Project FJ-Rankenstein.. rebuilding a drivetrain, toybox and more...

[freds40]

Nice pic in Trails. 

[fj-rankenstein]

damn..  i didnt get my copy yet!!   is it from the river shiver here in canada or the marlin crawler roundup??  i am super curious!!

*EDIT*

looks like its from the TLCA RIver Shiver up here in Canada.  i found it on the TLCA website..

http://www.tlca.org/trails/2012/0506/river_shiver_2012.shtml

[fj-rankenstein]

it was a good weekend in the garage..

i got the tranny completely torn apart and mostly cleaned up..  i do have an issue with the counter shaft that i am going to see if i can get fixed..  two of the bearing surfaces arent in good shape and a new shaft from toyota here in town is over 1200 bucks..   through the good people at 1st toyota though its 600.. so that sucks completely and i will see how much it will cost to get the two sections of the shaft re-chromed tomorrow..  getting that h55f apart was borderline sucky..  3 out of the 4 end shaft bearings were horrible to get out but once that was over the rest came apart easy.  i tried to make a couple of puller arms out of bolts but they didnt last too long so i got mad and welded them to the bearing that needed to get removed.. that did the trick..
  here are the pics..

i may as well have a quick recap.. this is where i left off..



and another pic of this toyota goodness.. shaft be gone!!



here are all these great looking gears wanting to leave the case..



here is a creative but wrong way to use a puller..  lol..   



the countershaft bearing surface that i have to get re-chromed.  i wish marlin made this shaft..



with welded puller bolts the darn thing finally came..   



the bare case waiting to get cleaned up..   



tranny and t-case madness!!   



all cleaned up and sandblasted so they can get a clean coat of paint..  ready for re-assembly..   

[fj-rankenstein]

so i ordered all my stuff today..  jesus jones thats gonna hurt the ole' credit card..   :lol:

i am hoping to run a conservative 10-14 pounds boost and have the fuel turned up a bit as well..  this should up my horses from 86 horsepower to about 150 and enough torque to pull over a small house..

i will list the vendors i got my stuff at..

the turbo..  garrett 2052 with the 52 trim..

http://www.agpturbo.com/garrett-journal-bearing-gt2052/

the intercooler

http://www.ebay.com/itm/Universal-Bar-Plate-FMIC-Turbo-Intercooler-28X9X2-75-/250751459607?pt=Motors_Car_Truck_Parts_Accessories&vxp=mtr&hash=item3a61f3a117

and all of the silicone parts and piping..
be sure to use the coupon code " link987 for 10% off" every time..

http://www.siliconeintakes.com/index.php?osCsid=21d4c9f396d0861336202512b164e956

as far as the small bits go, i will be making all of my turbo oil feed and drain flanges here in town with high temp hydraulic hoses and fittings..

i still need to make a flange to weld onto my manifold for my turbo to bolt to..

[fj-rankenstein]

yum...



i am expecting my turbo and intercooler to show up by friday!!

[*** YELLER ***]

AWESOME LOVE THE BUILD

[THK Matt]

Im so stoked to see how you finish this thing.

[Wermz84]

Very cool custom holder on the engine stand! 


You going to have this ready by the roundup?   

[fj-rankenstein]

Very cool custom holder on the engine stand! 


You going to have this ready by the roundup?   

thanks everyone!!     
..  i got tired of trying to hold the tranny and take it apart all at the same time..    this at least keeps it steady.. 

Round-up hey..   i should have no problem finishing the truck by then..    its the 3 days and 3000 kilometers each way that separates me and the rubicon is whats the problem....     i would have enough holidays to make a blitz run down there and meet you guys if i was overly ambitious though..      i dont know if i can spoil myself and do the rubicon trail two years in a row though. lol..    i assume you are going to the round-up??   i would sure like to go though..

[Wermz84]

We are going again this year, and I do understand it is a long way for you.  But we would be honored to have you and the misses again.   

[fj-rankenstein]

this thing showed up today!!  i just went to the post orfice and picked it up..      should hopefully work nice..  its too shiney though..

[fj-rankenstein]

ahhhhhhhhhhhhhhh,    and this is where the magic is...

double boxed for protection from those postal workers!!



pooooooowwwwwwer!!!!



more pooooowwwwer!!!

[THK Matt]

I just blew a load.

[fj-rankenstein]

 



got busy doing other stuff tonight so i didnt get as much done as i wanted...   i did get the top and doors off though..  i like this look much better..
box is coming off tomorrow so i can start working on a rear bumper and fuel cell cradle..

[fj-rankenstein]

i got started with both the rear bumper and fuel cell..  the rear bumper was supposed to made out of 3/16 material but instead communication got crossed and now i have a bumper that is 1/4 ich thick..   i will end of cutting quite a bit out of both corners once i "smiley" the bumper to help with approach angle but its still heavy.. looking online though it looks like there are a few companies doing bumpers out of 1/4 inch if they are really being loaded up with things mounted to them..  the bumper brackets are made from 3/8 tick material.

the fuel cell needs a few mods as well but the overall fitment is perfect back there  this was a used fuel cell that didnt get a chance to get used yet..  i have to move the filler to a new location, make a breather vent for it, notch out the bottom corner for the exhaust to pass by and install my factory fuel gauge..  should be pretty easy.... i cant wait to get some much needed cab space once i get rid of the original tank under the passenger seat..  after the tank is gone it will make room so i can also start on my metaltech roll bar..

[Wermz84]

Can I be your fabrication Padawan? 

[baxter650]

If i drove around here with no doors the 5/O would have a field day writing tickets and you would end up with a VI for good measure.
You can have a piece of fabric as a friggin door but no doors is somehow a criminal offense.
Love the truck though, great build.

[Wainiha]

Awesome build.  I hope there is more soon.  I need to learn how to weld

[fj-rankenstein]

Can I be your fabrication Padawan? 

but the force is strong with you...  this isnt the build thread you are looking for  (waving hand in air..)  move along, move along......     lol... 

[fj-rankenstein]

i got a bit more done on the bumper..  so much work but i will be happy with it when its done.. i hope to have the majority done by the weekend..


doing some planning where to cut it..


the first chop


i sure like plasma cutters..


here are the swing arm insets being built.  i havent really seen it done this way so i figured i would give it a try..


ignore the extra material hanging out the sides.. there are some mods to the bumper that will involve tucking everything in and up so i wanted to leave myself a little extra to work with..


and one final shot from the back..

[Quintin]

This is a really cool job you are doing here. I am in the process of redoing my Hilux and you gave me some very nice ideas.

[fj-rankenstein]

a few more of bumper progress

[THK Matt]

Interesting.... im tryin to figure out whatever your doing with it lol looks cool though

[fj-rankenstein]

lol..   it does look a bit odd in mid build..  i am basically going to follow that piece of angle iron to form a shape like   \___________/ from the top view kinda and also it will have this same "smiley" profile looking at it from behind as well..

hopefully in a few days when it is more complete it will make more sense..   

[Dooner]

Well my hats off to you again, the turbo and after cooler oughta give you some serious cruising speed making the trek out here to Cali for future round ups! Likely be a good increase in mpg's and pulling power too.
I'm really digging your ideas on the rear bumper too. If I'm following you, the swing arms that you mention are the swing out arms for a carrier rack that are inset into the top of the bumper. I've never seen that either, very innovative!
Man that's a nice fit on that fuel cell! I ended up venting both of my tanks to a Toyota charcoal canister from a pickup under the hood. Not sure if you'd need the vapor control for the diesel though
Mike

[fj-rankenstein]

thanks for the kind words..  its always motivating. 

i am starting to put some serious time into the truck again..  i wish i had another month before our trip to the black hills cruiser classic but i will get as much done as possible.

keeping on with the bumper.. the undersides are getting built..


its really starting to take shape now..


nice angle upwards for better departure angle..


nice overall shot of whats going on..

[*** YELLER ***]

awesome . . .

[fj-rankenstein]

thanks!

so far so good today.. i got the hitch put into the bumper..  i wish it didnt stick out the back end so much but there is no other way to do it and still get a hitch pin in..  it will be fine though..  i have a little more cutting to do and then i can take the bumper off and finish the underside welding, install some tow hooks in it mabey and put on the eyes where the chains for the trailer hook onto..  that will end the bumper part of the build.. from there i can work on the swing outs..

yup, its a hitch

the underside view



here is the ole' princess auto 10 inch drop hitch

[baxter650]

Lookin great, as per usual.

[fj-rankenstein]

thanks..    i am really enjoying this bumper build..

a bit more progress..

should be done the tire rack part of it today..  i am not going to worry about the other side till after our trip..












after it was too late to run the grinders and make loud noises i started on the exhaust manifold..