STAGE 1 - The Modifications
1ST ONE STOCK FJ40, TAKE AND USE ANGLE GRINDER AS FOLLOWS.
Air con removed and used as constant air pump, pressure switch added.
New springs with anti inversion shakes
Simex 35X10.5X15 Centipieds & Pro Comp 35x12'5x15 AT's
RidePro Shocks
Extractors ceramic coated
Custom built exhaust 2.5ins
Rebuilt 2F and Balanced Gas Cam too. 500Nm Torque & 70Kw at the wheels
5 speed Gearbox
Front and rear Diffs rebuilt ratio 4.556
Rear axel Moved back 30mm
ARB lockers fitted front and rear and ARB compressor
Constant air and ARB compressors linked ARB now only runs as back up
Gauges for constant air tank and ARB air tank fitted with front and rear locker switches in the same panel
One way air valve between consatant air and ARB compressors
Front wings Altered to allow for 35ins centipieds
Air tank
80 Amp altenator
Pirana electronic optical ignition
Air line to Distibutor and Clutch housing
Duel optima Batteries in parallel
8000lb high mount Warn winch modified
Dynamica 10mm winch rope
Bull bar cut down and narrowed and alltered to take the high mount then powder coated
Doors, bonnet and rear doors painted black
Snorkle by Perfomance exhausts, to my specs, top from ARB
Power Stering added from 75 series
Power steering cooler
Second airs
Leather bucket seat (easy to clean)
Four point seat belt for the driver
Two fire extinguishers
Radio Cassette & six stack CD player
Magellen FX 324 Colour Map GPS
GME TX4400
LightForce 170's
Jesus Bar or my navi will never stop complaining
6 point CCDA spec cage with swag bar armsup
Marine grade carpet and mats
New two part roof that can be used as a bikini top one part, wind jammer 2nd part or together whole roof. Or none at all.
ANYTHING ELSE I THINK OF I WILL ADD LATER
Up grades to come:
Continued repairs to damaged body work on going.
Second Bucket seat and 4 point harness 2006 he hopes
60 series rear axle 2007
Building a 2F-ETI 2007
Cut weight down. Bring on the Angle Grinder mmmmmm.
Sat Aug 13, 2005
The new battle armour is almost ready. We tapered it in towards the back and trimmed the sill just enough to allow the rail to come straight out
from the chassis. Had to use my favorite tool mmmm the Angel grinder!
There will be four mounting points once the old wings are cut away, the
support for the old wing will be externed and welded to the bar and new wings either in Ali or even rubber will be fitted.
Very big thanks to Dave and his pipe bender, great job.
The pipe we used is 32mm Nominal Bore black pipe and Dave also has a program downloaded off the net which gives a print out on A4
that you wrap around the pipe at the end giving you that perfect shape to blend the joins together what ever the angle.
We basically followed the outline of the old wings, using a spirit level off the tyre wall to give the correct width and off the top of the old wing
for the height. When you start bending it's better to bend a little at a time rather than too far as you can't go back, you can always put it back
in the bender if you need to go a little bit more. Also mark the centre of your bend before you start, makes it easier to reposition in the bender if
you have to bend a little more.
All thats left to do is cut the old wings away and plate the new ones up to the bar. Then a new coat of paint.
4.6 Crown and Pinions are in.
5 speed is in, but coming back out the mechanic has cracked the transfer case housing putting it in and now have a steady oil leak.
Sun Aug 28, 2005
Ok Sliders all ready, time for the wings to change.
On with the rubber, looks shit but will change to Ali checker plate later after Vic Winch.
Bring on the 35's heaps of room!
Mon Aug 29, 2005
Dave welded little spots down the slider to help with slip a little.
Power steering pump changed and just a cooler to get now, all seems ok.
Sat Sep 03, 2005
Time to see if the new wings and the moving of the rear axle back 25mm would accommodate the 35's. Had we done our maths right.
These are 11.5's we will most likely go with just the 10.5 but 35's fit just fine with no lift in either the body or suspension.
The springs are standard packs with a leaf taken out of the front and the rear to suit. They were fitted new in late 2003 and the leaf was removed
from each in 2004 to give more comfort (lost a little height though). Anti inversion shackles with greaseable pins were also fitted when the springs
were renewed.
So to be honest apart from removing a leaf all round we have done nothing, the Ranchos give good travel and don't bottom out, letting the springs go
as far as they can.
Sun Sep 04, 2005
Well, all Finished For Vic Winch, apart from the starter motor kacked last night! Both wings are now complete and ready to take 35x10.5x15's and
made a few mods to the front of the bull bar too.
Tuesday and we're off for a 4WD Dyno and we're not looking for ECONOMY time to see what the 2F has to offer after last years rebuild and
balancing now she's all run in.
Tue Sep 06, 2005
Had my 2F on the dyno today.
LPG is in red and Petrol blue
Thu Sep 15, 2005
Simex's are ordered and will be here Monday 35x10.5x15
Sat Sep 17, 2005
All finished for the Vic Winch. Well almost.
Bash plate is on protecting the new 5 speed, cut down a 60 series to suit.
Jesus bar fitted so that should..... nah you can never keep the navi quiet!
A few other minor mods that we won't mention just yet. Can't give everything away!
Ready to go and play in the mmmmmmud. Testing on Sunday 18/9/05
Tue Sep 20, 2005
Complete at last everything I set out to do is now done.
Picked up the new 35's today. All that's left for next year is a 6 point cage and new roof, bucket seat for Navi and 4 point harness.
It's been a long hard process, lessons have been learnt and unnecessary expenses incurred, but we learn from our mistakes and now I have
the only FJ40 i know of on 35's without any body or suspension lift.
So thanks to all that have helped make this possible.
Thu Oct 13, 2005
This weekend will see the start of stripping down of truck after its gruelling time at Vic Winch. Plus a few minor additions to the old girl.
Bonnet and doors will be coming off for a full respray, may even have the whole truck done though not sure on a colour. Quite fancy Holden's
Tiger Mica as the base colour and black.
Six point cage to go in early next year. The front leaf on the drivers side has softened a bit so we will have to look at what we can do there,
tempted to just swap the two fronts over and see what that does.
Maintenance is never ending.
Sat Nov 12, 2005
Ok I took it to bits at long last its been on there for far too long. 2 Vic Winch's, countless bog holes and not to mention swimming in the Tomson River
bonnet deep, ok it was over the bonnet - just! So I expected to find everything from mud to even the possibilty of a fish in the gear box, it's been
neglected for so long and it's had a few real hard winches to boot. So it was time to pull the high mount to bits and then figure out how to put it
back together again.
Have to say a big hats off to Warn, just a little water in the oil other than that pretty good really.
Now while it's off what mods shall I do?
Thu Nov 17, 2005
It seems our engineering workshop has a small shot blasting machine, so i put it to good use.
Ok mods to come
Air into gear box and motor housing
Gear box oil drain plug and filler plug
Motor mmmm thinking!
Fri Nov 18, 2005
Ok pulled the motor apart today, on the whole not too bad, brushes still have plenty of life in them. A little light rust on the motor soon cleaned up
with the wire brush. The only other area of corrosion was in the cap of the motor, not sure of the cause of this, it looked more like the electrical
deposits found on your battery terminals than anything from mud or water. Again like the gear box pretty damn good to say what it's been through
and under. So only needed to pick up a lower bush/seal kit from ATECO/WARN $55.
Looking for a 6hp+ motor to replace this one and keep this one as a spare.
Wed Jan 11, 2006
Just to answer a question I was asked about the bumps stops.
Did front and rear all the same 50mm box section. Used the bump stop as the template as they are tapered to allow for the mounting holes and
braced them down the centre by welding in a piece of flat bar right through for added strength.
It's a little of robbing Peter to pay Paul we could have more articulation but would have to run a smaller tyre without adding a body lift. If we add a
body lift we become more unstable and as we are competing in winch challenges stability at speed is paramount to me.
There are many different schools of thought here of which mine is only one.
Sat Jan 14, 2006
The new drum is complete, mods to the 6hp motor done, gear box too. Just have to put it back together. Another great job by Dave.
Jan 21, 2006
Part of the sponsorship deal with Penrite Oil is an ample supply of oil. It has been agreed that prior to each of this years competitions, engine,
transfer and gearbox oil, as well as both diff's will be given a full oil change. After each competition these will again be changed and samples of
each used oil sent for testing, to see how well they hold up when put to the test in extreme conditions. Penrite Oil have also agreed to supply
the results of these tests to post on Outer Limits. Samples of the oil from daily driving and personal off road abuse will also be tested. Also to be
changed and tested, transmission fluid in the power steering.
Tue Jan 31, 2006
I get my new phat rubber tomorrow so I will post some new pics if they arrive 35x12.5x15 AT's
Wed Feb 01, 2006
Winch mods complete, just need to cut the hole in the bull bar to suit and brace it a little, drill a couple of new holes. Will re-mount it this Saturday
and take it for a trial the following week. Big thanks to Dave for his engineering skills and awill4x4 for the tig welding and not forgeting Lockee too
for the new smick motor.
Thu Feb 02, 2006
The front wings and how they accommodate the phat 35'sx12.5x15 without any body lift, anti inversion shackles are about half an inch longer than
stock. Also the top of the wing has not been lifted, gap to the bonnet remained the same.
Sun Feb 05, 2006
Winch mods complete and back in the truck, just have to run a few breathers and pretty a few bits up. Take for a test run next week.
Mon Feb 06, 2006
Rear tail shaft came out today slip yoke is *%@#
Extractors are leaking again.
Bolts on the rear diff are loose.
Stub axle flange bolt, 4 missing 2 loose.
Various nuts and bolts loose.
All down to problem one - vibrating.
Mon Feb 13, 2006
We will be aiming this year to do the ATECO, ALPINE & VIC WINCH with the help and support of our Sponsor Penrite Oil. In our trusty FJ40 and
Marin's (winch Bitch) & DJB's (tec support) Mav's in support. The ALPINE will see us team up with Daz and his Yellow FJ40 V8 and coils. So in all a
busy year is planned if we are to make it to all three events.
First round of testing went well with the winch, though I have one electrical gremlin to chase down.
6 Point cage booked to go in on the 14th March.
Mon Feb 20, 2006
Will start work this weekend on removing all the switches for the spots and compressors. The new up coming six point cage means they have to be
moved. Also the overhead console will have to be stripped out, Radio/Cass and UHF too, speaker mounts and speakers, they will need refitting to
the new cage. Sat Nav aerial as well as all the wiring. Not sure what to replace the overhead console with yet, have a few ideas. Will also have
room for a centre console once the second bucket seat goes in too. Maybe time for drink holders or even a whole bar (chilled of course).
Tue Feb 28, 2006
The new extractors are ceramic coated which helps with the heat in the same way as the old wrap did, but looks a whole heap better.
Sun Mar 05, 2006
Thinking of Super Charging the old 2F, just a little boost!
This 2F surprises a lot of people with it's power and the way you can use it makes it very tractable off road. Just a little extra down the straight bit
would be an added bonus.
Sun Mar 12, 2006
Work began on removing all the switches from the right hand side of the dash as well as taking out the overhead console plus the old 4 point cage.
New 6 point goes in Tuesday then we will have to fabricate a new overhead console. No tunes till then.
Fri Mar 17, 2006
Will have to sit down and do some serious thinking, work everything out, may finally have to submit to some form of custom injection manifold too.
Wed Mar 22, 2006
The Six Point is in. Just have to sort some mesh out and plates for the roof, re-build the overhead console.
Next on the list new seat and 4 point belt for the Navi.
Longfield CV's are being ordered 3rd of April. Oh and a coat of paint when I've decided on a colour.
Tue Mar 28, 2006
And then there was one.
Yet again I have sheared the rear stub axle bolts, yesterday there were 3, this morning just the one *%@# now 6 again! :) So it looks like we will
have to upgrade to a larger stud and cone washer or some other alternative I believe 80 series are larger.
Mon Apr 03, 2006
Carpet has been re-cut and put back, spotlight switches re-fitted and re-wired.
Had a look today at the padding for the cage, white, nah get too dirty too quick, so it's black, yellow or red.
UHF new home is sorted just a bit of welding to do for mounting brackets.
Mon Apr 10, 2006
Took the truck out for a play on Sunday to Toolangi, cold, wet and drizzling. Very greasy and had a ball on Rocky and Vic Range + a few other bits.
Truck just work's a treat and these AT's from Pro Comp are unstoppable so far.
Mon Apr 17, 2006
Got the mesh in today, one more job off the to do list.
Sun Apr 23, 2006
[Quote: Marin]
Nobody hurt, I got the call at about 6:15 this morning, went and got my car and headed up, cauz the guys at camp had their phones off, but by
the time I was halfway there they were up and about, so I got straight to getting a trailer. When I got there, they had the car back on it's wheels,
and using James as a drag anchor behind him via a winch extention strap, Matt managed to pilot his rig down to the carpark where I had my car
and trailer. All captured on video I believe, the recovery that is.
So, the story goes......
Matt heads up a bit early to have breaky with the guys. Goes in via Cemetry track cauz it's still too early to break up BJ's beauty sleep. Heads up
Cemetry, goes round the corner to the left and heads up the steeper bit along the fence. Goes over a few washouts, and eventually loses traction,
stopping forward movement. So he backs it down to the washout, which looks decent enough, stops, rocks the car inside, seems good, gets out,
rocks the car from outside, still seems solid as (mind you it was dark), gets his stauns out, puts them all on. He hears the first 1 click off, so heads
around the front of the car, which is still pointing uphill. Cauz its a bitch of a day, it's bloody slippery on that red clay, so as he goes around, he does
a bit of a tap with his hand on the bullbar to stop himself slipping. This is where the car starts to slide down the hill. Absolutely nothing he can do,
both lockers are on, it's still in gear, four wheel slide backwards down the hill, Matt watching his headlights run away from him. Car does a 180 spin
approx 40 metres away from him, unbalancing itself, and continues down the hill not so straight anymore. Car slides itself into a tree, and flips over
onto it's roof. And that's where it stayed.
Matt feel free to amend any portions of this......
Damage.... hmmmm......
- chassis bent for sure
- winch could be recoverable, have to wait to pull it out and look
- drive shaft pushed into gearbox, would need to pull apart to see what the damage is
- front springs bent, not sure to what extent, or might just be 1 bent
- doors, panels knackered
- radiator punctured
- various smaller things under the bonnet
- engine condition unknown as yet, because of the drive shaft pushing into gearbox, the whole engine has moved so that instead of a north south
motor, it's kind of a north by north west/south by south east motor
Thanks to everybody who helped out, muchly appreciated.
Well, that's all I can think of for the moment. Well, apart from it's never taken me that long to get home from Warby, I didn't realize how long some
of those hills were until I was sitting in 2nd gear allllllll the way up them!
marin
P.S. We reckon it will be a write off, purely due to the HUGE chassis bending, when we were putting it onto the car trailer, the front wheels went
straight up the ramps, and the rear wheels almost missed the ramps.
Sun Apr 23, 2006
Time to take stock have a think plenty I can salvage mainly chassis damage poss gearbox/transfer case.
Either airing down changed the balance of the truck or something in the drive line broke as there is no way it should have moved off, even left the
ignition on so the lockers stayed in!
Mon Apr 24, 2006
Looking for a FJ 40 2F late model. Just need a straight chassis and good body.
There are 3 months to the ATECO so we're not giving up just yet.
Spent a little time looking over the truck which we will be buying back from the insurance company when they have writen it off. So can't do too
much until it's been assessed.
So on the whole the damage looks like just being chassis, body, radiator, spotties and most likely the front axle housing and front leaf springs.
The engine has moved back but looks like not enough to damage the gearbox/transfer case.
Who Rebuilt this 2F?
Engine Builders Details are as follows:
http://www.tdcengines.com/
TDC Engines
5/13 Turbo Drive
Bayswater N
9720 7620
Vic 3153
Refuses to give the secrets of this engine away happy to build another just like it. Cost around $4000 in 2005.
In conjunction with my mechanic Chris
New Car Service Centre ( he does old cars too)
1 Richard Street
Mitcham
9872 3677
I have no problems at all recommending both very highly. Chris has over seen most of the modifications and now knows FJ40's Inside out.
THE END OF MKI
If you have any questions about the build up or would like to make a comment then you can do so via the FJ40 2F ETI LOCKED AND LOADED BLOG located HERE .