Build Thread: "Red Headed Step Child" (Same old same...FJ40 Linked and tons) - Pirate4x4.Com : 4x4 and Off-Road Forum
 
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Old 04-13-2012, 04:34 PM   #1 (permalink)
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Build Thread: "Red Headed Step Child" (Same old same...FJ40 Linked and tons)

First let me say, this is not my (RJ) rig. It is owned by a buddy of mine (Dustin). He is not very computer literate so since I have been involved in the build I have volunteered to run this build thread.




The rig started out as a stock clean 1977 FJ 40.




From there the tinkering and building progressed.






Eventually the “Red headed step child” got a heart transplant and the build went to SOA, GM drive train and 37’s.

Last edited by rjubber; 04-15-2012 at 05:45 PM. Reason: Pics
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Old 04-14-2012, 06:51 AM   #2 (permalink)
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In this form it took a trip to the Rubicon for the first time and DID NOT LIKE IT! Massive failure of the knuckles lead to having to leave it on the trail overnight (even with the help of Marlin) and flying in parts.





The one good thing to come from the Rubicon trip was winning a rear Pro Rock 60 in a raffle.



In addition to winning the axle Dustin had a better idea of what he wanted his rig to be.

Last edited by rjubber; 04-15-2012 at 05:48 PM.
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Old 04-14-2012, 08:44 AM   #3 (permalink)
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looking good! cant wait to see more
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Old 04-15-2012, 05:58 PM   #4 (permalink)
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The “Step Child” sat for a year or so while the owner (Dustin) decided what to do with the rig. Should he build it once the way he wanted it? Or build it slowly and eventually get to where he wanted to go? The debate was over linking it from the get go or throwing Dana 60’s under it on leaves. With months and months of debate and convincing on my part Dustin decided to build a HP Ford Dana 60 for the front. To do this he flipped the housing to a passenger drop and added Reid Racing knuckles and a 6 lug hub conversion.

So the "Step Child" had axles...there was more decisions to make. One of the main keys to the build is that the rig has to drive good on the road! Also the rig has to be able to handle the dunes decently and the rocks and trails well. The only logical choice was a well mannered four-link rear and a well thought out three-link w/panhard front.

Work got done on the Rear in October of 2011.









Brackets and a rear truss was ordered.


Located the axle to get a 108" wheel base.


We used PVC pipe to work out all the numbers in the calculator and ease the trial and error of.


The uppers were the first thing to get located


The horse collar for the lowers was tricky because of the double transfer cases.
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Old 04-15-2012, 06:14 PM   #5 (permalink)
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The rear eventually worked out with very adjustable anti squat numbers and minimal under-steer as well. We essentially completed the rear in 72 hours. the only thing left is to order the drive shaft, check bind on droop and order ORI's to fit.
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Old 02-02-2013, 12:22 PM   #6 (permalink)
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Updates have been slow on this because of transferring pictures halfway across the country with no internet on one side. So here are some more pics of the rear...

The links and axle were finish welded by a friend who is a production welder





With the links finished the rear of the frame was given a little attention. The old brackets were cut out and the frame was boxed and prepped for mounting the 16" ORI's


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Old 02-02-2013, 12:27 PM   #7 (permalink)
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Rear Frame work





Brake Lines were ran for the rear:





The Rear was at a point that ride height and full stuff could be looked at and the body trimmed accordingly:
Ride Height:



Full Stuff:

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Old 02-02-2013, 12:34 PM   #8 (permalink)
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Now it was time to make room for the shocks.



Had to Channel the frame to clear the ORI:



The Shocks are being placed as close to the wheel and vertical as possible so the tub was going to be sacrificed.





Initial hoop mock up...This ended up placing the shock too close to the tire. It was also too low and needs to be moved up.



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Old 02-02-2013, 12:40 PM   #9 (permalink)
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The Rear is still not finished...Working on Shock hoop placement and roll cage tie-in.

Work goes a bit slow when working in these kinds of condition's during the winter:

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Old 02-02-2013, 12:41 PM   #10 (permalink)
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The front is just about there...I will post the pics of the progress later. Here is a little preview.




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Old 02-02-2013, 08:33 PM   #11 (permalink)
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After the rear was done the "Step Child" sat with little to no progress for about three months. Dustin was debating on what axle to run in the front. He had two Dana 60's. One from a Ford, HP and drivers drop, and one from a Chevy low pinion and passenger drop. The debate was HP vs. LP. I finally convinced him that if you have a Pro Rock 60 in the rear your front has to be at least close in cool factor. The other debate was leaf springs in the front vs. 3 link. the Chevy diff dropped right and was set for leaves. The Ford would have to be flipped and the spring pads wouldn't work. And the final debated point was the WMS of the rear was set to fit in a TJ So both axles would have to be cut down to match the rear WMS.
After careful deliberation and ridicule on my part Dustin finally had the Ford center flipped and cut down to match the WMS of the rear. Hubs were ordered to match the Toyota/ Chevy 6-lug pattern and what we had to work with was this:




Front Dana 60 with Reid outer Knuckles soon to be stuffed with RCV's

Now, How do you get Three links and a Panhard bar under this thing!

The Front design is based on 14" travel ORI's with 6 inches of up travel. At the same time we wanted it to be as low as possible for trail stability. The main thing keeping us from our goal was the front of the 40's frame. We decided that a Frame that has all of its front grill and radiator mounts at the highest point and then takes a four inch dive before going flat was pointless so we cut it off.

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Old 02-02-2013, 08:41 PM   #12 (permalink)
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In order to make sure the front of the frame was as strong as the 50 year old riveted stock section we found some 2"x3" rectangular tube and sleeved it inside the original frame. Then we added shims and a big fish-plate.



I hope it's strong enough!!

The front section of the Frame received a healthy dose of 3/8" plating to aid in stress management.



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Old 05-08-2013, 08:10 AM   #13 (permalink)
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Subscribed, any updates?
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Old 05-11-2013, 02:04 PM   #14 (permalink)
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Updates...well as most projects go this one is full of one step forward and two back. Every time there seems to be progress there is another setback. The Rear frame was a serious time killer. Keeping the shocks at a good angle caused them to need to be placed right in the middle of the frame so the channel was cut and braced from all sides. After that the shock hoops needed some work to make sure the struts weren't in the rig too far...the list goes on. So enough with writing an on to pics...








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Old 05-11-2013, 04:04 PM   #15 (permalink)
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The rear drive line may need a limit strap for droop...

The shock hoops turned out great and don't come into the tub area too bad. A small Jeep jump seat or plenty of storage space left...




Looks sweet drooped out with 16inch travel ORI's !!!



The front is still in the process of working out clearance and angle issues with the steering... and the front two piece drive shaft has to find room...

Links are prepped and ready for paint...

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Old 05-11-2013, 04:18 PM   #16 (permalink)
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Really? Absolutely no frame box left behind the axle? You have a bad ass axle trussed to death and no rear frame. Seems a little mismatched.
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Old 05-11-2013, 05:36 PM   #17 (permalink)
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Quote:
Originally Posted by Rat70FJ View Post
Really? Absolutely no frame box left behind the axle? You have a bad ass axle trussed to death and no rear frame. Seems a little mismatched.
Uh...REALLY???? See post #7 picture one and two and then ask your question again ...thanks for the input. There will also be a cross member put in behind the rear axle.
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Old 05-11-2013, 07:05 PM   #18 (permalink)
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Shake your head all you want. Looks like a hinge point to me. Don't really give a fuck, it's your rig. I'm done debating.
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Old 05-11-2013, 09:00 PM   #19 (permalink)
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Hey I don't care if you think that its a hinge point or not...don't come into the tread and start blasting from the get go. If you want to point out flaws and ad advise or knowledge cool but if you just want to be a dick then don't open the thread

I guess we will see when the rear is done getting braced what is a hinge point or not.
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