KB3GUN's '66 FJ40 Build

1/05/2008
I just took delivery of a 1966 FJ40,(thanks Sean!!) less engine and transfer /transmission. I've been wheeling the FJC, but as it's my daily driver, I wanted to get a second vehicle for the trails.

Once I make some headway, I'll start a build thread in the forums at Mud (IH8MUD for those that don't already know). I'm a member of TLCA and ALCA (Appalachian Land Cruiser Association). I wheel with ALCA at Rausch Creek for the most part.

cover-start1

This is my current goal:
I want to get this licensed for the street, but it's going to primarily be a trail rig. It'll be trailered to Rausch Creek when I want to wheel. I want it streetable so I can drive it around town in the Summer. I don't plan on highway speeds. I'm doing a frame-off build up, not a restore. It's going to get beat up. I just want to get rid of the rust that is currently dining on it. I hope to complete it by CMCC 2008. If I don't make it, I don't make it. I want to do it right the first time.

Plan of attack: (not in order I'm sure)

  1. Remove top, tub, and everything else from the frame (except springs and axles - I need a rolling chassis to get it to the sandblaster).
    The hard top is in great shape except for a few cracks (easily repairable) in the fiberglass top.
    The rear tub is going to take some work. I'll repair what I can and replace what I can't.
  2. Get the frame sand blasted and then POR15 the frame. In its current form, the frame is in great shape. I just want to make sure it stays that way.
  3. Replace stock axles with those from an FJ62. The axles have 4.10 gears, parking brake on axle, and F/R disk brakes.
  4. SOA conversion.
    I have the springs and a SOA kit from Proffitt's.
    Will cut and turn the front axle for pinion alignment.
    I've also found out that the front spring mounts will need to be relocated towards the outer edge of the frame due to a shorter passenger side axle tube. Found a good discussion of it on Mud and it doesn't look like too much extra work.
  5. Replace PO's mini-truck power steering setup with a Saginaw and high steer.
  6. Install 2F Engine w/ factory PS, 4-Speed tranny and split transfer from a 1982 FJ40. Will make a new wiring harness for the 2F to mate to the '66 chassis.

Last updated 6/17/08... (Tub & Engine sections)

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Bill Smith
kb3gun@verizon.net
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