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Old 09-12-2010, 08:48 PM   #1 (permalink)
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Aussie FJ40 Build-up

Few pics of a cage build we started on my FJ40 on the weekend. Still some tube and bracing to be added, but we got the main shape all done up in one weekend.











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Old 09-12-2010, 08:48 PM   #2 (permalink)
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Old 09-12-2010, 08:49 PM   #3 (permalink)
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Old 09-13-2010, 12:27 AM   #4 (permalink)
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Having a break from the shed tonight as I am buggered from the brews
Doing an order for the rest of the stuff for your 40 tonight, hope the exchange rate is good




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Old 09-13-2010, 12:30 AM   #5 (permalink)
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looks good, are you going to tie it into the frame?
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Old 09-13-2010, 12:37 AM   #6 (permalink)
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Quote:
Originally Posted by iancj7 View Post
looks good, are you going to tie it into the frame?

Definately, doing an order for tie in bushes & some bracing gussets so the chassis mounts can be done.




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Old 09-13-2010, 12:44 AM   #7 (permalink)
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Definately, doing an order for tie in bushes & some bracing gussets so the chassis mounts can be done.




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cool

only way to go
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Old 09-26-2010, 03:38 PM   #8 (permalink)
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Headed down to Brooksys on the weekend and we made some more progress on the cage. Still got lots of bits and peices to sort.

First thing was remove the 140l fuel tank and seats and the 75 series steering column. Then swapped in a standard 40 series steering column (which has been modded to suit p/steer) to help with getting the new seating position right. Really happy at the height of the seats now.

New seat rails.


Bit blurry, but shows the A to B pillar tube.


Old seating position


And the now lower one.




Diesel prefered it with no seats.
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Old 09-26-2010, 03:39 PM   #9 (permalink)
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New Fuel cell is a RCI2162A 15 Gallon (57 litres) tank, measuring 30"x12"x9" (762x305x230). Got it from http://www.rocketindustries.com.au for $405 delivered. It will be mounted under the body behind the rear diff.





Some of the bracing tubes.


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Old 09-26-2010, 03:39 PM   #10 (permalink)
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Old 09-26-2010, 07:19 PM   #11 (permalink)
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Nice!!
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Old 09-28-2010, 02:23 AM   #12 (permalink)
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Few more bits and pieces brooksy got done today.









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Old 09-28-2010, 02:24 AM   #13 (permalink)
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Old 10-04-2010, 05:04 AM   #14 (permalink)
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Bit lazy & tired to do a write-up but here are some pics, basically all done except tailgate/wheel carrier as I am still waiting for parts from USA. I have a little more work on tank bashplate too.
Twisty has some more detailed shots but here are the cage pics.















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Old 10-04-2010, 05:05 AM   #15 (permalink)
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Cage back in the 40















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Old 10-04-2010, 05:07 AM   #16 (permalink)
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Rear mounted 57L/ 15Gallon fuel cell with bashplate & fully removable cell mount
I have done a very trick dimple effect (thanks Don-fc187) on the bashplate but haven't taken pics, Dave has some.
I still have to do the same effect on the rear vertical section but time was getting away from us so I will do it during the week.
















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Old 10-04-2010, 05:08 AM   #17 (permalink)
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A lot of other stuff was done things like finish all welding, die grind out cage footings in floor, the fuel cell/bashplate assembly, battery box intergrated into seat mounting bracket, fuel filler in rear floor, run new fuel lines & refit wiring.
I still have to put in seat belt mounts in B-pillar & do cross brace. May while I am there do harness mounts for added safety when driving the more risking tracks.


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Old 10-04-2010, 09:05 PM   #18 (permalink)
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Some pics of the bomb proof fuel cell mount.







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Old 10-04-2010, 09:06 PM   #19 (permalink)
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Mounted in the chassis. (2mm bashplate with go fast dimples not fitted in these pics). Brooksy will have to post up some better pics with the bashplate fitted)








Sits nicely on the springs to allow the removal and fitting of the fuel lines.



Dimple died the floor for access to the filler.
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Old 10-05-2010, 12:40 AM   #20 (permalink)
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Here are a couple pics of the bashplate covering fuel cell.
The dimples are located where the X bracing isn't so the dimpling strengthens those points.
I still need to do the vertical return to the bumper section, I will do it this week.













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Old 10-05-2010, 06:33 AM   #21 (permalink)
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Can you show pics how the rear tube flares are mounted? Cage looks awesome!!
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Old 10-07-2010, 02:33 PM   #22 (permalink)
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Bitchin tube work, really like your design....
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Old 10-08-2010, 02:25 AM   #23 (permalink)
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Thanks,

Still got a bit to finish off but it is basically there !

I know Dave is happy which is the main thing. Going to give it a test in a couple weeks at a social wheelin' weekend that we have going now.




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Old 10-11-2010, 09:46 AM   #24 (permalink)
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Awesome thread! Thanks for sharing!
Intersted to know whats the wheelbase on your rig and how did you stretch it? Also are those 35s?
Thanks Again! Keep it coming!
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Old 10-11-2010, 06:35 PM   #25 (permalink)
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Can you show pics how the rear tube flares are mounted? Cage looks awesome!!
+

Thanks. Site I host my pics on is down at the moment, but I will post some build pics of the rear tube flares and tube front fenders once its back up.

Quote:
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Awesome thread! Thanks for sharing!
Intersted to know whats the wheelbase on your rig and how did you stretch it? Also are those 35s?
Thanks Again! Keep it coming!
No worries.

Yeah, tyres are 35x13.5 Krawlers.

Wheelbase is around 96" using custom springs. Suspension setup is.
1260mm (49.6") long front leafs 4" lift (bout 4.5" longer then std.) Fixed hanger was moved back approx 3"
1340mm (52.8") long rear leafs 4" lift (bout 7.8" longer then std.). Shackle hanger was moved to rear crossmember.
2" extended shackles
12" travel bilstein 5125s all round
High Clearance U-Bolt Plates
Rear diff back 5" from standard, front forward 1"
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