my FJ40 build.........BTG Lite

[JackA]

After years of buggy only wheeling, I began to miss the random dirt road exploration and remote camping. I am one of the founding members of the Built to Grind Rockcrawlers based out of Phoenix, AZ. A few others in the group expressed some interest in some "lite" wheeling as well. I have owned several Toyotas over the years, 3 4Runners and 1 truck, but always wanted a 40. So after searching around on Craigslist, I eventually pick up a couple and the project began. I am going to post up a quick rundown with pictures of the build so far. I started working on the 64 frame in March and later in June picked up a 69 to use the entire body. I am currently in the final assembly, but it's going slow cause it's wheeling season here in AZ.
Here's a few shots of what I started with.......................

[JackA]

I had to do some major frame clean up. I had also mocked it up as a SOA with some free Chevy axles (thanks Dennis). I even narrowed the front 10 bolt. It was way too tall.
I also picked up a nice motor to use. It's a 2004 5.3 out of a Chevy truck.

[JackA]

After I had a rolling frame, I built a front bumper. I picked up a th350 with an Advanced Adapters adapter to run the Toyota 21 spline mini truck case, another Craigslist deal.

[JackA]

Then I bought this pile and decided to combine the 2 projects. I stripped the 69 down alittle and introduced it to the 64. I retained the 64 frame and VIN and get to skip emissions now.

[JackA]

I then decided to take the project more towards being a resto mod. I tossed the Chevy axles aside and replaced them with the Cruiser axles in a SUA setup. I had to redo my front mounts, but they were only tacked in anyways.

[JackA]

Now we start getting to the good stuff. The driveline got stuffed in and made some mounts.

[JackA]

Finished up the driveline and then the steering box mount.

[JackA]

Mocked up some of the front sheet metal. Then the body work began. Tack, tack, tack

[JackA]

I cheated and reskinned the rear quarters. I made larger wheel openings to clear the 35's I am planning to run. Then I mounted up some new MasterCrafts seats and built a cage.

[orangefj45]

nice going!

we did some wheeling out there with one of your club members; barry. good times for sure, can't wait to do it again.

keep posting those pics dude!

[JackA]

The parts started to roll in. Mounted the radiator, steering column, master cylinder.

[JackA]

I picked up some doors for the hardtop that comes later. Started to restore some small parts. I got the radiator shroud built with the fan and ps cooler attached. Picked up some OEM bling

[JackA]

Next I took everything apart and sent the tub to the blaster. I got the cage painted and bought a ton of body work supplies. That about covers it for today. I'll post up the rest of the buildup to it's current state tomorrow night. It will get alittle more detail orientated as well. Enjoy.

[DHONDAGOD]

What do you want for the 69 VIN and title???


Rig looks killer BTW. Not what I expected to see coming from you!


Chris

[Kula]

Hey Jack, Thanks for sharing all the ideas and pic's,looks great so far! I've got a similar project that needs to be started. I hope that's not a picture of a single shear trail plug on your garage wall.

[Black06]

nice find there!

[JackA]

Originally Posted by Kula

I hope that's not a picture of a single shear trail plug on your garage wall.

There's actually a few pictures of some TC rigs. They are one of my favorite buggy builders, despite the single shear.

Thanks for the props guys. The build is moving along nicely, even though the majority of it took place in the hottest part of the summer. My swamp cooler would only cool the garage down to about 90-95 when it's 110 outside. Luckily fall is here with cooler temps.
The rest of the build consists of installing a mini truck rear axle to match the centered output of the tcase, plumbing, wiring, and general reinstallation of all the parts. I should have it done by the end of the year. My time is now split between working on this Cruiser and using and maintaining my buggy....................and KOH prep is coming soon too.

tonites pictures will include the shiney new paint

oh and the 69 VIN and title has a potential buyer already, but if that falls through, I'll keep ya posted

[RustyNailJustin]

Wow great build!
Good taste in parts, good mixing and matching old with new to make a FJ40 that will be fun to drive.
Looking foward to the picures tonight.

[Jason M]

It's cool to watch a lot of hardcore guys go back to their roots.

Awesome build man

Tha hard part will be NOT taking it on harder trails and beating it up

[tacoma73]

Tell me more about that spring plate! Looks sexy.

[JackA]

There is no rockcrawling allowed with this rig. Just some scenic dirt road cruising and lite stock 4x4 type wheeling.
As for the spring plates, I am not sure who makes them. They came with a ton of other parts when I picked up the 69. The other good things that were included were the Cruiser axle with mini truck disc already installed, a LSD Cruiser diff, all the heater parts even the rear heater, an extra set of rear doors and a really beat up hardtop.
Thanks again for all the props, I need this motivation to keep this sucka rollin'.

[azk5]

I didn't see a compressor on the engine, you have to be doing AC?

[wngrog]

Very cool. I am glad you finally started a thread on this build.

Keep them coming! The Cruiser page is mostly dead these days.

[JackA]

Thanks man. I'll try and keep this thread fresh. Like now, I will continue with the build.
So at this point I have a bare tub. It's August and a huge thunderstorm is about to hit. I wrap up the tub nice and tight and bam. It rains like crazy. I then get up early the next day to check things out. Luckily it stayed bone dry. I sprayed down some primer/sealer. Meanwhile in the garage, I finish welded everything on the frame and got it painted. Next was to stick the driveline back in. It is finally starting to look like all the hard work is paying off.

[wngrog]

Cool shot.....