1991 fj80- the offroad station wagon build.

[ryantowry_81]

So this is a copy over from MUD up to today:
Nothing fancy here but I picked up this 1991 fj80 cheap to make into my full time camping/fishing with the kids mobile until I can get the 40 built.

first step is to get the motor tuned up and then install the spartan i have in the rear. from there i will probably deflare as they dont match and then finish the front bumper to fit the winch i have. i really just want to go rally it and have fun with the kids so i am resisting the urge to throw on my 37's and regear.

 

[ryantowry_81]

took the old girl out last weekend for a quick day trip for a shake down. she did pretty good except it had a fuel delivery issue on the way out that was causing major surging and loss of all power to the point of not being able to even move in low range. I drained the tank and added all new fuel and that helped some but the idle is still very rough once warm and some surging. I have ordered a new FPR, damper, fuel filter and prefilter in the tank to eliminate those issues. I also bought new shoes and pads to make the brakes fresh. I am going to get out the timing light as well and check timing and clean the throttle body and AFM to see if I can get her running top shape and reliable. when the fuel is not surging she runs pretty well and pulls up the hill at 65 MPH well so I think she is a healthy motor, just needs some tune up.

 

[ryantowry_81]

little fire footage from the Evans canyon fire.

(sorry don't know how to embed video)
Luckily the wind shifted after they fought the fire on our side. if it would have been burning Monday the wind would have pushed it all the way down to our house.

 

[ryantowry_81]

not much update yet. I did get the FPR replaced and that seemed to fix the fuel surging issue. still need to do the damper and in tank screen but wanted to do one thing at a time to see results. I also added an amp back in where the PO had removed it so I got my radio back. also did the AFM 3 click mod and am going to check and set timing next. I am going to try and remove the cats next or pay to have them removed and see if that helps her breath better.

Did get to do some quick low range front yard drivers training:


she kept trying to floor it....lol still did pretty good for 8. I will make a wheeler out of her yet.

also put a down payment on this:

new work shop/ mancave for me!!!!

 

[ryantowry_81]

well no huge updates but I finally pulled the trigger and bolted up the 37's from the fj40 project:

completely stock suspension. I am going to commence trimming after I get back from T day visit to the In laws. I already have 5.29's and locker for the 9.5 from my fj40 parts but I still need a front 5.29 diff. I think I have enough marlin crawler gift cards saved up for the gears and a basic install kit. I just lost my job so money is sparse right now until I can get a new job. still trying to keep my shop build permit moving too so that is taking a lot of funds.

I also scored a parts rig. With title and running for 200 bucks. someone cut out the front axle to get to the high pinion 3rd so it would take some work to get it driving again but it has all the interior parts I need and some interesting spares.

the real score here is when I started looking into the front axle pats and the spare T case in the back of the truck.

when I was unloading the front axle parts from my truck I noticed some non Aisin or warn like I am used to. so I started cleaning them up and noticed a marks adapters sticker on the truck and realized they were some of the marks heavy duty hubs that come with the part time kit.

so I crawled under the truck and the t case would not free spool like a part time kit should and I got bummed. then I went to clean out the old tires and other randomness from the trunk and found another t case. can you guess.......
that one either has a busted center diff or a part time kit. I am going to have to tear it apart when I get home from T day.

Either way I think the truck was well worth the 200 bucks even with out the front diff and some weird noises coming for the transmission/ case.

 

[ryantowry_81]

finally got around to finishing up the front bumper and mounting the winch. added a quick little hoop for grill protection:


I installed the rear Spartan locker as well and then took it out to see how the Yokohama's would do in the snow. they did pretty well. not too many pictures but here are a couple.




imgur.com
imgur.com

definitely needs a front locker and a little lift, rear still rubs pretty easy. I am thinking I am going to build some homemade spring spacers to get it up about 1.5-2"

front locker wise, I have a good buddy of mine in Alaska that is sending me a full 3rd member with a ARB and 5.29's so that is a huge score. just need to get the compressor and install kit.

Also I finally dove into the T case in the parts rig and it definitely has a part time kit in it. thinking I am going to sell that to try and fund some chromo front axles. I don't really need part time with how I use my truck.

 

[ryantowry_81]

so in an effort to keep wheeling but also being unemployed and broke I have been concentrating on free mods to help. I decided to build some 2" spring spacers to keep my 37's from rubbing in the back so much while wheeling. for the front I copied the Metaltech style. Because I had the bump stop holders from the parts truck I decided to just cut those up and add a plate to make the 2" spacer easy and fast for the front.

 

[ryantowry_81]

for the rear I had not seen many home made spring spacers so I took out the rear springs and rubber spring isolator from my parts truck and started to make a metal spring spacer for the rear. my concept was to copy the print footprint for the bottom of the spacer and copy the spring isolator base for the top plate so it would rest on there well.

then I bent some 3/16" X1-1/2" strap into a tight circle and tacked and bent to fit the middle radius of the bottom plate.

little trick I learned if trying this. over bend and then open up the circle while tacking vs going big and trying to bend it tighter. it was a lot quicker.

forgot to take any painted pictures as it was the middle of the night but I finished up with a little spray paint after wire wheeling off the slag etc.

 

[ryantowry_81]

next I wanted to drop the bump stops in the rear too. I found some old fj40 front bumps I pulled off my other project and welded them onto the stock base for the fj80. only netted me about 1-1/2" drop so I might still need to ad some plate beneath to get me to a full 2" but we will see how the 37's and the cut fenders match once flexed.

these may or may not last long but it was a free experiment.

I also dropped the internal bump stop 1-1/2" as well by drilling out the stock mounting hole and welding on the metal cones that were supporting the front bump stops on the parts truck. this added right about 1-1/2" as well.

the inner bumps will still contact a little before the outers like stock and then only use the outers upon flexing.

 

[ryantowry_81]

all installed and ready to test. I ended up duct taping the rubber spring isolator to the top of the spring for ease of installation.
hard to tell from the pictures but it is definitely taller and I removed the front sway bar while I was in there to help the front flex a little as the rear usually does most of the work.

I still need some shocks as they are all limiting down travel now and my rears are completely spent. might need to just build some shock spacers and get some cheap stockers for now.

also found my old CB and a non ground plan antenna and cable in the attic so I decided to add that as well for some on trail coms. going out Sunday to play in the snow and try it out.

bigger upgrades to the drive train coming next week hopefully.

 

[ryantowry_81]

sorry I have been lacking on the updates so here is a blast of stuff.
finally got the gears installed. instead of pulling the diff with the spartan in it i used another third i had from a fj60 and put in the detroit i had laying around for the fj40 project. ended up having to clearance the housing some for the gears to fit well and then had to do alot of work on the detroit to make the center pin go in and out and work with my semi float axle. really made me wish i had a full float, this job would have went alot quicker.

Instead of grinding on the gears a bunch i decided to modify the center pin on the sides that dont touch the axle shaft when installed. i still had to trim the gears a little but nothing even close to the pattern. I also had to shorten the retainer bolt that holds in the center pin to clear the end cap.

the pin moved more than i liked after clearancing so i added some little welds to help keep it from walking around and then filed them down to fit tight

 

[ryantowry_81]

i installed the pinion with a solid pinion spacer and took a long time there to get it right and ended up with an acceptable pattern.

 

[ryantowry_81]

on to the front.

I ordered new bearings and gears from marlin with gift cards i had saved up and a good friend of mine from alaska sent me a new in the box ARB locker he never had a chance to use and had sold off the project.

this is the new 29 spline 8"HP pinion vs the old 27 spline. MORE BEEF!

definietly going to get the 29 spline stuff when i build the diffs for the fj40. 2 splines does not sound like much in thickness until you see them side by side.

setup here with a solid spacer as well went smoother without all the carier massaging for the center pin. gear pattern turned out ok

 

[ryantowry_81]

now i needed air for the locker. iwas too cheap for the ARB unit so i went on amazon and found one that would go to a high enough PSI for the locker. ended up on this unit for around 45 bucks

also added a pressure switch to control on off by pressure

plumbed in on the outlet of the compressor head.

it was a metric thread so i took the compressor apart and tapped it for 1/4" NPT to use standard fittings. this was delicate work as it was a cast aluminum part and it was soft but i achieved good results and it ended up sealing up well. been running it for a couple months now with no bad results.

 

[ryantowry_81]

snow wheeled that a little then realized my shocks were drastically limiting the down travel with the 2" spacers so i looked up the part numbers for the cheap procomp shocks and ordered some from summit.
overall added about 3" of travel and 5" of droop. still really soft shocks and it is not ideal for the road but does great at moderate speeds on the forrest roads getting to trail heads and works well on the couple trails i have hit so far with them. well worth the roughly 45 dollar a piece price tag.

pin/pin shocks are the fronts, pin/bushing are rear. all mounted in stock locations.

 

[ryantowry_81]

fronts are about perfect bump stop location, maybe could even raise them back up a little and get a little more out of the front. I also dropped the front sway bar to help get it to flex a little more.

rear needs the bumps dropped a little or a little more fender trimming. once i get time i am going to try and open the rear fenders a little more before i paint the whole truck one color.

 

[ryantowry_81]

I have decided to try and end my unemployment by starting my own business:

https://highoctanespirits.com/

I am opening my own Craft Distillery in Naches Wa inspired by Motorsports. I don't want to give to much away until i have actual label approvals but i am hoping to do some wheeling inspired spirits including a over-lander gin.

Please follow and like on social media to help me get the word out!!!

 

[ryantowry_81]

sorry not much of an update on the fj80 yet, been busy enjoying the summer, trying to get the business in order, and working a new job.

Have been getting out wheeling with my crew here and there.
here was one trip up Darland mountain area.

and this trip up toward Naches Pass and then over to Manastash ridge with @Borrego and his crew (thanks again for letting us crash the guys weekend)

(Kids wanted to draw art on the truck so what the heck. kept them happy)

could still see some of the snieder springs fire in the distance

this one slept for a good hour while we bounced over rocks and bumped along. she was tired.

 

[ryantowry_81]

just ordered up some 30 spline RCV's for the front and working on getting the 80 back in the garage to get some maintenance stuff taken care of and work on better steering and brakes. I twisted my sector shaft sometime on my last trip and need to swap that but also need to rebuild my pump as the steering feels really weak. Might just pony up and buy a assist kit, we will see.

 

[ryantowry_81]

well, Christmas came early for me this year:

My wife encouraged me buy these RCV's to help make sure the girls would be able to enjoy the snow wheeling season without breakdowns. She is a keeper!!

they had initially said 6-8 weeks and they showed up in 2. now to get them in there.

 

[ryantowry_81]

well, thought i only had a twisted sector shaft from tagging a tree last time i went out but turns out the damage was a little bit more severe.

looks like it is time to plate the frame and gusset the panhard mount while i take the front axle apart to install the RCV's