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Project SAC'D FJC - "The Rebuild" and then some...

107K views 521 replies 76 participants last post by  MotioncontrolMike 
#1 ·
Finally getting around to starting a new thread. :nerd Some of you may have seen my other build threads, but if not click on the links below and have a ball reading for the next couple of hours...

Phase 1 - The original SAS build thread... that covers the initial build up, some additional post build changes, offroad expo coverage and a bunch of the wheeling trips.

Phase 2 - The post SAS thread that includes everything from the DIY beadlocks, reaer tire carrier, tube doors, shock tuning, lots of wheeling pictures and a bunch of helpful posts on the electronics and how to disable them.

In this installment :wink I'll cover the rebuild of the front end and the rear 3-link with 14" Fox 2.5" coilovers plus a bunch of other things as we go...

First... the original solid axle swap was completed almost 7 years ago and my FJC has performed amazing over the years. Over the last few years I've seen a number of successful rear 3-link setups on late model Toyota's and that made me believe it was time to do the rear 3-link on my FJC.

The parts list goes like this...

- 14" Fox 2.5" body coil overs with remote reservoirs
- Eibach coilover springs 300/350 spring rate as a starting point
- RuffStuff antiways (this thing is crazy stiff - same diameter as a Dana 60 axle shaft)
- Branik 2.25" solid aluminum links (all the way around)
- Currie's new chromoly narrow johnny joints (all the way around)
- FK heims on the panhards
- Fox air bumps (reusing the ones I had in there, but relocating)
- Polyperformance limit straps
- FJ-80 High pinion third member with an ARB for the front (moving away from the elocker third)
- and a bunch of pretty welds from the fabricator...

So enough with the words and on to the pictures.

Here is what I started with...



A few pics of the parts... new johnny joints



Fox coilovers



Started off by putting the FJC on the scales... let's just say it needs to go on a diet. PIGLET!





The first thing we started with was swapping out the front diff. When I originally built the front axle I chose to use an FJ80 high pinion third with an elocker. This go around I'm switching to the same FJ80, but with an ARB locker instead. This involved adding some steel to the face of the housing in order to make the ARB third fit. With elockers there is a large chunk of steel missing where the elocker shift fork passes through the diff and connects to the locking shift fork. We welded in a piece of 1/2" plate, drilled and tapped it and then installed the new diff.

Sorry for the crappy pic... this is post adding the steel to the face.



Post diff install...



At this point... things change direction and I decide to rebuild both the front and rear. After 7 years of hard wheeling the link mounts at the frame had taken a beating as had the front axle mounts. So...

Off came everything... :surprise and we started completely over. We kept the shock towers, steering and frame side panhard mount, but stripped the front axle and belly bare and started over.





The plan going forward it to rebuild the front axle mounts, new front and rear cross members with integrated link mounts, fully belly pan, 3-link in the rear with coilovers up into the rear cargo area, sway bar and a bunch of other cool things.

I will post more as we make progress...
 
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#362 ·
What part of california are you located in?! This is one of the most impressive builds ive ever seen...
 
#364 ·
Picked up some billet shock reservoir clamps from the guys over at Chassis Unlimited. Installed them today and put the roll bar padding back on the rear down tubes of the cage.



Say bye bye to the Fox hose clamps and rubber mounts...



Say hello to some sexy billet clamps...



Got the noodle padding reinstalled too...



There was enough slack in the lines that I was able to push the reservoirs outboard a fair amount. It's hard to tell from the picture, but the reservoirs are actually hitting the factory plastic at the top.
 
#381 ·
Thank you... I could probably fit 40's with a little strategic sledge hammering, but then I would start to worry about breaking axle shafts or other parts. Where I am right now gets me through anything I want to go through and I don't stress over breaking parts. I also don't flog on my stuff either... I love to crawl up things nice and slow. If I can't make it I have no issue with trying another line. There was a guy that went up the staircase in the video just before me. He had a VERY nice rig, well built 40" tires, dana 60's, big V8, blah, blah... but no low gears in the tcase. It took him a good 20+ minutes of jockeying and A LOT of throttle to get up the same line that I walked up.
 
#380 ·
It's neat to see those front bump-stops in action along with everything else. The suspension seems to function flawlessly; all components operating in concert as designed. Very cool. I can't say enough about the direction chosen and the sheer quality in engineering and design.
I am in awe; also one that is generally not easily impressed. :cheers:
 
#387 · (Edited)
Ran Niagara Rim Trail... never been on this trail before. Fun trail, not real hard, but lots of tippy stuff if you start playing around. I almost put the FJC on it's lid twice. Fun stuff... got some pictures while we took a break about halfway through the trail. All poser pics. :)

At the top of PH Rock...









Incredible views from the highest spot on the trail... made for a good lunch spot!





Playing around a little...











My buddies BRAND new JK. This thing is awesome... if I were a Jeep person I would definitely be looking at one of these things.





At the end of the trail all aired up and ready to head back home. FJC worked amazing again!

 
#392 · (Edited)
Took a break from wheeling this past weekend to help my son build his front Tacoma bumper. This is a Relentless Fab DIY kit. Basically all the pieces needed to build a front bumper and a much lower cost because WE get to stick it together.

They ship it like this...



Center section is pre-bent and bolts up nicely... the rest is a big puzzle. :)



Tack the top plate in place, then start on the wings...





All tacked together... this happened pretty darn quick.



Then removed it and started burning it together. With my little Lincoln it took FOREVER to do the front side.... but we got it done and started grinding things down.





While my son was grinding I was in the house researching new welders. As you can see he did a great job getting it cleaned up.



Next weekend we are going to weld the backside and start the hoops. But FIRST... I ordered a new welder so it doesn't take FOREVER... :D Ordered a Miller 211 that should be here this week, so we can burn in the back side. Fun little project, but certainly took away from time with the FJC.
 
#394 ·
Sol,
What you do for an ebrake?

Limited access, pics take ten minutes a page to load, so if depicted, apologies.

Trying to figure out what to do with the 80 cable on the RS housing....
 
#395 ·
銀チタン;5306569 said:
Sol,
What you do for an ebrake?

Limited access, pics take ten minutes a page to load, so if depicted, apologies.

Trying to figure out what to do with the 80 cable on the RS housing....
I used the stock FJC ebrake setup. When I had the Diamond axle housing built I sent all the rear brake parts to them so they could build a housing and adapters. My entire brake system is stock FJC parts (calipers, rotors, backing plates, ebrake, master cylinder, absolutely everything). Makes it easy to buy parts and I didn't have to change out the cables.

Look at post #30 in this thread to see the adapters and install.







 
#396 ·
:bigthumb:

Betting the drum brake hubs are the same size on all, but gonna confirm.

Backing plates, I know, differ between models, but dunno why the backing plate could be adapted to reorient the cable penetration.

Auto part Disc brake Locking hubs Vehicle brake Brake


Gonna make it work, somehow, simply from an aesthetic perspective, if nothing else, 'cause who wants look at this on the back of a linked, RS housing.

Suspension part Suspension Auto part Wheel Vehicle


Especially, if an RS housing with cable locked diffs....

Tire Wheel Automotive tire Automotive wheel system Auto part
 
#397 ·
Hey sol, great build. Are you in the Bay Area? I'd love to talk about some coil rates and shock valving. I've tried multiple rates in the rear. I would love to soften things up. I think I can after I buitlt the swaybar setup in the front. I'm in concord. I'd love to talk with you about some suspension stuff and shocks. Thx, Phil.
 
#398 · (Edited)
Pretty pathetic that it's been over a years since I added anything to this thread. Been busy building a 1st Gen Tacoma and 4th Gen 4Runner for my boys. Did manage to change the oil in the FJC this past weekend. Drove it a total of 540 miles in 2015. I think I'm just about to break 28k miles on the FJC.



Here is the 4Runner that we've been working on... 2004 4Runner, Icon lift, Demello Front bumper, homemade sliders, tires, wheels and a few other things. This thing was a basket case when we got it... used this as a chance to teach my youngest how to take care of a car and had my son do all the work to get it into great mechanical condition.



Here is the 1st Gen Tacoma... 2001 Double Cab Tacoma, This thing was a cream puff when we bought it. 230k miles, one owner, bone stock, well cared for truck. My oldest is building this on into a nice trail rig. Drives great and he's done a great job on it. Demello sliders, Relentless DIY front and rear bumpers, homemade rear swingout, Icon lift, home made bed rack and a bunch of other things...



Goal for 2016 is to put more miles on the FJC that last year... :) We have a few more projects for the Tacoma and 4Runner, but I hope to get the FJC out in the dirt a bit more this year.
 
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