Trail buggy FJ40 tear down and build up. v2.0

[brimy311]

Alright, for those just tuning in...

I full rolled my FJ40 after 3 years of hard wheeling at the end of July. I jacked it up pretty good (worse then pics show) plus the combinations of many other flops had the body looking less then desireable.



I contiplated for a while on what to do with it, then I decided I wanted to build something new that would still be fun to have on the trail and something that would hold up better then the wide body cruiser. So I started tearing it down :nana:







Started cutting the tub.




3 hours later...


More to come tomarrow

[Wilson]

Did you smack your head? that shitlbuffout

[brimy311]

Sure it would, but I was ready for a change! Plus I was beyond tired of the width of the tube at the back of the doors.

[Wilson]

So seriously, looks like not much head room, unless you're Nolan did you hit your head?

[fj40forlife]

x2? how much head room did you have. I do like how the cage is low. I was throwing out a pretty crazy idea to like shop the body down a few in

[brimy311]

Originally Posted by Wilson

So seriously, looks like not much head room, unless you're Nolan did you hit your head?

No Nolan, but I will be using some of kate 6.0's lines on this build up

I am 6'1" and did not have any height issues with the cage. It actually looks short, but is pretty tall. It is all in the swept back look.

Here is a couple pictures:

[brimy311]

Finished the tub/firewall cut on the passenger side and then started working on removing the Dash and then reworking the cowl. I really did not want to have to remake the dash for a third time, so I am going do some flaring off the new cowl to make it fit. Should look pretty nice when it is completed.

Damaged cowl, both sides pretty much the same.


Cut out the sides, and then removed the dash.




New side and new top. I am going to have to wait for another person to be around to help me bend the outers in and force the top flat. For now it looks kind of wavey and out of square.







That is all for today, more to come tomorrow.

[RustyNailJustin]

I always liked the look of that cruiser. Hope the new version is as cool looking.
Plans on suspension work too? Or rollin with the leafsprings?

[brimy311]

I am going to be linking the front and running Air Shocks. Johnny Joints and Air Shocks are suppose to be delivered on monday.

My plan currently is:
-Cutting the frame off just behind the front seats, cutting the frame in front of the Bib and putting the winch behind the bib.
-Boatsides (not really huge but somewhat)
-Going to try to keep the rear of the FJ at about 35-36" wide.
-Leave the wheelbase at 103"ish

Stuff I am up in the air on:
-Trail gear rear housing, or use the currently housing I have.
-Full hydro or leave it with assist.
-Trentfab hood or use a stock hood
-Air bumps or not.

[twisty_toy94]

40 looked cool before the roll. I love the low look of the front of the cage.

Do you have a buildup for it before the roll?

[brimy311]

Originally Posted by twisty_toy94

40 looked cool before the roll. I love the low look of the front of the cage.

Do you have a buildup for it before the roll?

Thanks! I was really happy with it for the last three years. I plan to keep alot of the old style in the new build.

I don't have a build up thread, but I do have some pics of the orginal buildup as well as some of the other things I have done over the years here:
http://jcroffroad.com/misc/fj40

Wheeling pictures here:
http://www.jcroffroad.com/wheelingpics.html

[twisty_toy94]

Originally Posted by brimy311

Thanks! I was really happy with it for the last three years. I plan to keep alot of the old style in the new build.

I don't have a build up thread, but I do have some pics of the orginal buildup as well as some of the other things I have done over the years here:
http://jcroffroad.com/misc/fj40

Wheeling pictures here:
http://www.jcroffroad.com/wheelingpics.html

Sweet, thanks

[brimy311]

More....

After I rolled the FJ on the last trip, I beat the crap out of it for the rest of the day. After about 3 hours of water crossings like this, the cruiser finally stopped working and we had to drag it out:


Everyone suspected that the clutch pressure plate was packed with mud, but I some what thought maybe I broke an output shaft on the dual tcases.

Well, everyone else was right:




Amazingly, this autozone clutch disc is over 3 years old!


New quality clutch pressure plate vs. Cheap Autozone pressure plate. This should keep that from happening again!

[brimy311]

UPS dropped off some parts today! Going to start putting the front 4-link together.

[lilMikey-az]

Are you just going to tap the links or do you have rod ends?

[brimy311]

Originally Posted by lilMikey-az

Are you just going to tap the links or do you have rod ends?

I bought the links from someone elses project. They are tapped for 1"-14 LH and RH. I am using the JJ's on one end and poly Bushings on the other. I will get pictures tomorrow of the completed links.

[brimy311]

UPDATES!

I am using Johnny Joints on one end, but wanted to use poly bushings on the other end to help with some dampening from shock load. The Links I got were premade and taped for LH and RH. So I made up these to allow for them to still be adjusted when installed:



Front Uppers Mount/truss:


Links in place:






Still have to finish the lower axle mounts and make a small truss for the passenger side of the axle. Then I can make the air shock mounts and move on to chopping the frame up!!!

[brimy311]

Air Shock Mount:




On the ground, ready to cut the frame.

Before:


After:




DOM here and ready to go! Starting tube work on Sunday.

[brimy311]

Rear Frame before:


Rear after:


Capped:


Cut off the sliders and cleaned up the prepped the frame for the boat sides:

[brimy311]

Started working on the Boat Sides, just finished up the Dside. Thye are going to be skinned with 1/2" UHMW eventually.






I used 1 3/4 x .188 tube for the rockers/boatsides. Here is what the thickness looks like! BEEFY!

[kling-on]

OH DAMB thats lookin good keep the pics comin

[brimy311]

Bending tube is not my forte, so MonkeyEvil is going to be doing all the kick@ss tube work on this thing. He is absolutly AMAZING at creative tube work! He has a pretty bad@ss idea for the top half, which will be built tomarrow. The middle section of the cage so far is 1 piece, bent from 199" of tube and has 8 bends in it.



Here is what it took to finish up the bends:


Test fit driver:


For the fun of it, we test fit a YJ bench:


Rest to come tomorrow!

[brimy311]

I finally found someone selling a Bib and Bezel reasonably priced. This came from somewhere in Georgia.


I cut all of the tube work remaining off the front end and got it ready for the end front end.


Frame rails prepped.


Mockup of Radiator, Bib, Winch.




Teaser shot of what Daryl is working on:

[brimy311]

Last pictures for tonight.

[Wilson]

do my eyes deceive me, 22R?