Builds "The Milk Truck" FJ45 Preservation Sorta (1 Viewer)

[Tank5]

I finshed the front axle for now. I notched the housing to fit the carrier on the opposite side. Then fitted a complete third so I could measure the axle lengths and compare them to a stock housing.

The long side measured 3 7/8 inches shorter than stock. I was aiming for 4 inches shorter. I planned to buy a custom inner shaft for this side, so I am happy woth how it came out.

I was aiming to have the short side use the stock length shaft it ended up 1/8 inch shorter than stock. I am hoping that the stock shaft will work. I expact I may have to trim a little off the stock shaft.

I ended up with a housing 4 inches shorter than the 80 front housing.

I finshed cutting off the front suspension brackets too. That was a lot of work but it is done.

 

[Dizzy]

Are you going to run a front sway bar on this 45?

 

[Tank5]

Are you going to run a front sway bar on this 45?

I have it in mind to run front and rear sway bars. I have the front and rear sway bars from a fj60 and hoping I can make them work. If not I will look at after market options.

 

[Tank5]

I started on the rear axle last weekend. I decided to do it a little different than the front to save some work. Rather than remove the spindle right at the end of the axle I cut it on the other side of the shock mount. Cutting the shock mount off so I could reuse it was extra work I wanted to avoid.

I decided to sleeve the inside of the axle to give it a little more steength and help align it. I measured the axle tube ID at 2 5/8 inches. The only Dom tube I could find that had an OD of 2 5/8 had a 3/8 wall. It should be plenty strong on the short end.

I cut 4 inches out of it and put it back together. The rear housing is now done minus the brackets which will get set when I start mocking it up.

 

[Tank5]

On to the next step. I stacked the 40 body inside. I was pleasantly surprised to find it would fit like this mostly worried about height, I have a few inches to spare.

There is still a lot of clean up on the frame needed to get it read to blast. Then on to mocking up the 80 suspension and narrowed housings.

 

[alia176]

Dude - have you given any thought to taking up fishing?

 

[cruisermatt]

So the rear is about FJ60 width now? What are you planning to use for an axle shaft?

 

[Tank5]

So the rear is about FJ60 width now? What are you planning to use for an axle shaft?

I picked up a set of new nitro 80 axles from another member a while ago. The short side spline section is long enough I can cut 4 inches out of it. The long side is unchanged, so I could use the nitro or stock shaft there.

 

[Tank5]

Dude - have you given any thought to taking up fishing?

My fly rod does have some dust on it andI have not tied a fly for a few years. I hope to get back to it at some point.

This truck won't build itself, so I continue.

 

[Tank5]

I tacked the suspension mounts on the rear axle where I hope they will stay. It is ready for mock up.

Then I started removing all the extra welds left behind by the junk I removed from the frame. I am still not done but getting closer. I cut the front shock towers off too.

 

[SNLC]

I have not touched this yet since resting the body on the chassis. I have been thinking about about the first things I need to tackle when I finally get to start on it. Boxing the rear of the frame is one the first tasks after I get it cleaned up. I am planning to weld in the spring buckets and square cross members from an 80 series and boxing the rear of the frame seems necessary for to support the suspension.

I have looked at ruff stuffs boxing kit but am considering another approach. I have a very solid fj40 rear frame half and it looks like the rear wheel arches are the same, so I am thinking of using the rear to box the 45 frame. It is already shaped correctly and it is a duplicate of what is already there. I am interested to see what the experience here on the forum thinks of the idea.

The first picture of the frame cross section is from an 80 series. The construction is "C" channel with a smaller "C" channel inside. Since I would be using two equal sized "C" channel frame pieces the overlap would be one in the frame and one side under it. The second picture is two pieces of 40 frame and would be how I would try to box the frame. Does anyone see any issues with boxing the frame this way?

pictures coming

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I have looked at doing this, more or less.

I cut up a nice 80 frame last summer. I saved all the front suspension bits but for the rear I cut the whole crossmember out in one piece. On the 67 pickup I am doing now I looked at fitting the rear crossmember to do coils in the rear. It is doable but will take a lot of work and mods because the 45 frame angles in so much. Totally doable though, especially with some fab skills.

Cheers

 

[SNLC]

Usually for boxing I just close in the outer c-channel. Make a template, cut it out and fit.

Seems like a lot more work to fit a c-channel to the existing outer rail. It’s not like the rails are wimpy, inner is about 1/8 and outer is nearly 1/4”. I would use 3/16’s to box it in.

Not to say what to mention is not a good idea and certainly strong but also a lot of work. Also, I try and work with new metal as much as possible vs old. No matter what you do old metal will have rust and pollutants in its pores unless it was always coated. I truly hate when a weld goes to crap because of old dirty steel.

Cheers

 

[Tank5]

Today I drilled 16 plug welds on 1/4 plates a PO welded to the frame. Not that much fun but that was the last of the excess I needed to trim off the frame. I continued to removed the left over bracket welds from the frame until I ran out of flap discs. I got the areas around the suspension done first, so I could push it outside to try out my new dustless blaster.

I now have the start of a beach in my driveway. I bought the blaster setup from Eastwood. It worked well enough for what I needed. I had to upgrade my powerwasher to a unit that flows 3.5 gpm which is what the blaster setup calls for. I think if you have a bigger powerwasher it might go a little faster. It seems like it would be a 6-8 hour job to do the entire frame with it. I was soaked and had sand everywhere by the time I was done. I will take the frame to town for a full sand blasting after I get the suspension mocked up.

It is drying now.

 

[Rigger]

Awesome thread!

 

[Tank5]

I have looked at doing this, more or less.

I cut up a nice 80 frame last summer. I saved all the front suspension bits but for the rear I cut the whole crossmember out in one piece. On the 67 pickup I am doing now I looked at fitting the rear crossmember to do coils in the rear. It is doable but will take a lot of work and mods because the 45 frame angles in so much. Totally doable though, especially with some fab skills.

Cheers

The rear presents the biggest challenge I feel. You pointed out the way the 45 frame widens as it goes back means I cannot just narrow the rear support assembly and set it in. I am planning to take it all appart so I can fit the angles.

I am also planning to move the rear axle back about 7 inches which is right where the rear shock mount tube sits. I am think that in order to do that I will need to build a support structure that continues off of the top of the arch rearward to fit it. Setting the axle farther back will require me to lengthen the upper and lower control arms too. I am concerned a little that extending the control arms is going to mess with the geometry too much but at this point I am just pushing ahead and will fix or adjust whatever doesn't work.

 

[jomelo]

This is such a cool build. Cannot wait to see it progress.

 

[Dizzy]

And, it doesn't hurt that you happen to be building it with a backdrop of the Yellowstone-of-New Mexico.

 

[Tank5]

And, it doesn't hurt that you happen to be building it with a backdrop of the Yellowstone-of-New Mexico.

It is a nice view but it comes with challenges. While I was powerwashing and blasting the frame a windy cold front with snow and rain came through for an hour. Not the best weather to be soaking wet and in the middle of something for. The sun came out at the right time though. It is a good place be. Social Distancing is a little easier up here.

 

[4Cruisers]

It is a nice view but it comes with challenges. While I was powerwashing and blasting the frame a windy cold front with snow and rain came through for an hour. Not the best weather to be soaking wet and in the middle of something for. The sun came out at the right time though. It is a good place be. Social Distancing is a little easier up here.

A bit of snow forecast overnight into tomorrow. Just a few clouds and a some gusty winds over on this side of the mountains. For me, it'll be more distributor refurbishing - inside work.

I've been searching for a decent sand blasting business in Albuquerque or Bernalillo, where will you be taking the frame? I'll be getting serious with my '71 FJ40 build now that we're getting into better weather (well, maybe after Tuesday).

 

[Tank5]

A bit of snow forecast overnight into tomorrow. Just a few clouds and a some gusty winds over on this side of the mountains. For me, it'll be more distributor refurbishing - inside work.

I've been searching for a decent sand blasting business in Albuquerque or Bernalillo, where will you be taking the frame? I'll be getting serious with my '71 FJ40 build now that we're getting into better weather (well, maybe after Tuesday).

Indoor work is good when the is weird like this. Really I suppose it is normal for this time of year.

I will take the frame to absolute powder coating. They have powder coated some wheels for me and both sets have held up great.

I am not going to have them powdercoat the frame, just blast it. I will use por15 or something similar to coat it.