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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
What size u-bolts are you guys running on FZJ80 rear ends? I got one ready to swap into a leaf sprung rig and the tube measures 3.17" with my calipers, which is a hair over 3-1/8" (this is after I ground the factory mounts off and smoothed out the welds where the perches will be). My googling...
Hey Folks, Wanted to get some input/advice on a build of mine. Specifically I have a 1981 HJ47 that I’m making into a pretty capable camping rig. As it sits now it had a 1hdt with Gturbo (whizzy Australian turbo) H55 5 speed, NWF black box and split case. This is routed to the factory 40...
FJ 40 that has been in the family for some time now finally got pulled out of storage after sitting for a good ten years.
Thought this thing was pretty sweet when I was a kid. However I was unaware of the amount bootyfab and ghetto rigging the previous owners (and possibly my dad :laughing:)...
Does anyone know of any pass threw rear diffs for the FJ 60 i built a 6 wheeler but its stock 4X4 want to engage the rear axle with out all the transferase and routing of shafts. Thanks to dumb to post pictures URL number ?/Users/chrisbrunner/Desktop/IMG_1456.jpeg
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