Topic: FJ40 buildup

[Dooner]

Im still at the research parts gathering phase of this project but heres what I gots going. 71 FJ40 with a 327 / TH400 with the 3 speed transfer case, Saginaw PS w junkyard cross over steering. Ive decided to change this setup for a number of reasons. I picked up an SM465 ( '86 with the  long 32 spline output shaft) for its low first gear and being stout. I looked into upgrading the cruiser axles but decided to scrap them in favor of  spring over Toy Mini truck axles ( thanx Toyota Boy and Sky Jacker! ) to get front disk brakes and an offset rearend for more transfer case options. Thats where I am now, looking at T case alternatives.
 #1 somehow swap a 10 spline output shaft into the 465 and use the stock TLC 3sp t case
 #2 Pick up an NP 241 w passenger side drop along with a shorty SYE setup / adapter
 #3 pick up a Dana 300 with adapter and shaft
 #4 NP 208 - not sure if pass. side drop is available decent low range, kind of on the long side
 #5 NP 205 - Heavy like 135 lbs! long adapter, super stout, meager low range

Next Question - Since im going to have to go outboard on the frame for the spring mounts to suit the Mini axles, I would like to go with longer springs for a bit more articulation but not much more ride height.
What junk yard springs would work on a 40, I know alot of guys run wagoneer / Chevies, F150's but how about us short wheelbase guys?

After I get the transfer case adapter thing figured out, Im planning to get some driveshafts made up at Fresno driveline, find a good radiator shop, have a nice family cage fabed up throw a coat of barn paint on the sheetmetal, a high steer setup, maybe some chromoly axles and wheel the kagata out of it!

Any help, Ideas, tips or guidance would truely be appreciated
Thanks, Mike

[WHITE_TRASH]

Wow you just described what Im building with a buddy.  Its getting a mini front axle, ford 9" rear, sm465, mini t-case and ifs yota steering box for hi-steer.  Im building mini rear spring for the front and using broncoII's on the rear.  The wheelbase will be stretched about 4" in the front and the rear so some added stability.  Once I get started on it Ill let you know the pitfalls to avoid.  Im inboarding the rear springs and puting a sway bar on it for th estreet beings it'll still see some pavement duty.

[Dooner [OP]]

A Mini t case you say.. What goes into adapting it to the 465? Am I going to have to ditch the long a$$ 32 spline output shaft? Im really having a hard time seeing how the long shaft will work without having a huge adapter to join the 465 to the t-case. Ive heard that it is possible to swap in a 10 spline but doesnt the 32 have a larger diameter shaft and bearing? Soo what to do about putting a skinney 10 spline shaft into the gapping 32 spline hole.
Tell me more, Im gonna need to pick up a t case and springs real soon. How do your springs compare to stock LC's width and length> by the way, what is the proper way to measure a leaf, center of  each eye to eye along the surface of the spring? 
Thanks, Mike

[WHITE_TRASH]

The springs are 2 3/8" for the yota mini truck springs and the broncoII's are 2 1/2" wide.  The stock fj-40's are 3" wide and rather short.  Im doing a shackle reversal for the front at the same time for better driveability.  To measure the springs measure from each eye to the center pin.  That way you get a true measurement along its length.  Im pressed for time right now but Ill address you other questions later this evening.