Mustard Whale, Fj40 build

[Fakey]

Well this is my 3rd attempt at starting a new build topic for my fj40 dam computors .
Ive had it for 3 months now an its my 1st 4x4

As i bought it


My 1st mod was a new bumper with rated tow hooks on the chassis to tidy up the front end


Next on the list was disc front brake front end so i picked up a complete 84 surf front axel with all the bits i needed

[petefj40]

Nice pix there mate.

To put them in a post here on ORE instead of a link just cut n paste the IMG Code into the post. it's as simple as that.

Keep up the good work.

Now lets see these pix bud.

[coxsy]

like this mate

[coxsy]

you may have to resize them to fit

[williamhamilton]

ALWAYS good to see 40 projects so I can steal advice and ideas lol

Looking damn good

W

[niblik]

*nibz puts hands up in the air*

"weeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee..

more 40's"

[petefj40]

And it looks good to nibs.

[Fakey]

Oh i see i think ill have to make them smaller then. Yeah it looked good when i got it but if ya have a look thru the pics on my photobucket album you can see the extent of the rust in the sides,

ive since gotten slightly more repairable ones an got most of the rust round the back of the tub cut out an plated.




Got my full floater an that locker i bought off you nibs in on saturday just got to sort out my rear brakes nowstupid 8 bolt housings

Hmm its telling me it cant determine the size of the image even tho ive resized the image ( im just pasting the link into the img thing is this right or am i still doin something wrong?)

[Fakey]

Sweet figured it out but ill have to resize the pics ill post more up tomorrow

[niblik]

still wrong me thinks..

it should have an image address and not so much the 'link'. when you paste it the
[img] is at the start and

[/img] at the end...

found in the 'share this image' box on the left.. hit the img code.. you'll see 'copied' come up briefly..

should look like this when posting:

[IMG]http://i851.photobucket.com/albums/ab74/Warren_fakey/DSCF1789.jpg[ /IMG]

p.s.. i put the space in the last [/img] so it wouldnt link the picture and you could see...

hope thats clear as a well used shithouse?

[Fakey]

Bit of an update, been busy with body work so havent had much spare time lately. Havent even uploaded any new pics to photo bucket either(got heaps tho).
Spoke to the certifier about cage brakes seats an belts etc he seemed to think i was on the right track so full its steam a head,Scored a tube knotcher off trademe for $100, should make life easier when it comes time to make the cage an bar work. Getting my surf p/steer bits tomorrow as well as surf discs an calipers for the rear

[petefj40]

Bit of an update, been busy with body work so havent had much spare time lately. Havent even uploaded any new pics to photo bucket either(got heaps tho).
Spoke to the certifier about cage brakes seats an belts etc he seemed to think i was on the right track so full its steam a head,Scored a tube knotcher off trademe for $100, should make life easier when it comes time to make the cage an bar work. Getting my surf p/steer bits tomorrow as well as surf discs an calipers for the rear

Don't mean to throw anything negative into the pot here.
Sounds like you're making head way. Cool.

Which cert fella did you chat with? I'd be double checking. Just easier to double check now if you know what I mean.
Hey, is that surf front axle as strong as the stock FJ40's running gear?

[Fakey]

Don't mean to throw anything negative into the pot here.
Sounds like you're making head way. Cool.

Which cert fella did you chat with? I'd be double checking. Just easier to double check now if you know what I mean.
Hey, is that surf front axle as strong as the stock FJ40's running gear? [/quote]

A guy named ken from wellington vehicle compliance.
Not sure what you mean about the surf front axle. I just used the steering knuckles, discs/rotors an cv's (which are bigger than the fj40 cv's), The axle housing,hubs, diff an half shafts are the original fj40 parts,
It all bolted together fine so as far as i can tell it should be ok

[petefj40]

Sweet.

I've always thought the FJ40's running gear was stronger than any Surf running gear. But it's only what I've been told. I've never seen the diff/UJ's apart on a Surf. Well. I've seen the guts of their 5 speed boxes/transfer cases and they don't look as strong as the old 40's running gear. So anything Surf that goes into a 40 rings alarm bells for me....

[Fakey]

Fair enough the fj40 gear is heavier than almost any thing

When i put it all together i bought a complete seal kit for the 80-84 fj40 an everything was exactly the same as the old surf seals so i figured the swivel hubs etc were the same given that the surf was an 84, i would have loved to have used all cruiser parts but theyre getting a bit hard to find at a reasonable price..

The only thing that worries me a little is that i was told the other day the hilux/surf swivel hubs i used were poorly cast an prone to cracking if put under enough stress, I say it only worries me a little cos the same guy told me i should cut the bottom off my sills cos they offer no structural strength to the tub yeah right..

Anyway got my surf calipers an steering setup today one more thing to add to the waiting list of mods
Dont have time to add more pics atm so heres the link to my photobucket album if anyones interested
http://s851.photobucket.com/albums/ab74/Warren_fakey/

[petefj40]

To link the pix on your thread is easy bud.

Just cut n paste the, "IMG code" into the body of your message.

Keep it coming.
To see your progress is cool.

[Fakey]

Oh yeah i realise how to upload them i just didnt have time to resize an get them uploaded.

[petefj40]

Oh yeah i realise how to upload them i just didnt have time to resize an get them uploaded.

Easy way round that one.
My upload settings on photobucket are set to the size 640X480 pixels. So when they are up on photobucket they are already ready.

[Fakey]

Cheers for that pete, much easier lol.
Bit of progress this weekend, got the vented rotors an bigger ln130 calipers with new pads all round




Also got the disc caliper prototype brackets made out of 10mm plate(the final ones will br lazer or profile cut from 12mm plate) theyre a bit "agricultural" looking but for setup purposes theyll do just fine



The 6mm slip on spacers were required to clear the shoulder on the studs as the standard 70series front studs are too long



Once I bled the brakes I took it for a skid round the yard, it stops pretty well but still locks the rears early under hard braking, so i put it on the brake rollers to check balance an efficiency . The fronts were 80% an the rears were 69% efficient so ill need to use the wilwood proportioning valve i bought

[petefj40]

Well done.
Looking good.
Hey, if it's a shiny truck you worry about an agricultural look.
Are you going for braided brake lines? I found they made a big difference.

[Fakey]

Nah was just goin to stick with the original brake lines for now. It seems to pull up well as is.
Where did you get the braided ones made? Do you mean the line from the chassis to the diff? Im not surprised the new braided ones made a big difference compared to the possibly 30+ year old cruiser lines

[petefj40]

Nah was just goin to stick with the original brake lines for now. It seems to pull up well as is.
Where did you get the braided ones made? Do you mean the line from the chassis to the diff? Im not surprised the new braided ones made a big difference compared to the possibly 30+ year old cruiser lines

Forget who Rick used to get em made up now. But he'd know. 03 365-1909.
Think the old rubber ones worked ok. But if you really stood on em you could feel the pedal soften. I guess that's the rubber lines expanding.
With the braided lines the pedal is hard as a rock mate. And the brakes improved HEAPS!

[Fakey]

Yeah the older the lines get the more suseptable they are to expansion. I talked to the hose doc the other day he said he cant make any hoses unless they have some factory certification number on them, ie modified factory hoses, did the certifier say anything about the braided lines?

[petefj40]

Yeah the older the lines get the more suseptable they are to expansion. I talked to the hose doc the other day he said he cant make any hoses unless they have some factory certification number on them, ie modified factory hoses, did the certifier say anything about the braided lines?

Nah. Cert fella knows every mod on my truck, that one include. There was no issue what so ever.
I'd talk to the Rick at 4X4 Accessories coz he's already been down this road. I'd say the people you talked to haven't.
For the extra cost of the braided lines? It was worth it.

[Fakey]

Got new brass fittings to suit my proportioning valve an 4 lengths of 42mm pipe for my roll cage turned up today, should be a busy week/weekend

[petefj40]

Got new brass fittings to suit my proportioning valve an 4 lengths of 42mm pipe for my roll cage turned up today, should be a busy week/weekend

Sweet!

[Fakey]

Hmm was doin some practice bends with the new pipe bender last night an managed to split one of the formers after only 4 bends Got another one coming tho..
Impulse buy of the day

Not sure if it was a good idea with all the work ive still got to do but oh well seemed a good buy at the time..An also bought this steering box, the guy was selling as a hilux box but i think it is a 70 series one

[niblik]

the hilux boxes and cruiser boxes look exactly the same bar the mounting bolt holes.. by the looks of this one me thinks your right.. looks 70 styles pitman with rear facing arm.. goodfind on both counts!

you've been hardcore shoppin.. lookin forward to the connecting of bits!

[petefj40]

you've been hardcore shoppin.. lookin forward to the connecting of bits!

X2

[Fakey]

Busy weekend, but pretty pleased with myself. got most of the cage done Just got a bit of additional bracing, seat belt mounts an seat mounts to do then i can pull it out an fully weld some of the bits i couldnt get to.

Some of the bends arent perfect but this is the first time ive ever used a pipe bender, let alone tried to build a cage so im pretty pleased with the way its gone so far.

Tube knotcher=best $100 ive spent in ages

Knotched tubes (33mm an 44mm)

main hoop tacked in place

Rear hoop

Main hoop lower brace



Rear hoop floor mount



Floor mount


Front hoop

Front hoop brace

Front view