FJ-60 Build-Up

[freds40]

Thanks. That's on the list for this weekend.

[freds40]

Start of my new rear axle build. Started with a full width 14 bolt SRW.



Had 2 sets of wheel hubs so I traded 1 set for a set of C&C hubs.



I decided to run the C&C hubs as they would give me a WMS-WMS of 63" while the SRW hubs would put me out @ 67". My front axle is 63" so the C&Cs are perfect while retaining the stock 14 bolt axle shafts.

[freds40]

The 14 bolt hubs are obviously 8 lug from the factory and I wanted to retain 6 lug on my rig.



First step was to plug 2 of the holes. I cut the heads off 2 of the 14 bolt wheel studs and pressed them back in. Welded the head and turned them on a lather to insure the WMS was flat.

[freds40]

Next problem was the hub OD. It was way too big for my 6 lug Allieds to fit over so I had to turn down the hubs.



Then I could transfer the 6 lug pattern to the 8 lug hub.



The OD of the axle flange has to be turned down too for the wheel to clear. I took a bit of extra time and cleaned up the shafts a bit. They are still stock shafts though so replacements are a dime a dozen.

[freds40]

The rotors I used are 8 lug 3/4 ton GM parts.



To attach them, I drilled and tapped the remaining stud holes for 3/4" bolts. You can also see the milled sections for the Toyota wheel studs to seat flat.



Studs pressed in, a little paint, and it doesn't look half bad.




Bolted up and ready to go.

[freds40]

Now back to the housing.



FJ60 t-cases have the front and rear outputs on the passenger side. My truck gets driven @ freeway speeds and I didn't want to have to worry about drive shaft vibes with an offset t-case/axle.

I decided to build an offset axle housing.

[freds40]

My goal was to retain stock axle shafts so replacements would be cheap and readily available.

I found that by making the passenger axle tube loose 6" and the driver side to pick up 6" the shafts would swap side to side and give me my offset.

I marked both sides....



and cut away.



Both axle tubes cut. One 6" longer than the other.

[freds40]

Now to reattach the tubes on the opposite sides.

I machined some sleeves that would fit inside the axle tubes to help align and to give me some backing to weld to.



Drilled a few holes for use as plug welds.



With the tube slid into the axle housing, I used some 3x3 3/8 wall angle iron to act as a jig. With it clamped down, I filled some plug welds.

[freds40]

Since the housing was out, I decided to shave a bit off the bottom. Didn't want to take a ton and have to plate the bottom so I just too 3/4 of an inch off.



Beginnings of welding up the spiders. I needed some additional traction and this will do until I can afford an ARB for the back end.



I had a couple of pairs of Ruff Stuff SRW disc brackets and I found that by mounting them inside the outer flange, they would be close to where I need them. I have no problems mounting them here as they should never have to come off.

[freds40]

Got it tossed under there.





Drive line location.

[freds40]

When I got the 14 bolt, it came with a Ballistic Fab diff cover. It comes in pieces and you weld it together. It's got a 3/8" ring as well as 3/8" plate. Stout piece that will hold up great.

[freds40]

Got it together and drove it a few days around town and on the freeway.

I was set to run the Dusy Ershim trail for the 4th of July. About 10 minutes from my house on the way there, I felt a small jolt in the back end followed by a slight drag. Pulled over on the side of the freeway to check it and saw nothing. Limped up to the next freeway off ramp and got off. Took a closer look and found nothing. Thought it might have been a wheel bearing based on how it rode after. Passenger wheel hub was warm but not out of the ordinary. Driver was too hot to hold onto. BINGO!!!

After about 3/4 of a turn backing off the spindle nut, roller bearings started to fall out. 



Pulled the hub and found this.



I made the cut in an attempt to free the inner race, then decided to take a pic. The sealing surface (in front of the seal) was also messed up from the rollers thrashing around on it.

[freds40]

Sooooooooo long story short, the new axle I built to combat the larger tires and crawl ratio is torn back apart after a wheel bearing killed the spindle and 1 wheel hub. The passenger side hub is still in great shape. Hopefully have it back up and rolling next week as I've got some wheeling to do. 

[Joey88RUNR]

pretty impressive! you gots mad skills

[freds40]

Thanks Joe. Glad to finally be getting back on the trail next weekend. 

[NoPower]

Well l just wanted to tell you that your 60 is badazz. I loved my old 60 but I did'nt have the time or money to put into. Looks like you have built a great vehicle that should be alot of fun for years to come

[pumkin toy]

looks great!  thats pretty sweet you can still run stock shafts in your rear axle

[Yota87Truck]

NICE!! I relaly like how you modded the rear fenders.  Nice Low COG rig!

[buss-stop]

NICE!! I relaly like how you modded the rear fenders.  Nice Low COG rig!

new to this amazing b-board..  your  build up looks rite on... im going to completely mimic it in a lot of ways...  just, JUST got my 84 fj 60 the other day...  quick q- did you widen the rear axle?

[buss-stop]

im an idiot how about that...

[freds40]

Some small updates. I've got to do a few things to get it ready for the season. I'll leave for Cruise Moab 2 days after getting back from Tin Benders so it has to be ready to go in a little over a month.

I've been running some pre-production proto-type lower caps on my 25 mm pin kit from the beginning and I finally decided to add new lower caps.





Also went ahead and did the 6 pin mod @ work one weekend.

[freds40]

The wife went a bit crazy for Christmas.



Rocky helped me out and set up both of my diffs along with some new traction aids. 







I got one of Jess' flanges to run a Toy shaft on a 14 bolt. I had to turn down about 1/4" from the radius to make it fir through the hole that's in the Ruff Stuff pinion guard.



Heres a quick testimonial for our seals. I pulled the front end apart to install the third and even with the extension sleeves I used on the front end and not using an alignment shaft to install them, there is still no gear oil in axle balls.

[freds40]

This one I've been wanting to do for a bit. Finally had the time one night after work last week. I keyed the knuckles to the steering arms to combat the added torsional loads the tires and hydro assist put on the knuckle studs. Pretty simple mod and it should add a fair amount of strength.

[Joey88RUNR]

       thats a nice wifey!      Looks awesome!

[pumkin toy]

sweet mod with the keyways!  great idea

[Slolyfe]

Nice work Brendan, I haven't seen your build thread yet! But im along for the ride now. See yea out there this summer.

[rgacord]

great pics along the way. i like checkin the ideas and the fab work,,,,,,nice job!!!!!

[Bazzi]

damn... nice idea with the keys     

[crawlerdad]

I like this build.

[baxter650]

Are there plans for an anti wrap bar in your future?
I have been watching your build for a while now, talented build and i love those wheels, i have been looking at the black ones and may step up.