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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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#318 ·
Going wheeling/camping... got my to-do list (the list was long) all done. Now she's ready for the trails. We are going to run Slick Rock and camp at Utica for a quick shakedown run before hitting the Rubicon.

Before going I had to give her a new look... my son helped me remove the roof rack. Decided that I'm going to go rackless for a while. Not to mention that the Gobi weighs 125 pounds with lights. The roof isn't where I want all that weight.

:surprise glad the garage door was mounted to the studs...



worked like a charm...



then we removed the doors...



the "No BS" look... ready for wheeling/camping...

 
#340 ·
That's a great idea for the rack in the garage! I took my All-Pro rack off to re-powder coat it and really got to liking the rackless look as well. Also found out it was making a 3 MPG difference in gas mileage.

Anyway, great looking FJ, it's always been one of my favorites, thanks for sharing the build!
 
#326 ·
Looks great.

I took my rack off a couple weeks ago, couldn't be happier. Visually I like it more, plus it's quieter by a good margin.
 
#330 ·
Made them. Super simple and removable... :) The sheriff's in the Sierras like to write tickets for not having mud flaps.

These go up through a square tube that's welded to the side of the frame. A quick release pin at the top gets pulled at the trailhead and I yank them before heading into the trail.



 
#335 ·
Was roof rack removed as a result of a change in butt dyno feel after the latest round of surgery?

Just curious.

When I pulled mine, it felt like a go cart again.
 
#336 · (Edited)
Mudflaps. Hahahaha.

Forgive the dumb question, because I could search....

BS on wheels?

Edited: Yes....Catching up.

Outta have Don make a set of low doors, like the boat side Pigs but with upper tube, that way you can have speakers, too.

Off topic.

In all of my dreaming and scheming, after this last round of yours, started thinking an SAd UZ(F)JC-Ute would be pretty cool!

Chop at the lower rear well, pull the roof forward to keep the rolled line, and box the bulkhead, maybe with a caged bed.....and 2UZ, of course. Hahahaha.

Probably a good thing I'm 2400 miles away....
 
#337 ·
銀チタン;5028113 said:
Was roof rack removed as a result of a change in butt dyno feel after the latest round of surgery?

Just curious.

When I pulled mine, it felt like a go cart again.
Roof rack was pulled because it's heavy (125 pounds) and it was at the highest point on the FJC. The recent changes didn't have anything to do with it, but without the rack there is a huge difference in handling feel. I talked to fc about making a small aluminum platform for it. Might go back in this winter for it.

銀チタン;5028121 said:
Mudflaps. Hahahaha.

Forgive the dumb question, because I could search....

BS on wheels?

Edited: Yes....Catching up.

Outta have Don make a set of low doors, like the boat side Pigs but with upper tube, that way you can have speakers, too.

Off topic.

In all of my dreaming and scheming, after this last round of yours, started thinking an SAd UZ(F)JC-Ute would be pretty cool!

Chop at the lower rear well, pull the roof forward to keep the rolled line, and box the bulkhead, maybe with a caged bed.....and 2UZ, of course. Hahahaha.

Probably a good thing I'm 2400 miles away....
4" on the backspacing in memory serves. I've planned to add speakers, but will probably just add them to the rear doors or replace the ones in the dash. The doors tend to get wet and don't wet speakers. I say go build the Ute... I bet it would be killer... :grin
 
#342 ·
Went for a little shakedown run this weekend. FJC performed flawless! It's my new rock limo... actually felt like I was cheating at time. :grin Here are a few pictures. Trail is Slick Rock near Lake Alpine. Not very long nor technical, but very pretty trail.

All important poser picture... :p



Coming down a little off camber section...





I walked for bit while my boys drove... it was a beautiful day out!



Came upon a fellow wheeler that was high centered in multiple places on his skid plate and axle. Front tires were actually in the air. Gave him a link yank with the strap to set him free.



My buddy in his new JK... this is a very nice rig. Went through everything no issues.



Next sequence is walking up the staircase...







We camped at Utica reservoir... got prime water front spot. So pleased with the new setup.



Here is a VERY short snip of the climb up the staircase. Camera ran out of storage... DOH! Click on the image below to view the video... I see a gopro in my future.

 
#343 ·
Awesome pics and video...envious of your camping spot, too!
 
#348 ·
Sweet FJ man, I was up at SlickRock a few weeks ago and a bunch of people were dragging massive boulders into the middle of the trail making it near impossible for me and a buddies fj to pass through.. If only we had that mad articulation you have lol. Keep up the wheeling pictures!

:cheers:
 
#354 ·
yummy hood
 
#357 ·
Cool.

Trying to maintain a particular builders philosophies, which is proving very difficult.....because I'm stoopid.

Very hard to ascertain what the perfect numbers are, for any given circumstance.

Kinda thinking that neutral makes the most sense, but can't find enough data for, say a U4 design principle to attempt to mimic.

Tried enlisting the Enlightened One, for a professional review, but only had Mud threads to reference.....so, that lasted about five seconds, the reply being "ih8mud". Hahahaha.

A Sutherland-ish approach, but, for anything beyond the mechanical on this build, considering the epic suspension failure of the last, I'd like to just write the check.....
 
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#358 ·
銀チタン;5090985 said:
tried enlisting the enlightened one, for a professional review, but only had mud threads to reference.....so, that lasted about five seconds, the reply being "ih8mud". Hahahaha.
Hahaha! Hopefully you didn't expect more...

All I can say is no matter what you put down on paper/CAD it will end up slightly different on the vehicle.
 
#359 ·
All I can say is no matter what you put down on paper/CAD it will end up slightly different on the vehicle.

Haha.

Translated reply:

"I don't plan anything.....just wait 'till it's in front of me, and dive in....which is the same approach taken to life, in general.....which may explain a lot."

Question.

What was the deciding factor on Branik's or Al over chromo?
 
#361 ·
銀チタン;5122778 said:
Question.

What was the deciding factor on Branik's or Al over chromo?
Time, cost and weight. The time is would take to fabricate 8 links is just about the same cost as ordering AL links. The AL links are unbelievably light and I need to put this pig on a diet. FC has been using the AL links for a couple of years on his builds and has had really good luck with them.
 
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