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Discussion Starter #1 (Edited)
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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Discussion Starter #2 (Edited)
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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Discussion Starter #4 (Edited)
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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Discussion Starter #5 (Edited)
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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Discussion Starter #6 (Edited)
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 http://www.pirate4x4.com/forum/toyota-land-cruiser/2321881-just-another-fj40-build.html. Also I didn't know where I wanted to go with finishing the body. Hmmmm.......
 

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Discussion Starter #7 (Edited)
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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Discussion Starter #8 (Edited)
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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Discussion Starter #9 (Edited)
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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Discussion Starter #12 (Edited)
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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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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Discussion Starter #17 (Edited)
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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Discussion Starter #18
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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