the factory steel 15 x 5.5-inch rims (with hubcaps), and absurdly skinny and short 215-series tires of a brand I do not recall, but which were genuinely tiny enough t

www.exploringoverland.com

Thanks for sharing your experience. This really is the way I want to go. Now I just need to sort out the budget and try to do this in a way that doesn’t take the truck off the road for too long. Wish my tires were newer so I could phase this a bit over a couple years, but here I am planning for lift, wheels, and tires.

 

[EWheeler]

Two options I’m playing with. Have to get new tires before spring, so that’s a cost no matter what.

#1 stay stock with a regear

• 30x9.5 tires (KO2 or KM3) on stock wheels
• regear to 3.70
• Keep stock springs as is (shocks are relatively new)

#2 bit of lift for rubber overdrive

• 235/85R16 (or maybe 255/85R16, though I like the skinnier option with the 235)
• CityRacer 16” wheels
• Terrain Tamer parabolic or Dobinsons or ? for a mild lift to handle the taller tires
• Keep stock 4.22 gears

#1 is easily 1/2 the price, even less if I can find a used set of 3.70’s to install instead of regearing my existing diffs with new gears. Gets the cruising speed I need, but no more ground clearance and still on old springs/bushings/etc.

#2 is close to the same final gearing as #1, but so much more expensive. Gain ground clearance and also new suspension all around. I can see the value, but boy is that price tag making me consider. This option also might drive me to a 4Plus tire carrier to take that extra weight for the spare off the tub. Slippery slope.

Probably need to call @orangefj45 and talk options to get my thinking more clear. And take a few more gigs to build up that budget!

I'd vote spend to money on suspension of choice (don't forget the Redline kit), keep the 15" stock wheels, and put on some 33x9.5" Kenda's in tread style of your liking for rubber overdrive.

 

[drooartz]

Thanks, I’ll look into those Kenda Klevers as well.

 

[EWheeler]

Thanks, I’ll look into those Kenda Klevers as well.

A couple threads with the 33x9.5 showing them on 40's:

Post in thread 'FYI - Kenda Klever R/T KR601.....NEW size on the way..... 33x9.50R15LT'

Sep 5, 2025

I couldn’t find the 33x9.5r15 on simple tire. Size didn’t seem to show. How did you find them on the website?

Edit: I just looked and was able to see them, for some reason it doesn’t show on the drop down menu under the kenda klevers for me, but if you search the tire size they showed up.

Labor Day sale is still going on but not sure how you got $183… they are showing $263 as of today

I saw that too. Wonder if they caught wind of too low of a price and raised them. If you create an account it's cheaper and showing 237/tire.
I placed my order on 8/29.

Also if you chat with...

• bhsdriller

• 

There is a green 40 in there with stock suspension running these tires (post 126), so you may get away with no lift, if you decide you don't want to spent the money on a lift right away.

Post in thread 'Intro- "The Dude Magnet"'

Jul 5, 2023

Summer '23 wheels and suspension project complete! Posted on a couple other threads but want to keep this complete here.

Ground, primed and painted the wheels with a gloss Rustoleum grey:

Replaced the dry-rotted 235/75/15 KO2's with 33x9.50x15 Kenda Klevers:

Clay bar and wax:

4th of July deadline met!

Now I'll start obsessing over the seats...and stuck 4WD hub...and assorted leaks and drips...

• CBFJ

• 
• 

Tires:

R/T Tread:

https://www.prioritytire.com/by-brand/kenda-tires/klever-r-t?var-kenda=26575&utm_source=google&utm_medium=cpc&utm_campaign=15771753492&utm_content=&gad_source=1&gad_campaignid=15775588699&gbraid=0AAAAADAVMJSJbR3DFIV3OkCIQfKPsTPf_&gclid=CjwKCAiA2svIBhB-EiwARWDPjnkMI0MCjYRne50xJdEBgR_8CmJDSYmoY6bLOhN5l8wTkB7WbUZNFxoC8mgQAvD_BwE

M/T Tread:

https://www.prioritytire.com/by-brand/kenda-tires/klever-m-t2?var-kenda=109167

 

[drooartz]

Thanks for all that info! I’ll dig in.

 

[Andrew S]

Unless your current tires are really checked or showing other signs of concern, I'd run them another year or two without worrying. 9 years isn't that old.

 

[iliketrucks]

I love the color and your plans for it. Personally I'd keep the 30" tires for at least a few years, wait till you're truly bored with it to switch things up. It will still take you all over the place. I'm rarely there but you should take it to cruisers and coffee next year!