Wisdom Turns Folly (WTF). 1973/75/76/78/85 Mashup

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Question to the metallurgists in the crowd: outriggers are new steel, frame has been treated with Coraseal rust converter, etching primer, and John Deere blitz black paint. Obviously new clean steel is best but how far into the coraseal conversion should/could I go to ensure a good bond for old to new steel with my glue gun?
I haven't used coraseal but their website reads like ospho, which I have used. I usually clean back about 1/2" on either side of the weld, spray weld through primer of some kind, then get to welding. Top coat with whatever you want after that.
 
Still sitting in storage with a bunch of old crusty parts sitting on her. WTF was I thinking! I need to retire so I can get rolling on this thing. 1FZ-FE swap has been abandoned and the 2F with a 4 speed will be the next pipe dream. Next steps are to rebuild the 60 axle with the 40 innards and obtain the necessary missing axle parts on the 60 axle. Axle stays intact, 40 frame to be modified to handle the extra perch width. My mud handle namesake came home and I am busy bolting all the crap on her that’s in the way of this one moving forward.

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Still sitting in storage with a bunch of old crusty parts sitting on her. WTF was I thinking! I need to retire so I can get rolling on this thing. 1FZ-FE swap has been abandoned and the 2F with a 4 speed will be the next pipe dream. Next steps are to rebuild the 60 axle with the 40 innards and obtain the necessary missing axle parts on the 60 axle. Axle stays intact, 40 frame to be modified to handle the extra perch width. My mud handle namesake came home and I am busy bolting all the crap on her that’s in the way of this one moving forward.

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What 60 axle parts are you looking for? I may know of a 60 that’s getting parted …in my garage. Too many parts and grand ideas without enough room to work.
 
@FJnoob i will snap some pictures. It’s basically everything on one side and a few bits on the other if memory serves.
 
@FJnoob i will snap some pictures. It’s basically everything on one side and a few bits on the other if memory serves.
I have plenty of bits, as well as pieces and parts.
 
So the trip to visit @FJ Noob was an utter success. Thank you sir for your fair handed pricing of all the bits and pieces. 1985 2f fully dressed with a 4 speed split case, drive shafts, and a front clip for Comet to boot. I can not wait to see what joy awaits me with this opportunity.

This WTF moment is brought to you by indecision that may or may not be my problem. I will put in writing (for the umteenth time) that WTF version 1.3 will be a 1973 frame with 1975 body from @R.K. with a 1978 front axle with disc brakes from @bkfj40 and rear 1985 60 rear axle/2f engine/split case from @FJ Noob and first gen sr5 4 runner bucket seats from @mwalls54

Frame to move out of storage February 16, weather permitting.
 
Now that is a plan that actually can bolt together in a few weekends.
Get it on the road. Fine tune from there.
I would recommend 1” wheel spacers up front and flipping rear springs since you’ll have to mod rear spring perches and have body off anyways.
 
Can’t wait to see it all come together!!
 
Guys, thanks for the input and participation n what is still glacial progress. Rear Axle brackets to be cut off to set driveline angle rather than outboarding the frame perches. Spacers up front definitely needed. @cruisermatt thank you.
 
Sorting, stacking, moving, rearranging, and stacking some more doo dads and I get to have a look at the transmission/transfer case. Cleaned up the transmission cross member and placed copious amounts of gear oil from the transmission fill plug on the workbench and floor of the garage. Ordered the banjo bolt/fuel hose temporary fix.

Get her flipped around after this picture last Tuesday (thanks to Stephon and Joe popping in). Engine hoist and ratchet straps ready for tonight. Hoping to separate body from frame. Bringing the 60 rear axle home to start cutting things off to mount perches.

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My sophomoric sense of humor aside. Double Cardin wouldn’t work?

I know the Fz has been done and I’m asking out of more than just a passing curiosity.
 
With the auto and awd case it was going to be over 12" longer.
 
I walk away for one second. One second!

Length of shaft was discussed but I also have yet to diagnose what ails my ‘97 80 series with the same engine. This option isn’t dead, just turned into a maybe.

With my advanced middle age, I just want to drive the thing once before I check out. Plus, this gets me moving in the right direction. 32 of the 36 hot rivets removed with the Chinesium plasma cutter. Ruff Stuff rear boxing kit in hand. Crossmember mount on deck

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