With some additional effort and heat you might be able to smash the tank back another 1.5", but I would be very careful as that is a lot to move it. The Longfield chromoly output shaft was right around $285 IIRC.
__________________
'76 FJ40 running on Propane.
1964 FJ45LV, 6.0L Vortec, 700r4, FJ62 split case, FJ62 axles, Power Steering, Spring Over, 35s, OD green. Metal Tech
I used a couple of heat guns to heat up the end of the tank nearest the transfer case. I then reshaped the front of the tank so that it would clear the transfer case. Reshaping the tank worked like a charm and I didn't lose any fuel capacity from the tank.
Heating the tank and reshaping it also sounded like a good idea to us as well and this is what we did. The tank did not leak and seamed ok. However once the output shaft broke on the Inchworm set up (It was a used stock Toyota part, that broke in an unusual area, but these things do brake in these older style cases, just ask the Mini truck guys) We did make the switch and installed the first FJC proto type Marlin Crawler box in our Orange FJC. To do so we needed another 1” off the fuel tank. We ended up cutting the previously bent end off. This is what the inside of a heated and bent tank looks like:
First off the tanks are almost 3/8” thick (9mm), stout buggers! But with the heating technique we can see the tank has torn and has gas bubbles that formed in the side of the tank.
We went ahead and invested in the almost $5k plastic extrusion welding equipment to properly cap and weld the tank. Here is a photo of the test single pass weld. The tank on the truck and future tanks have two passes to seal and strengthen the welded area. We now offer this service in house on new (in stock) or your used tank.
Sorry to here about your output shaft. I received a call from Jim and he informed me that a few FJ Cruiser owners running Lefty with the stock Toyota output shafts had broken the output shafts. Apparently the weight of the FJC is a bit much for the stock Toyota output shaft. He offered to replace my stock output shaft with a Longfield chromoly output shaft. Even though I had zero problems with the stock shaft in my Lefty, I opted to have the chromoly one installed. LT I'm sure Jim would be willing to help you out as well. Jim is now installing Longfield output shafts for anyone planning to run lefty in an FJC. I think it was pretty cool of Jim to proactively call me about the output shaft and install the Longfield.
Our shaft let go during the photo shoot we did with Toyota for the new Trail Team edition FJC. Woody from Ih8mud was spotting us on loose wet rocks when it went. Now those who wheel a lot know things can brake at any time, or they really broke on the last trip out but just did not let go yet. This was one of those times, the spot we were in as a non issue spot, Woody, LT and I all agreed on this.
We made the decision to try the Marlin Product since he is the original duel case shop, and a hell of a guy. By retaining the stock case in the rear, we also retain the 30 spline output shaft over the 23 spline shaft the early gear driven boxes have. The case is also quieter since it’s a chain drive over the all gear so daily driving is no different. The stock case is of course designed for our application, rt hand drop, and meant to turn full time unlike the gear driven cases. I have no issues running the stock case as a daily driver. Marlin sent us his proto type and we went to town to get it in before SEMA. Our truck was on display at SEMA with the Marlin set up in and running! (Also was at Surf N Turf the following weekend) As LT said earlier we custom machined a new style of shifter to allow the stock case to fit well under the tub and still perform. I am glad we have run both case set ups, it has given us a good exposure to the options out there.
We are now a Marlin Dealer and will have the cases in stock as soon as they are available, along with our new low profile shifter assembly.
Mark, thank you very much for the insight you provided. I was at Pismo and had I known you had the crawler already installed, I'd come over and bugged you guys . I did because I was afraid you'd pour me a tall one and I don't drink...
So does this setup add any noise at all? Would you also recommend swapping for Longfields when the Marlins are added or do you feel confident the stocks will be fine?
Thanks.
__________________
Click for the "Genie" build up
Sandoo Blue FJ
Walker Evans adj. F&R reservoir shocks. Pro Links. AP F&R bumpers. Demello skid. Mile Marker SE9500C. Viking Trail Line. Super Swamper LTB 34s on Tacoma wheels. 305 MTR on Wheelers wheels. Trail Gear Sliders, Aeroflow, Lightforce Blitz 240, Powertank 10lb, Hi-Lift, Jack Mate, Pull-Pal.
Mark, thank you very much for the insight you provided. I was at Pismo and had I known you had the crawler already installed, I'd come over and bugged you guys . I did because I was afraid you'd pour me a tall one and I don't drink...
So does this setup add any noise at all? Would you also recommend swapping for Longfields when the Marlins are added or do you feel confident the stocks will be fine?
Thanks.
You don’t need a stronger output shaft if you run the Marlin set up. With the Marlin set up you are running the stock T case as the rear case, so you retain the considerably larger 30 spline newer output shaft. No added noise for at all, its all the stock case until you through the crawler box in gear. Now yes the crawler box has some gear noise but, I don’t hear it since the RPMs are higher due to the lower gears.
Dude the keg we had at Surf N Turf went the fastest I have ever seen a keg go! We tossed out 200 pints in about 40 min. Short of people doing keg stands I don’t think we could get pour it any faster, and with a pump tap at that!
__________________
'76 FJ40 running on Propane.
1964 FJ45LV, 6.0L Vortec, 700r4, FJ62 split case, FJ62 axles, Power Steering, Spring Over, 35s, OD green. Metal Tech
I will give Marlin a call this week and see how they are coming along with finalizing their production of the FJC dual transfer case.
__________________
'76 FJ40 running on Propane.
1964 FJ45LV, 6.0L Vortec, 700r4, FJ62 split case, FJ62 axles, Power Steering, Spring Over, 35s, OD green. Metal Tech
I was reading CRAWL earlier this week and found a product spotlight that showed Marline's case for the FJ. It's model MC11. It's advertises that it's available for the FJ. I contacted Big Mike, but haven't gotten an email back yet. It's not on their website either. It must be close to release since CRAWL has already released a model number.
__________________
Click for the "Genie" build up
Sandoo Blue FJ
Walker Evans adj. F&R reservoir shocks. Pro Links. AP F&R bumpers. Demello skid. Mile Marker SE9500C. Viking Trail Line. Super Swamper LTB 34s on Tacoma wheels. 305 MTR on Wheelers wheels. Trail Gear Sliders, Aeroflow, Lightforce Blitz 240, Powertank 10lb, Hi-Lift, Jack Mate, Pull-Pal.
I received a call from Jim and he informed me that a few FJ Cruiser owners running Lefty with the stock Toyota output shafts had broken the output shafts. Apparently the weight of the FJC is a bit much for the stock Toyota output shaft. He offered to replace my stock output shaft with a Longfield chromoly output shaft. Even though I had zero problems with the stock shaft in my Lefty, I opted to have the chromoly one installed. LT I'm sure Jim would be willing to help you out as well. Jim is now installing Longfield output shafts for anyone planning to run lefty in an FJC. I think it was pretty cool of Jim to proactively call me about the output shaft and install the Longfield. 
Linear Mode
