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Old 10-25-2014, 03:26 PM   #1 (permalink)
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Kula's FJ220 build

Well here we go again...After my last two year build, I needed a little break from a long term project. I ended up selling my buggy and buying a Rzr 900 xp.
It kind of ruined me as far as trail wheel'n was concerned. We could go to Moab and run every trail there in about a quarter of the time. They are an absolute blast and a lot easier on your body. I did miss the fabbing and creating part and had an idea in my head for quite some time. My wife's Uncle gave us a 1967 FJ40 many years ago and I always wanted to turn it into something cool. My buddy Gary built a FJ45 on an 80 series chassis many years ago, and I always thought it was a great idea. The chassis is beef, it's linked, coiled, full floater, high pinion,...most of you know the rest...

I had bought an 80 chassis a few years ago, but there it sat until Gary's misfortune. He had built another Cruiser FJ60 on an 80 chassis and it was sweet. An hour into his first drive and older gentleman smashed into the Cruiser and it was on it's lid, totaled.

It took about eight months to finally talk Gary out of the remains, but persistence prevailed.

So here's a brief description of my next project...
FJ40 sitting on an 80 chassis with a 100 series engine and tranny.
40 inch tires sitting low, hot rod paint job and some cool detailed touches ( I hope )

I was going to build my own tub, but the more I thought about the time involved, the more I just wanted to have it made. I contacted Todd at Aqualu and started explaining what I wanted. At first he probably thought I was just another moron on the phone, but as we started working on a design, the marketability peeked his interest. I wanted a tub that would fit on an 80 chassis like a glove and retain the 112 inch wheelbase without a huge rear overhang. After a few weeks he started sending me pictures of a 18" over tub designed to sit about half an inch over an 80 chassis and pick up the two mid stock body mounts. The rear tubs are raised up high so I can make tube flares to accommodate the 40 inch rubber. Raised tube fenders will be made for the front as well. Pictures are with 33 inch shop rollers for initial setup.
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Old 10-25-2014, 03:42 PM   #2 (permalink)
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I received the tub and made a few floor cuts to make room for the T case. The tub fit like a glove and clearances were spot on. I was concerned about fitting this aluminum tub to a steel cowl, as I heard that there might be fitment issues. I was very pleased to see that connecting points were very well matched. I wanted to keep my steel cowl and hood as they have more "cruiser" details that I find cool. If you are a purist you probably don't want to look any further...
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Old 10-25-2014, 03:47 PM   #3 (permalink)
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Gary's 45 My inspiration with a few changes. Higher and narrower fenders and flares and about 6 inch's lower. Also big thanks to Jim (Double XL) for picking his brain for likes and dislikes on his past build.
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Old 10-25-2014, 05:17 PM   #4 (permalink)
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Old 10-25-2014, 05:21 PM   #5 (permalink)
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Build a ruffstuff 9.5 front with hellfire knuckles. all the cool kids have um
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Old 10-25-2014, 05:44 PM   #6 (permalink)
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Build a ruffstuff 9.5 front with hellfire knuckles. all the cool kids have um
Hey Justin, what's up

Will I really need that for my wife and daughter to go get ice cream on nice day's?

Eventually I will do some beefing up, for now it should be fine as I am hoping to drop a couple thousand pounds off of the 80 platform. Gary's been moderately wheeling his 45 for a few years with good axles and birfs with no issues. I think being light and long, and keeping it out of the big rocks will help quite a bit.
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Old 10-25-2014, 06:00 PM   #7 (permalink)
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First big change was the rear section of the chassis. It obviously stuck out the back a couple feet, but the real concern was the drop and tapper of the frame rail. I ended up cutting a lower section out of the aft section of the frame and relocated it forward to shorten the diagonal leg. I also cut the frame in a fish mouth cut so that I could increase the height of the rail to match and increase the joining welded cut. The frame narrows on height about a 1/4 inch from the section I cut to the more aft section I spliced in. I will also add a combination plating and fuel tank mount to add more structure.
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Old 10-25-2014, 06:06 PM   #8 (permalink)
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A couple hours of breathing metal dust and welding fumes and the fit is looking a little better...
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Old 10-25-2014, 06:11 PM   #9 (permalink)
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Tub back on to check clearances and start fitting the fuel cell. Exhaust will be moved up and back for tire and ground clearance.
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Old 10-25-2014, 08:06 PM   #10 (permalink)
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Yeah!!!!!!

What do you think about the Tcase options(or lack there of)? Wanna join the group that doesn't exist in dissecting the 2uz a343 into an a340 ass end that accepts a 23 spline crawl box(mini truck) and defunct marlin split case toybox?
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Ducati street fighter 1098s. Spoiled 1wd.
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Old 10-25-2014, 08:28 PM   #11 (permalink)
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Yeah!!!!!!

What do you think about the Tcase options(or lack there of)? Wanna join the group that doesn't exist in dissecting the 2uz a343 into an a340 ass end that accepts a 23 spline crawl box(mini truck) and defunct marlin split case toybox?
I'm planning on doing the gears from Marlin for now. That, with the 4.7 V8, 5.29's and automatic should work pretty decent. If I'm unable to climb the driveway at our local Dairy Queen, I may have to rethink my options.
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Old 10-26-2014, 12:26 AM   #12 (permalink)
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Yeah!!!!!!

What do you think about the Tcase options(or lack there of)? Wanna join the group that doesn't exist in dissecting the 2uz a343 into an a340 ass end that accepts a 23 spline crawl box(mini truck) and defunct marlin split case toybox?
Kyle at NWF is thinking about this doubler situation..
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Old 10-26-2014, 05:31 AM   #13 (permalink)
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lovin it!!
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Old 10-26-2014, 10:15 AM   #14 (permalink)
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Awesome! Keep going!!!
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Old 10-26-2014, 11:19 AM   #15 (permalink)
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UBER COOL, Mark!!!
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Old 10-26-2014, 12:45 PM   #16 (permalink)
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This is cool, great idea!
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Old 10-26-2014, 03:41 PM   #17 (permalink)
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Thanks for the comments guys !

Up next is the fuel cell. The cell that I got with the 60 was a 43 gallon expedition tank. It has a lower sump and is baffled inside, so with a little cutting, I'll make it work. I cut it in half and placed it into position. I didn't like how low it hung so I removed the top section along with an additional two inch's. Cell is know 16 gallons which should be fine for what the truck will be used for. I'll eventually make a skid for protection...
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Old 10-26-2014, 04:39 PM   #18 (permalink)
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Kyle at NWF is thinking about this doubler situation..
He's been thinking for awhile

Are you holding out on the 3.1:1 in anticipation?

I'm really tempted to buy an a343 and taco/tundra a340 and see what can happen w a 23spline crawl box and toybox to split case.

I'll stfu if it doesn't interest the OP and this beauty of a build.
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Old 10-26-2014, 04:45 PM   #19 (permalink)
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Nice fuel cell. Gonna put all the fzj factory bits on the top(pump and sending unit flanges)?

You gonna mess w the factory suspension?
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Old 10-26-2014, 04:45 PM   #20 (permalink)
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As a guy who's putting an HJ47 body onto a stretched 80 chassis and running gear I can't wait to see this come together.

Already looks mint.
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Old 10-26-2014, 04:51 PM   #21 (permalink)
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I'm planning on doing the gears from Marlin for now. That, with the 4.7 V8, 5.29's and automatic should work pretty decent. If I'm unable to climb the driveway at our local Dairy Queen, I may have to rethink my options.
Some of us coming from mini trucks have polluted our heads w gearing ideas since those options are so incredible...

Dairy Queen urban flex pics expected eventually
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Old 10-26-2014, 06:33 PM   #22 (permalink)
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Nice fuel cell. Gonna put all the fzj factory bits on the top(pump and sending unit flanges)?

You gonna mess w the factory suspension?
Yes, The fuel cell was made with all the factory Toyota pump, sending unit, ect. Will just bolt to the top like factory. I'm leaving the suspension stock other then maybe changing the shocks out later on. The 60 I bought from Gary had a brand new two inch OME shocks and coils. I've already pulled the coils off and put the stockers back in. Problem is lack of weight.(If that's a problem, lol) I want this to sit as low as possible with the 40's and there is barely enough weight to compress the stockers for now. I'll see where I'm at when the cage, seats, fuel cell, ect are installed. I think Todd at Aqualu said the tub is 300 lbs. I've wheeled with Gary in his 45. Being light, long and stable makes that thing really work. Gary's also using a Marks under drive unit that mounts off the back of the T Case. I can't remember what the reduction is. When it comes down to it, I'm always open to new ideas!

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Some of us coming from mini trucks have polluted our heads w gearing ideas since those options are so incredible...

Dairy Queen urban flex pics expected eventually
I had one of Marlins original Iceland crawl box adapters back in 1986. My original mini truck went through three or four transformations back in the day, so I'm with ya brotha Once I built my buggy with a V8 and auto, it kind of changed my way of thinking. Don't get me wrong, I loved being able to get out and watch my mini go through a rock garden by itself.

DQ flex pic's are added to the list.

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As a guy who's putting an HJ47 body onto a stretched 80 chassis and running gear I can't wait to see this come together.

Already looks mint.
Thanks! Here's a shot of V8 and no crawler gears.
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Old 10-26-2014, 06:42 PM   #23 (permalink)
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Pretty sure most of us remember that rig and the mess it made us make around the keyboard when looking at the pics back then(6/7 years ago, Jason paulie goodness?)
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Old 10-26-2014, 07:22 PM   #24 (permalink)
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Pretty sure most of us remember that rig and the mess it made us make around the keyboard when looking at the pics back then(6/7 years ago, Jason paulie goodness?)
Thanks...I think... Yep, Jason and Nate built the chassis. This one won't be exposed to that type of scenery.
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Old 10-27-2014, 07:43 AM   #25 (permalink)
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You're building one of my dream rigs!

Is the 2UZ set back in the frame relative to the 1FZ's original location?

I'm wondering how the Aqualu body interfaces with the complete 80-series package. Does it just match up to the frame/suspension/axle locations or does the stock drivetrain location work as well?

These chassis/body combinations are obviously catching on, as Aqualu has several variations in the works it seems for 80-series chassis'(this style and a 4-door).
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