Project SAC'D FJC - Phase II

sbechtold · 03-31-2008, 09:22 PM

Since my first build up thread has grown and it's hard to find anything I thought I would start a new thread to cover the next phase of modifications.

DIY Beadlock Wheels and 37" MT/R's:

I recently completed a set of weld-on beadlocks and up-sized my tires to 37" MT/R's. The process of installing the beadlocks was pretty straight-forward, but very labor intensive. I'm happy with the way they turned out.

Bare metal rings:

Anti-coning ring welded to outer ring.

Inner ring welded on and rim painted:

Windex is your friend when mounting tires with tires irons

A little ultra black to help make sure nothing leaks:

35 bolts per wheel had to be installed and torque down. What a pain!

Add some air and check for leaks, all is good:

Finished product:

sbechtold · 03-31-2008, 09:23 PM

Diamond Axle - Full Float "Extra Wide" Rear Axle Upgrade:

After finishing my SAC project I wheeled my FJC for a few months, then jumped right into my next project. I wanted to increase the rear axle width by 3.5" and move up to a larger third that would handle the weight of the FJC. I decided to go with a full float axle running a Land Cruiser 9.5" third. I then called Brian Ellinger at Diamond Axle and placed an order for a new rear axle. Brian was great to work with and makes incredibly strong axles. I then called Jim at Inchworm Gear and order a Land Cruiser 9.5" third member.

Here are the rear axle specs:

Diamond Axle housing
Toyota Full Float ends
67.75" WMS-to-WMS
FJ80 LC 9.5" third member
4.88 gears
ARB air locker
Solid pinion spacer
Quad drilled flange
Toyota IFS Hubs
Longfield drive flanges
Custom length 30 spline chromoly axle shafts
FJ Cruiser stock brake setup (ebrake, and service brakes )

I am re-using my FJ Cruiser backing plates, emergency brake setup, calipers and rotors. Brian was able to design and build an adapter that allowed the FJ Cruiser stock brake system to bolt right up to the housing.

Before jumping into the pics here is a quick comparison of the Toyota 8" third to the Land Cruiser 9.5" third.

9.5" on the left, note the size difference:

9.5" on the right. That ring gear is huge compared to the 8".

Before I started to disassemble the rear axle I needed some jack stands. After shopping around I decided to make my own. A little 3x3x3/16th square tube and this is what I came up with. The stands are adjustable in 3" increments.

FJC up on the jack stands. Let the rear axle removal begin.

Axle out and ready to be disassembled. I sent the stock axle housing, axle shafts, backing plates, calipers, rotors and ebrake setup to Brian so that he could use them to make the new adapter that allow me to reuse all the stock braking parts.

Pulling the axle shafts so I can send the axle housing to Brian.

Empty axle housing...

So I ship all the parts off to Diamond and I wait while Brian works his magic.

sbechtold · 03-31-2008, 09:24 PM

Diamond Axle - Full Float "Extra Wide" Rear Axle Upgrade:

Last Friday I arrive home to find a large container in the driveway. It's obvious that the UPS guy struggled with the package and decided he'd just leave it in the middle of the driveway with a few other boxes laying around.

After unwrapping everything this is what arrived. There are more part on the way and according to Brian it will be like Christmas for the next week at my house. I'm sure this will piss of the UPS guy.

I spent Sunday painting and making some new longer shackles.

Since my shackle hangers are frenched into the frame I added a spacer to the shackle by welding a piece of 1/4" plate to the bottom. They are made of the 1/4" steel, so in theory they shouldn't bend, but I may need to brace them.

After replacing all the leaf spring bushings I bolted them back into place with the new shackles. The reason I went to a longer shackle is because the Deaver springs have settled A LOT since they were installed. If this doesn't work I will have to have them rebuilt and add a little lift to the springs.

Today I installed the ARP studs for the third member, then installed the inner oil seals and then installed the third.

I then rolled the axle under the FJC and bolted it in place.

Here the axle is mounted and the u-bolts and shocks installed. I need to charge the shocks with nitrogen tomorrow and mount the reservoirs.

I need to make some tabs for the limit straps and brake lines and weld them onto the axle. As time permits and the rest of the parts arrive I will continue to install parts and update this thread.

**JDEMELLO** · 03-31-2008, 09:32 PM

Can I have your FJ?

Runt · 03-31-2008, 10:12 PM

I second that......I'll give trade you a hot slightly used 32 year old blonde and two little....wait a minute....forget what I wrote, what was I thinking....ohhh ya damn that Cruiser is amazing. To quote Homer Simpson "uhhhhhhhhaaaaaaaa".......drool ....drool.