FJ40 Bush Truck Project

[MNC]

Well even though this truck was not much to look at when I got it since owning a few other cruisers I've realised how much more enjoyable it is having a rough truck that you can really push and not worry about breaking it :


There are a few little mod's that I'm planning for the truck to make it that little bit more capable and fun to drive so am starting this build thread to record them...

I picked up a set of half worn Swampers for a good price that should give me some better clearance under the diffs. First need to make some room to fit them. Starting with the rears found a bit of rust getting in the way of the new rubber. Marked up a new guard shape:


And quickly lightened the truck, removed rust, opened up the guards in one big movement with a 230mm Angle grinder (remember this is a bush truck not show car project):


Plenty of room in there now but needed to move the diff back about 100mm. Could have done a spring reversal but instead went with upgrade to longer 60 series springs and a spring reversal. Considering my options here as problem is mounts on my chassis are the older (smaller & narrower bush and pin sizes) and 60 series stuff is the later model bigger pins & bushes... on the hunt for some spares now...

[mickey]

ome make bushes to fit the small pins with the larger spring eyes.

[MNC]

ome make bushes to fit the small pins with the larger spring eyes.

That's got to be the easiest answer. Will need:
4 x bushes with 18mm inside diameter and 31mm outside diameter (to fit in the old shackle swinger housing on chassis and take the 60 series shackles). 40mm overall with 7-8mm flange thickness
4 x bushes with 15mm inside diameter and 35mm outside diameter (to fit inside 60 series spring and still use original 40 series fixed pin). Widths will be an issue

Issue with fitting the front fixed pin is the 60 series spring is too wide to fit inside the original 40 series fixed pin mount... Some massaging maybe required.

[petefj40]

I'm sure you'll sort something out.
Cool thread.

[MNC]

Dont know why but I seam to have got motivated to do some work on the truck (think my dad wants it out of his shed )...

Just a little progress but have completed a spring over in the rear (sorry for the crappy cell phone pics):



Just need to sort out drive shaft and brake lines... and think about a torsion bar...

Tyres i'll be using are fairly worn so have grooved the centre bloks to get some square edges back. Little over finger depth of tread and some nice new edges now:



Have cleaned up the front diff for a little experiment I have been thinking about for a while...



And going to do power steering at the same time. Am hoping to have the truck rolling in next two weeks and drivable in next four (famous last words). Front end is looking a little dragster at the moment - maybe I'll keep it that way



Thats all for now but will put up some better pics in a couple of weeks (hopefully with front end completed).

[niblik]

woot!!! go you good thing.. nice to see some work happening that hasnt got to do with nappies.. i know how that is!

sweet dude, so why the motivation and stuff?

lookin forward to some better pics of more gettin done too.. now ya just got to stick at it..

[petefj40]

now ya just got to stick at it..

niblik knows how to do this ya see.

Well done!

[MNC]

woot!!! go you good thing.. nice to see some work happening that hasnt got to do with nappies.. i know how that is!

sweet dude, so why the motivation and stuff?

lookin forward to some better pics of more gettin done too.. now ya just got to stick at it..

Boy is nearly 11 mths old and spends 2 days a week at childcare now which seams to have made things easier for the wife and makes it easier for me to get out to the shed.

Also just paid $80 for my 4x4 club membership so really want a truck to drive this winter - The rain has started and the mud is on its way back

[guestynz]

hey so wats the diffs u fitting up under it 40s

[MNC]

hey so wats the diffs u fitting up under it 40s

Patience grass hopper all will be revealed...

Got some pics of the truck flying tonight - but crappy cell phone pic's so you wouldn't want to see them

[jaslux]

Got some pics of the truck flying tonight - but crappy cell phone pic's so you wouldn't want to see them

Always wanna see flying truck photos!!!

[MNC]

Got some pics of the truck flying tonight - but crappy cell phone pic's so you wouldn't want to see them

Always wanna see flying truck photos!!!

Ha ha, ok you asked...

Back diff hanging low - Front diff... still under cover

[MNC]

Front end tacked in...

[Fakey]

Nice work, What are those arms off?

[MNC]

Nice work, What are those arms off?

Prado LJ78

[ClassicCruiserSpares]

Looking good mate, are you going to coil the rear also or leave it sprung over?

[MNC]

Looking good mate, are you going to coil the rear also or leave it sprung over?

Yes, I am definitely going to take one of those options

Still deciding although have just come up with a cunning idea for a traction bar so will probabily leave as SOA for now...

Only reason I would change to Coil is if someone offers me a cheap 80 series rear end with a factory locker (hint, hint, hint) or bigger tyres end up needing rear disk brakes

[MNC]

hey so wats the diffs u fitting up under it 40s

Diffs are 60 series cruiser... cause I already had them and they are cheap to get parts for.

Arms are from Prado LJ78, rest is from my spare parts pile...

[MNC]

Bit of progress...

Front end is pretty much done, is sitting under its own weight now:



Power steering box is in with a bit of modification done to the front chassis:



Different view, I can get full lock without any rub with this setup:



Entry angle is just over 90 degrees (just the bad angle I have taken this photo from that makes it look like the chassis sticks out past the tryes - chassis also is out past the box):



Just drive shafts, dampener, bracket for power steering pump, and brake lines and front is done.

[skid]

faaaark me, you not working at the moment

hahahahaha, all that talk about approach and departure angles that went on
I don't think you have a problem with your approach angle

[MNC]

faaaark me, you not working at the moment

hahahahaha, all that talk about approach and departure angles that went on
I don't think you have a problem with your approach angle

My brother in law is helping me out which has lifted motivation levels

I measured the wheel base which was 98.4 inches so am going to push the rear diff back by another 4 inches. Other than the tow hook on the Back this should give me 90 degrees exit angle as well.

I dont know how to measure ramp over angle but its not looking like thats going to be a problem.

[Fakey]

Looking good, I like the knotch for the steering box . What are those front springs out of? Looks like it sits at a good height

[MNC]

Looking good, I like the knotch for the steering box . What are those front springs out of? Looks like it sits at a good height

Thanks, yip was tacked in with a bit of guestimate but ride height has come out pretty level.

Still got rear to do - I need to source a pair of rear VX springs and lower trailing arms (the bigger diameter and longer ones) and the rear panhard rod. Let me know if anyone knows of parts for sale at a reasonable price. Cheers

[sig]

might have those bits in my lockup .just need to decide if i have a use for them or not

[MNC]

might have those bits in my lockup .just need to decide if i have a use for them or not

I've scored a panhard rod from Fakey (Cheers Fakey ) so mainly need the two rear lower longer trailing arms (think they are about 700mm long).

Should be able to find some springs reasonably easily (I hope).

If you decide you don't need them let me know Sig... I promise I'll take good care of them (actually I cant promise that - they'll probably have a hard life)

[MNC]

Bit more progress...

All steering and suspension done.

Roll cage braced to chassis.



Front guards/panel are sitting in place - brackets to be made-modified.

Replaced bonnet rubbers (thanks to lead from Niblik ) and trimmed front guards back.





Replaced rusty aircon vents windscreen and plywood doors with fibreglass panels...



Still lots to do.

[ClassicCruiserSpares]

Looking good fulla, keep up the good work.

[flyingbrick]

fark thats a cool build so far

Aren't you the same bloke with the 1uz powered one too?

[MNC]

Aren't you the same bloke with the 1uz powered one too?

That's just a rumor... Never get caught with two builds at once

[flyingbrick]

Aren't you the same bloke with the 1uz powered one too?

That's just a rumor...

but im sure i saw wayne working on the 1uz at DB's work a while back.. im the random dude that turned up half way through the morning.