5-12
We are not quite at the fun part of the buildup. Right now stuff is being taken off, last minute parts ordered. So much work is involved, I don't know how these guys make any money.
Complete:
1. TC UCA's and LCA's are on.
2. Assembly of the new halfshafts complete (brutal job).
3. Jason is roughing out the bumper.
4. He was just completing a trick little intercooler radiator mount. My intercooler needs it because it was not getting airflow.
This week:
1. hood and fenders come off.
2. Both differentials come out tomorrow for the 4.56 gears
3. Rear end comes out. Diff armor goes on.
4. ARB locker install w/compressor.
5. Jason will fab rear lower links - everybody call him and make him do a production run.
6. About 70lbs of mud has to be removed from my radiator fins. DON'T go play in the mud unless you give the radiator a major, careful sprayoff.
Next week:
1. Fiberglass hood and front fenders will get a rough fit.
2. 4 hood hold-down points and pins will be installed in the engine bay.
3. The front clip will be final-fitted and painted blue at Anaheim Hills Auto Body, the crew that did the donahoe race FJ.
4. The fenders are very strong. I'm not worried about them. But the hood, being a large panel, flexes a bit. Jason had the creative idea of removing the hood inner frame and fastening the fiberglass to that.
5. We make a determination on tires. Do I need to go to 35's or are my current 33's OK?
6. Suspension calibration.
Week after that:
The rear fenders from Donahoe should be ready. This is complicated and may require it's own thread. Essentially the body sheetmetal is cut out around the fender opening, up to the edge of the wells. If you feel around, this is about 4" from the current opening.
And then the tricky stuff begins. Fuel filler, fairing ... oh it just gets worse. I'll just have to show pictures when it is underway.
On a side note, I complimented Jason on his near-perfect weld beads... and then he told me they sucked and he would never let them leave the shop! He is very detail-oriented and the parts he is fabbing are TUFF.
5-16
Above, notice the crinkle on the left fender inner panel, along the top. That is a $15,000 crinkle.
Edit: a $22,000 crinkle.
Today:
- Front and rear diffs removed, new 4.56 gears and ARB front locker ready to install.
- Exhaust and driveshaft temporarily removed.
This is an opportunity for me to get on the soapbox about mud again. Before I brought it in to Jason I spent 2 hours under the car with a power washer. And it is still filthy. My radiator is just about half plugged up, which is why I saw a 268 degree water temp at Hungry Valley.
I have only gone thru mud ONCE, about 4 mos ago. Don't do it unless you can go under your car with a toothbrush. I have about half the state of Utah piled up on my driveway and still there is more under there, usually crammed into places you'd rather it not be.
Below Jason is removing the transmission valve body to send to Import Performance Transmissions, per URD's recommend. They perform a mod that is necessary for higher-HP Toyota applications.
IPT custom calibrates the valve body to provide much higher, faster clutch application power and clamping force. Without this mod it is possible to burn up the torque converter from slippage. We should also see faster acceleration because the shifts will be quicker and firmer.
Jason's gloves are for a new more personal type of employee interview he is doing. Something about coughing.
Below is NOT my car, it is the
4WD Toyota Owner magazine FJ. They are gonna race it in Baja, and after all a
major total chaos install they now have to take it OFF because another competitor complained. Sucks!
So they will race in factory stock where they can do a shock and that's it. Even the Demello bumper will be covered up by strapping on their old factory one over it for the race!
Their cage above is similar to what Jason will do for me, but his will be much more hidden and family-friendly. The way he describes it I am really stoked to see what he comes up with.
A week from now we should be ready for paint. Because the rear fenders from Donahoe are not yet ready I will make a second trip to Demello in about a month for that little episode. The rear fender panels will be drilled and cut up for the new glass fenders and I think I will go and throw up at that point.
5-24
5-24
4rnRJ, This is about 85% close to what Jason and I talked over, based on my understanding. Hard to tell though from this pic and I'll try to make some others.
The idea is to still make it livable for family trips. Jason should talk about the details, not me. It will still allow the interior to be used except for the headliner. We'll be able to use and fold down the rear seat, and get luggage in the back.
There are sure a lot of issues as you know, 4rnRJ - seems you and Jason are well aquainted with them.
5-24
Close, but the front tubes will not go down to the frame but straight out and possibly attach to the front bumper. The bumper will still un-bolt but it will help support the truck front to rear. The rear area will have some more down bars and extend to the very back of the FJ cargo area.
The plan is to weld the cage into the frame and into the body as well. This is done to help make the whole truck one piece and not a rattle trap. It's allot of work, but in the end it will be really clean and you will only see the cage in a couple places.
Were also going to dyno matt the headliner and floor to reduce outside road.
Noise
I would like to take this time to thank Mr. Air2Air because of him not only is my son going to be able to go to college now but I can now go back and learn my self how to speel.:roller:
6-1
Sorry Shadow, looks like this last week was held up waiting for parts. Next couple weeks will include the following, and there will be tons of pics:
1. Total Chaos completed, Fox bypasses on, wheels on
2. Stinger baja bumper beginning fab, including 6061 skids, winch base
3. Final glass trim and fit
4. Custom hood structure - more on this later
5. Install 4.56 gears, ARB front locker & compressor
6. Custom rear lower links
7. Reinstall 3" straight exhaust, Y-pipe, driveshaft
8. Cage design and install
9. Headliner/interior refit to accomodate cage structure
10. Entire car soundproofed with Damplifier Pro
11. Install of Lucrum Light System
12. Total interior remove and replace including dash, stereo, computer
13. Hood scoop on hood
14. Final glass prep and paint
15. CB install
16. Duck when wife gets the bill
There is much more that I can't remember! Can you blame me?
6-10
Above is the Donahoe race truck stinger bumper, and below is the first pic of Demello's version in prgress.
1. Just like the Donahoe race FJ, the plastic top cover is cut from a donated factory bumper, from Demello's always-growing supply of cast-off factory parts.
2. The Donahoe FJ does not have a winch. The space is very tight because we want the bottom of the skid to go aft as much as possible. If you look closely you can see that the winch base is tilted forward. The fairlead will exit there. As seen in the other pics an aluminum skid goes across between the two bars.
3. This 1.5" horizontal bar pushes out the angled bars to allow room for the winch base. The Donahoe truck does not have these.
4. The factory frame towhooks are about to adorn the shop floor. I think everyone with an aftermarket bumper should do the same since all they do is dig into the ground.
Below is something you don't see every day; a fiberglass FJ hood. This piece will get a cool Demello engineering makeover for stiffening and use of the existing hood hinges.