76 FJ40 Wheeler Build

[Danger Noodle]

A small update. I had a lot of schoolwork to catch up on today, so I didn't get a ton done.

Some side armor added.

And the front mount done.

I still need to gusset everything and fully weld, and then finish the other half of the skid for the tcase.

 

[MDH33]

Nice job! That thing is going to be so much fun. Don't see many 40's getting the full wheeling/crawling builds anymore

 

[Danger Noodle]

Nice job! That thing is going to be so much fun. Don't see many 40's getting the full wheeling/crawling builds anymore

I love wheeling my dad's 40. It's amazing how capable they are with a lift and lockers, so I'm really excited to get to go crawl this thing.

 

[Danger Noodle]

Skidplate Part 2, Electric Boogaloo.

I got the Trans/Toybox skidplate gusseted and welded up.

I then started on the T-case skid.

Roughly folded out of 1/4 steel.

Test fit.

Welded up.

Front mount holes drilled and nuts welded.

Stuck on.

Drain plug hole plasma'd in.

Final install.

18 1/2" of ground clearance at the dropdown. I can lift the entirety of the rear up with it, with minimal flex, so I think I'm ok dragging it around.

 

[Danger Noodle]

I got the brake master mounted up, and a bracket for the proportioning valve made up. I know the valve probably is not 100% necessary, but I want to be able to have control of it.

Bracket.

Proportioning valve.

Brake lines.

I did the big stupid. I thought the plugs that came in the master would be tight enough to bench bleed the master and keep it from leaking, but no such luck. I need to drain the master now.
Anways, last line finished.

Does anyone know if this is the proper routing for the master cylinder? What is the front and rear output?

Anyways, I got the defrost vents mounted as well.

 

[Danger Noodle]

Clutch line. It's pretty meh. I'm going to change it out with some AN stainless line to prevent fatiguing, and eventually loss of the clutch.

My grommets from Cruiser Corp finally came in, so I pulled my wires through the firewall.

Much nicer.

Finally getting around to the rear brakes.

This will add +10 hp, right?

 

[Danger Noodle]

My Coilovers are supposed to be here tomorrow. Exciting! Still missing springs, but I can work with that. The Hellfire Fab guys are hoping to have a knuckle set for me within the next couple of weeks, so I should be able to get this thing ready for exhaust and driveshafts.

 

[shellb]

Crazy talented! Love what you are doing and your vision!

I feel like I should just buy a project so I can start to learn how do these things...never too late right?

 

[Danger Noodle]

 

[Danger Noodle]

So, after some screwing around, I managed to get 6.5" of uptravel out of this link system. If I link the rear, I could haul ass through the desert. Another time, maybe.

Anyways, about 25" to the center of the axle at full stuff. It normally is around 18.5" at ride height.

Good clearance for the upper link.

Close to 90° from the lower link at full stuff. The other side is the limiting factor for this, as my A/C stuff is wanting to live in the same place.

I'm placing the shock hoops at a dead 90°

Flexyyyyyy. I still have another inch of droop, but the floor got in the way.

I can't wait to have this thing in the rocks.

Other side. All angles are matched within 1°.

Now I gotta get caught up on homework. Ugh.

 

[Danger Noodle]

Crazy talented! Love what you are doing and your vision!

I feel like I should just buy a project so I can start to learn how do these things...never too late right?

Thanks! This is my first real build, so I'm learning everything as I go. Its always the right time to start a project, and they are a ton of fun.

 

[Danger Noodle]

A few other pictures I forgot to post.

 

[Danger Noodle]

I got my speakers up cause they were just lying around.

After some extensive research and talking with my friend @Godfather90 (Mike) and Ben @ Filthy Motorsports, I didn't like the angles that the coilovers were sitting at.

The King 2.0s don't like much angle due to their smaller shaft, so between 0°-5° is recommended. On larger coilovers up to 15° is more acceptable.

Starting back at full stuff, I started reworking the angles.

For high-speed racing applications, 90° to the fully compressed lower link is what is recommended. Although this 40 will not be seeing high speed over whoops and rocks much, I want to have the best possible geometry that I can achieve.

I'm about 1° shy of 90° with the coilovers now, with the compromise being that I lowered my stuff by about 1/2". So only 6" of uptravel.

Within 5° of the horizontal angle at full stuff. Note that they will all get closer to 90° as the suspension droops out.

Man, the Kings are pretty.

The hoops ended up around 90° as well.

Readjusted angles.

Anyways, I'm much happier with those angles overall. The panhard and steering is up next, once I get the hellfire knuckles.

I'm hoping to fully dive into wiring while waiting for those knuckles.

 

[MDH33]

You're going to make Moab too easy. Nice work.

 

[J Kimmel]

Don’t be afraid of angle if you can it’ll help with stability mine are 15 in 15 back

 

[Danger Noodle]

So uh, this followed my dad home last night....

Anyone need 80 parts?

@cbmontgo dropped by to look at the 80 and the project. It was nice to talk to ya, Carson.

I then started working on my shock hoop cross member.

First bend.

Installed.

I then got the reservoirs mounted up.

Looking like an engine bay.

I got the reverse switch plug made.

 

[cbmontgo]

Enjoyed the visit today, @Danger Noodle. This 40 looks even better in person than in the photos. Gonna be an incredible rig.

 

[Danger Noodle]

Don’t be afraid of angle if you can it’ll help with stability mine are 15 in 15 back

The main reason I want to keep my shocks close to 90 is for the constant valving and spring rates. According to Ben @ Filthy Motorsports, the 2.0's don't like a lot of angle too much.

 

[Danger Noodle]

It was cold today. Luckly, with the heater, it's about 40° in the garage. Plenty warm to work.

Pretty cold on the peak this morning. Pretty though.

I started by making a mounting plate for my relay box.

Basic plate.

Studs welded on.

Mounted up.

Buss bars for my overhead console.

Spaghetti time. My fingers got really cold.

Dome lights wired up and running of a 9v battery.

The red lights are pretty bright.

White lights.

Not quite as bright, but will still be very effective.

 

[Notyourmomslx450]

Dang dude. Busting out all the tricks. Can’t wait to see it on the trail.