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Old 09-20-2016, 04:37 AM   #1 (permalink)
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Rustomod FJ40

I picked up this neglected FJ40 early last year. An old trail/mud truck. It had a 396 BBC/SM465/Stock 3 spd case. Spring over with 2.5" leave springs and a 2" body lift. ARB in the front axle and a welded rear diff. I bought it with no motor.



Started by removing everything that wasn't needed, wanted, or beyond repair.



Determined the frame was beyond repair, tore it down all the way. Found a frame in Northern Georgia and picked it up. The prior owner had some funky rear tubular cross member, fortunately the cross member from the original frame was salvageable.





PaulC
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Old 09-20-2016, 04:45 AM   #2 (permalink)
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Started rebuilding the frame. Ruff Stuff had a big sale and I ordered up the rear boxing kt and spring over conversion suspension kit. Also got new rear shackle frame mounts and frame braces.





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Old 09-20-2016, 04:48 AM   #3 (permalink)
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Pickuped up 4x4labs front frame kit to box the frame rails and redo the power steering box mount.









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Old 09-20-2016, 04:54 AM   #4 (permalink)
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Finished painting the frame and springs, installed new leaf spring bushings and assembled it all.



Starting with rebuilding the rear axle. Got 4Plus products rear axle flanges to make the rear a full floater using front Toyota spindles, hubs and brakes. Also shaved the drain plug.





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Old 09-20-2016, 05:02 AM   #5 (permalink)
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Rebuilt the front axle. Put an extension tube on the passenger side to widen the front, shaved the drain plug, welded on a ring gear skid, and installed 4x4labs steering, and Ruff Stuff knuckle ball gussets and steering stops.







Wrapped up the front axle build with some new birfields (I know, I know they are trail gears, they have to be better than stock) and rebuilt knuckles.





Stabbed a good 2F I had from a 60 series and finally an assembled rolling chassis.

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Last edited by deadlew; 09-20-2016 at 05:41 AM.
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Old 09-20-2016, 05:12 AM   #6 (permalink)
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Put the transmission and split case I had from my FJ60 in.





Drilled and tapped and then capped off the holes in the power steering box for hydro assit.



Picked up a pair of 9.5" E-locker diffs.



Which meant a new inner front passenger shaft.



New hardware to mount the diffs front and rear.





Then this project got shelved because I wanted to finish my other cruiser https://www.pirate4x4.com/forum/toyot...j40-build.html. Also I didn't know where I wanted to go with finishing the body. Hmmmm.......
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Last edited by deadlew; 09-20-2016 at 05:37 AM.
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Old 09-20-2016, 05:20 AM   #7 (permalink)
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Since I "finished" the other FJ40, there was a few things I wanted to fix before I went any further with this one. It was still to tall for my taste. So I cut off the rear spring perches and raised the radius up to lower the rear a little.



Tore the whole truck down so I could convert the front suspension to a shackle reversal, it sat higher than the rear, and managed to drop the front 2.5"s



The tubing notcher makes a great mobile drill press.



Now is has a much better shackle angle too.

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Last edited by deadlew; 09-20-2016 at 05:38 AM.
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Old 09-20-2016, 05:26 AM   #8 (permalink)
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Since I installed a shackle reversal the castor was way off. Tried shims, should have just done it right from the get go and weld new perches on at the correct angle. Also had very little drag link clearance between it and the leaf spring.





While I was fitting the new spring perches, I raised the radius up on them to lower the front a little more, before welding to the axle housing.



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Last edited by deadlew; 09-20-2016 at 10:08 AM.
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Old 09-20-2016, 05:31 AM   #9 (permalink)
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Reinstalled the body to get some more garage space and assess what I wanted to do with it. Picked up some used 37x14 Iroks and put them on some wheels I had laying around.





This is where the Rustomod idea hit me. Just repair what is needed in the tub, build a nice cage for it and run it. Leave the body, paint, bondo, and rust just like it is.
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Last edited by deadlew; 10-18-2016 at 07:46 AM.
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Old 09-20-2016, 08:20 AM   #10 (permalink)
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Another cool buy build. I like the theme
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Old 09-20-2016, 10:09 AM   #11 (permalink)
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Where did you get the rear shackle hanger plates?


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Old 09-20-2016, 10:32 AM   #12 (permalink)
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Thanks RustyNailJustin.

Deliverance,

I found them online. I did a google search "FJ40 rear frame plates" and found them on ebay, and also btbproducts. I don't remember whose specifically I used.

PaulC
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Old 09-20-2016, 10:59 AM   #13 (permalink)
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Perfect, thank you.


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Old 09-20-2016, 12:28 PM   #14 (permalink)
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Where did you get the rear shackle hanger plates?


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A couple years ago Rock Tactics made a prototype with the intent to market. I am not sure if they did? It changed owners and I haven't delt with them in awhile.
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Old 09-21-2016, 05:46 PM   #15 (permalink)
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It is good to see Ted's old 40 getting a new life. Let me know if you do not re-use the rear flares. I can not decide what to do on mine.
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Old 09-21-2016, 06:14 PM   #16 (permalink)
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who'd ya get the custom axles from?
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Old 09-22-2016, 04:49 AM   #17 (permalink)
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Thank Rob, the flares got tossed because they broke when I took them off. I may have another pair in the shed, I can't pomise anything.

Skullyota, the "custom" inner for the front I got from Trail Gear. It is for one of they mini truck application. The rear full floater shafts I haven't had made yet. Though I'll probably order them through RCV. I called and talked with them about it and they said no problem.

PaulC
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Old 10-16-2016, 10:49 AM   #18 (permalink)
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Finally got a little break from home improvements, school and life and had some time to work on the Red 40 again. Knocked out the winch mount this weekend.





The reason I went with just a winch mount is because I couldn't really think of any bumper ideas i really liked. I kind of like the minimalist approach. The winch and steering box tucked in nice and tight, along with keeping the winch as low as possible.







Sorry for the crappy hazy cell phone pictures. Thanks for looking.

PaulC
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Old 10-18-2016, 07:33 AM   #19 (permalink)
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you are making me miss the old girl. Glad something is being done with it instead of it rotting in my yard.
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Old 11-09-2016, 01:03 PM   #20 (permalink)
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really like the build so far, keep it up!
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Old 11-10-2016, 05:19 AM   #21 (permalink)
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Thanks carslut. I wish I could work on it more, but with school and finishing up my friends Cruiser, I just don't have the time.

What was "supposed" to be a simple hydro assist install, has turned into 25 hours plus of reworking the front suspension and steering completely. The front sat 2.5" higher than the rear, and the steering box mount was a compilation of several people's work throughout the years with no cohesive plan. When the axle traveled up, it actually traveled forward because of the angle the leaf springs were sitting at with the huge shackles. Basically it was best to remove all of the front suspension and steering box mounts from the frame and start from scratch (6 hours of grinding and cutting alone). One hour of that was just getting the power steering box off the frame rail, someone had bolted the box to the bracket and then welded the bracket to the frame, without thinking of how the power steering box would be removed later on.







The 40 now sits level and the steering and suspension set up is loads better. The axle travels back just a little during it's cycle and the approach angle is greatly improved.





Thanks for looking.

PaulC
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Old 11-11-2016, 03:56 AM   #22 (permalink)
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Great to see that still around. I remember bringing her home back in 95! John has a good truck. If that rig could tell stories!
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Old 11-11-2016, 08:46 AM   #23 (permalink)
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No doubt it is a good truck. It just needs some updating and refined a little here and there.

PaulC
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Old 11-17-2016, 09:17 AM   #24 (permalink)
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The e-locker motors that came with the diffs worked fine, but I wanted to make things a little simpler and have less electronics on this truck. I ordered chillkat's cable shifter kit for the 9.5.



Did manage to find a little time today and installed the diff part of the kit. I'm very happy with how simple and easy it works.





If anyone needs a good working 9.5 e-locker motor send me a PM. It will have new a new shaft seal and o-rings installed.

Thanks for looking.

PaulC
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Old 12-27-2016, 01:24 PM   #25 (permalink)
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Finally some time off school and nice weather outside. Managed to get a good amount of work done to the Rustomod today.

Picked up some side mount shock mounts from Ruff Stuff tacked them on the axle before I pulled it out of the truck. Needed to make a hydro assist mount on the axle, and it is easier with the axle out of the truck. Ended up mounting the ram to the driver side spring plate. The two legs that come down off the plate will bolt into the driver side spring perch once I get the weight on the axle and u-bolts tightened down.



Also needed to make a mount of the axle housing for the cable actuated e-locker.





Thanks for looking.

PaulC
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