FJ40 Rebuild thread

[Bjordan]

I am new to this forum but was a longtime lurker in PBB and been out of the game for a while. Sold my last rig a few years back and finally got the itch to build another rig. My last build was a CJ based buggy.

Simple CJ build

I figured it was time to post up my build and get some feedback. Hopefully its worthy of the Hardcore section. If not please move it to Non Hardcore. I have been wheeling since I could reach the pedals and have always loved CJ's. I have owned 5 over the last 16 years and beat them all. I sold my...

www.pirate4x4.com

Long story short I sold the buggy, kids got into dirtbikes, moved to a bigger property and now my boys are older and into trucks, so time to build another rig. I picked up an FJ40 with enough extra parts to build a few rigs. The problem is I don't know a damn thing about Toyotas. Last few rigs were Jeep CJ based with Chevy and Ford one ton drivetrain. New rig is 73 FJ40 frame and tub, Locked and chromo 80 series axles (I think), chevy 350, SM465, ?? on the t case. I had a 205/241 Bohemoth doubler in my last CJ but I am not sure I want to deal with Bohemoth again. Who makes a good doubler kit for a Chevy NP205 behind a SM465? I have a Chevy 241C so I would love to use that if I can. Any good reviews on DIY kits out there? I will post some pics in a minute with my phone.

 

[Bjordan]

I have a complete rig with a busted t case and boxed frame with fiberglass tub. Also I have a hardtop for it.

 

[Bjordan]

When I brought it home. Packed a bunch of parts into a barn and pallets.

 

[Bjordan]

I have multiple doors, front doors, rear doors, 3 hoods, 3 grills, 3 wind shield frames, 3 frames, 2 tubs, SM420, SM465, 3 Toyota t cases, np205 Ford and Chevy, NP241C, a couple of yota axles (that I don’t know much about) and the list goes on. Long story but I got it from a buddy that lost interest.

 

[Bjordan]

Started cutting and working on the frame

 

[Bjordan]

My youngest son and main helper Casey

 

[Bjordan]

Suspension and foundation for the cage

 

[Bjordan]

Main hoop bent up. Still have a ton of crap to do before I can really start on the cage but the bender mount I was using sucked so felt the need to make it better. The bender is my buddies but his mount was crap so I made it better.

 

[Bjordan]

Much easier to use vertical or horizontal and can adjust to get it to perfect 90

 

[reptillikus]

FJ40s are cool.
So whats the plan here? Nice & streetable, or full blown trailer queen?

 

[Bjordan]

Streetable by my standards. Plan is 105-110 wheelbase, leaf front with slider boxes, 4 link rear with TJ coils, 40s, hydro assist steering, and about 4” lower then the current blue rig. The blue rig is complete but busted the t case years back. When we started replacing it my buddy realized the frame was toast, tub was toast and it had good parts but poorly done fab work. He bought a bunch of parts for the rebuild but then life got in the way and he lost interest. My current dilemma is what t case to use? Looking for feedback and experiences with economic 205 doublers. I am hesitant to go back down the behemoth route. Hated the service there but loved the product. I have a couple yota cases but I don’t know **** about yotas. I have killed many D300s in the past and love NP205 when they have deeper gears. I am afraid the yota cases will not survive long.

 

[Bjordan]

Also I plan to have my kids drive it when they get their permits. Oldest is almost 15. I have 3 sons and all are just like me so I want them in something big, slow and can take a hit or 2.

 

[Bjordan]

Pulled the driveline from the old rig.

 

[94toytruck]

I do dig a FJ40 build

 

[IowaOffRoad]

All those extra parts are cluttering your work space. Tell me when and where and I’ll help you load them in my truck. Won’t even charge you!







Like it!
Treat it like the typical Jeep build. Put anything in it you want. The grill and hood don’t care what it’s covering.

 

[Bjordan]

Yes sir I am building it the way I know best and what parts I have available.

 

[Bjordan]

Pulled the donor apart last night. Axles pulled out and tub ready to be set aside for a bit. Made some room in the shop to start the 4 link and cage.

 

[Bjordan]

All those extra parts are cluttering your work space. Tell me when and where and I’ll help you load them in my truck. Won’t even charge you!







Like it!
Treat it like the typical Jeep build. Put anything in it you want. The grill and hood don’t care what it’s covering.

I will have a ton of FJ parts to move after this project. I am not a yota guy so I don’t know the market but when this is done I will be cleaning shop for sure. Hoping to be done June this year so I can join some buddies for a trail run so maybe a yard sale shortly after.

 

[Bjordan]

Starting to get the body lined up. Need to work on the front fenders. On to the 4 link next.

 

[Bjordan]

Rear axle cleaned up and ready for brackets and truss. Hope to get the truss this week.

 

[Bjordan]

Snowed this weekend so I got some shop time. Got the axles under the newer frame and tub. 4 link tacked and it’s a roller.

 

[Bjordan]

Seems to cycle well but limited on how high I can take it with just the hoist.

 

[Sterlingfire]

You're making great progress. Looks ****in good man!

Hint time... after you attach files, and they complete their upload, hit the insert button in the upper corner of the thumb picture, then hit full size. We'll be able to see the full picture in the thread and won't have to enlarge it from your thumbnail...

 

[Bjordan]

You're making great progress. Looks ****in good man!

Hint time... after you attach files, and they complete their upload, hit the insert button in the upper corner of the thumb picture, then hit full size. We'll be able to see the full picture in the thread and won't have to enlarge it from your thumbnail...

Good to know, thanks

 

[Sterlingfire]

Good to know, thanks

You can even go back through your old posts and fix them if you feel so inclined

 

[Bjordan]

Pulled some of the body panels out to see what I have. Hopefully the pictures are better.

 

[Bjordan]

 

[rugburn]

The lifted stance of a 40 is so bad ass.
Can’t wait to have another 40Series 🍻

 

[Bjordan]

Back working on this for a couple of weeks.

 

[Bjordan]

Steering mounted