Nice build, looking forward to how it all pans out with the footwell extension.
West Coast Australia FJ45 cruiser build
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- #62
deflection
ok, haven't posted any pics for a while . Sorri to those who are following this build.
I didn't mention in the last set of pictures the problems I discovered when doing a trial assembly on both side of the fire wall. The steering mounting plate had to be cut and shifted about 30mm outwards away from the engine to provide satisfactory clearance of the steering and extractors. Also the platework on the RHS was protruding into the engine space. I had to cut the corner out and plate to suit the engine position.
Following this I fitted the doors and discovered a major set back, the front of the cab had dropped causing a problem with the doors. The doors wouldn't close properly, about a 15mm overlap plus the original clearnace of approximately 10mm. Maybe is was worst than this, can't really remember the exact misalignment.
Lucky I fitted the doors and discovered this problem now rather than later.
Once I accepted this problem I set out to chop the cab in half while braced with turn buckles. I used the turn buckles to bring the cab back into alignment. This took several weekend, but fortunately I was able to correct the situation. Had to make up around 10 turn buckles to provide the adjustment I wanted, basisly vertical, horizontal and cross positioned buckles.
As can be seen in the picture below, a wide gap in the floor opened up following the correction work. I really didn't like this so I decided to cut the patch work floor out and replace with 3mm thick one piece floor. Unfortunately this required me to cut out the PFC for the body mount used on the existing floor. This required a couple of mock assembles to align the front body mounts. To achieve this I basilys had to assembly the entire front end and ensure the bonnent and guards were aligned with the chassis.
The following picture shows the mock assembly to ensure the front body mounts are correctly positioned, marking out the position and setting the height of the pipe built in mounts.
Bottom view of the cab following completion in the second quarter of 2010. As can be seen in the picture, the handbrake connection plate has been moved back to suit the position of the transfer case. With the LS1 coupled to the 4L60E and the toyota handbrake type transfer case, the handbrake lever needs to be moved back to suit the original cable length.
ok, haven't posted any pics for a while . Sorri to those who are following this build.
I didn't mention in the last set of pictures the problems I discovered when doing a trial assembly on both side of the fire wall. The steering mounting plate had to be cut and shifted about 30mm outwards away from the engine to provide satisfactory clearance of the steering and extractors. Also the platework on the RHS was protruding into the engine space. I had to cut the corner out and plate to suit the engine position.
Following this I fitted the doors and discovered a major set back, the front of the cab had dropped causing a problem with the doors. The doors wouldn't close properly, about a 15mm overlap plus the original clearnace of approximately 10mm. Maybe is was worst than this, can't really remember the exact misalignment.
Lucky I fitted the doors and discovered this problem now rather than later.
Once I accepted this problem I set out to chop the cab in half while braced with turn buckles. I used the turn buckles to bring the cab back into alignment. This took several weekend, but fortunately I was able to correct the situation. Had to make up around 10 turn buckles to provide the adjustment I wanted, basisly vertical, horizontal and cross positioned buckles.
As can be seen in the picture below, a wide gap in the floor opened up following the correction work. I really didn't like this so I decided to cut the patch work floor out and replace with 3mm thick one piece floor. Unfortunately this required me to cut out the PFC for the body mount used on the existing floor. This required a couple of mock assembles to align the front body mounts. To achieve this I basilys had to assembly the entire front end and ensure the bonnent and guards were aligned with the chassis.
The following picture shows the mock assembly to ensure the front body mounts are correctly positioned, marking out the position and setting the height of the pipe built in mounts.
Bottom view of the cab following completion in the second quarter of 2010. As can be seen in the picture, the handbrake connection plate has been moved back to suit the position of the transfer case. With the LS1 coupled to the 4L60E and the toyota handbrake type transfer case, the handbrake lever needs to be moved back to suit the original cable length.
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- #63
Front Guard Supports
The front guard supports took me alot longer than I anticipated, pretty much like everything else on this build. When someone asks me how long something will take, I reluctantly guess knowing I have no idea.
To make these brackets involved numerous fit-ups, making cardboard templates, tacking, welding, grinding and so on. The pictures will not show the effort and time or maybe it will to thoughs who how have built similar projects.
The right hand side of the vehicle has the power steering unit, steering shaft and shock mounting bracket (both sides for this). Some might recognise the F150 or F250 shock bracket. Rather than fabricate one, I found it quicker to use one of these and looks the part. I did get my idea on IHMUD so I can't take the credit for this one. I brought a pair of shock brackets from F-Trucks Welshpool. I modified the ends to suit the Toyota cruiser chassis.
The guard mounting brackets are different on each side because of the gear on the right side. Anyone who has the landcrusier 40 or 45 series will know that the original guards are supported by the formed bracket mounted off the chassis and two small bolts that tie it to the cab. To faciliated easy removal, strengthen the connection and allow repeatable fit-up in the absence of the chassis, I added to large M10 bolts on each side to tie the guards to the cab. These bolts are in addition to the two small factory bolts. I had to weld in spacers between the cab and guards where the new bolts are fitted. because of the gap. Here are some of the pics of the guard bracket fabrication process.
The front guard supports took me alot longer than I anticipated, pretty much like everything else on this build. When someone asks me how long something will take, I reluctantly guess knowing I have no idea.
To make these brackets involved numerous fit-ups, making cardboard templates, tacking, welding, grinding and so on. The pictures will not show the effort and time or maybe it will to thoughs who how have built similar projects.
The right hand side of the vehicle has the power steering unit, steering shaft and shock mounting bracket (both sides for this). Some might recognise the F150 or F250 shock bracket. Rather than fabricate one, I found it quicker to use one of these and looks the part. I did get my idea on IHMUD so I can't take the credit for this one. I brought a pair of shock brackets from F-Trucks Welshpool. I modified the ends to suit the Toyota cruiser chassis.
The guard mounting brackets are different on each side because of the gear on the right side. Anyone who has the landcrusier 40 or 45 series will know that the original guards are supported by the formed bracket mounted off the chassis and two small bolts that tie it to the cab. To faciliated easy removal, strengthen the connection and allow repeatable fit-up in the absence of the chassis, I added to large M10 bolts on each side to tie the guards to the cab. These bolts are in addition to the two small factory bolts. I had to weld in spacers between the cab and guards where the new bolts are fitted. because of the gap. Here are some of the pics of the guard bracket fabrication process.
Mate, this build is epic. Impressive work!
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- #65
thanks mate, 
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- #66
I bet your curious about how the guard support brackets turned out.
I'll let you be the judge.
The following pictures include the new platework developed for the guards. I intend on fixing rubber skirts and the bottom of the guards to shield the engine bar from dust and rocks..
I'll let you be the judge.
The following pictures include the new platework developed for the guards. I intend on fixing rubber skirts and the bottom of the guards to shield the engine bar from dust and rocks..
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- #67
updates
I may have not posted any pictures for ages, but doesn't mean no work has been done. I got some flares from Bursabaju. He is based Indonesia, Surabaya. Fortune enough I was able get these flares imported earlier in the year. Not 100% shape wise, but more than safisfactory. I have glassed in small steel mounting brackets to ensure when bolted up the surfaces are flush and stop the fasteners from pulling through. Here is the result following fitting.
I may have not posted any pictures for ages, but doesn't mean no work has been done. I got some flares from Bursabaju. He is based Indonesia, Surabaya. Fortune enough I was able get these flares imported earlier in the year. Not 100% shape wise, but more than safisfactory. I have glassed in small steel mounting brackets to ensure when bolted up the surfaces are flush and stop the fasteners from pulling through. Here is the result following fitting.
So how do you like the fenders? Any detailed pics of them?
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- #69
I like there appearance, makes the vehicle look a bit wider. Just the shape is a little inconsistent in places, rating would be 95-8% perfect.
Great thread- did you end up finishing it? 
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Project on hold
Project currently on Hold-
Commitments ruling at the moment, building a garage to house the cruiser. Hope to recommence in the last quarter of this year. Vehicle is in primer and gathering dust.
Project currently on Hold-
Commitments ruling at the moment, building a garage to house the cruiser. Hope to recommence in the last quarter of this year. Vehicle is in primer and gathering dust.
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- #72
Cronology 1
Yes as previously said the project is on hold
, H renovation duties and now building a G (almost complete).
For those interested, in late 2011 the cab was sent off to get plastic coating (poly-urea) applied to the under-body and front guards. Here is how it turned out with the seats fitted to add to the effect. In hindsight I should have got the areas primed prior to coating. But I was really trying to push forward and complete the project. Priming first really didn't fit in the with the program at the time (just joking I had no program or schedule) just prioritized things on the run.
Around the same time I finally sat down and measured the templates for the dash and reproduced files for lazer cutting. The plates were cut and fitted up perfectly first time (yaa).
Yes as previously said the project is on hold
, H renovation duties and now building a G (almost complete). For those interested, in late 2011 the cab was sent off to get plastic coating (poly-urea) applied to the under-body and front guards. Here is how it turned out with the seats fitted to add to the effect. In hindsight I should have got the areas primed prior to coating. But I was really trying to push forward and complete the project. Priming first really didn't fit in the with the program at the time (just joking I had no program or schedule) just prioritized things on the run.
Around the same time I finally sat down and measured the templates for the dash and reproduced files for lazer cutting. The plates were cut and fitted up perfectly first time (yaa).
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- #73
3d fun
