Troyoda Resto FJ40

[FreshSeaBass]

Made some decisions. This is a North American build, so by God why not use North American tie rods?

GM 1Ton steering for the sake of parts availability and a robust steering setup. Parts should be here this week, but the upgrade should be worth it if everything packages as I expect it will.

The customer is in favor of this direction so I am giving it my best to make it package appropriately.

 

[FreshSeaBass]

Transmission crossmember interference meant that I had to cut and modify this crossmember to make everything tuck up inside of the frame.

Gained a significant amount of ground clearance in the process.


Once again, the juice appears to be worth the squeeze because we are only 3.5" below the frame rail at the lowest point of the transfer case.

 

[FreshSeaBass]

Fenders and front apron off again now! I am tucking the engine up even higher than previously planned.

New engine mounts (old mounts were only tacked in).

Really not a fan of the original engine mount style. I am reworking these with a design that I believe to be a bit more robust.

The new mounts on the engine side create a V Shaped mount interface focusing the engine mounts to the center of the engine bay rather than two parallel flat mounts on a rubber isolator.







This will be a notched 2 x 4 x .250" wall tube on a plate to interface with the rubber isolator.

 

[FreshSeaBass]

Now THIS is the exciting stuff. FJ60 forward swing power steering box, Reproduction 'Ford Style' shock towers which are just beefier in every way than the original stamped steel type.

If you know. You know ... FORD towers are awesome. I really like how it gives a bit of an OEM look to the whole suspension package.

Lower shock mounts are coming off an being replaced with some nice notched tube lower shock mounts above the axle tube for max ground clearance.

 

[Dukestaco]

Now THIS is the exciting stuff. FJ60 forward swing power steering box, Reproduction 'Ford Style' shock towers which are just beefier in every way than the original stamped steel type.

If you know. You know ... FORD towers are awesome. I really like how it gives a bit of an OEM look to the whole suspension package.

Lower shock mounts are coming off a being replaced with some nice notched tube lower shock mounts above the axle tube for max ground clearance.
View attachment 85993

Nice work.

 

[FreshSeaBass]

More money shot packaging. Towers will obviously be trimmed once vehicle is back at ride height and shock compressed/extended length is reset in relation to axle housing.


I am piecing together a borgeson steering shaft setup from the column I am running a (3/4" to 1" - DD u-joint ) to 1":3/4" telescoping shaft with a (3/4" to 36-spline u-joint).



Super happy with how this is fitting together.


Pitman arm, 1-ton steering, and some column part should be arriving today. Planning to keep building and packaging this whole system then hopefully get it all tacked in to cycle the suspension.

 

[FreshSeaBass]

Still filming videos, but hardly any time to put it all together.

Should be getting more shop time with this extra daylight.

 

[FreshSeaBass]

Sky's Off-road came through with the flat pitman arm!

GM ES2234L 1-ton tie rod taper and machined very nicely.

This steering package is coming together
It is incredibly difficult to get this to fit together on a SUA axle setup, so I am pleased thus far.

 

[FreshSeaBass]

Made sure everything fit. Got the engine mount horns fit up.


Blue + 85 ft/lbs



Everything fitting together tightly

Vis A Torque everything


Trimming off the little corner on the end , folding it to wrap the frame and set!

 

[FreshSeaBass]

I like this engine mount arrangement more. A lot more.

Owner agrees

 

[FreshSeaBass]

Steering arm machined out for the GM taper insert.

Yes, GM 1 Ton steering. Plans to gusset these arms.

 

[FreshSeaBass]

This makes parts availability a breeze in North America, steering will never be a weak link, and generally scaled to size with the whole rest of this awesome machine.


Excited to run this. We will see what I can do about a solid spacer over the boot for the drag link to mimick the "cure" for ball joint roll.


I'm sure it's been done before but I've never seen a 1Ton Y-Link on the 40 series, but I appreciate it a lot in person.

 

[FreshSeaBass]

The size and scale is just insane.

Clearance looks really good too.


Full driver steer lock and clearance is awesome

Love this mid-steer setup. Nice compromise for a SUA build. I should probably be able to squeeze out all of the articulation possible with this. Axle to frame is fairly similar to tie rod/frame.

 

[FreshSeaBass]

Truth be told. I am making sure this all fits prior to working on putting together more videos. There's a lot going on here that ultimately changed for the better, but it is finally time to work on the plumbing and close the loop on air, oil, fuel and cooling to get it fired up.

 

[Dukestaco]

Bro that build is looking awesome.

 

[FreshSeaBass]

@Dukestaco Thanks Duke!

I'm enjoying being able to keep working on it and although my day job now consists of desk-jockeying, this keeps me in touch with real work.

I can't wait to smell this thing burning off that sweet diesel.

 

[FreshSeaBass]

Spent some time making the next part of the steering system. Everything on the column. Making sure to improve this system by putting a beefy support bearing in there at the firewall.

First, a slice to make some new firewall plate blanks.


Fits nicely; a 3/4 bore bearing housing with 4 x M12 fasteners.


Poking some holes

Cleaned it all up and time to turn the attention to the splined shaft end of the column.

 

[FreshSeaBass]

Shaft end turned down to .750" ish.... perfect light slip fit.


The end of the 3/4" Borgeson u joint is a .552" Across Flat / .750" OD (D- shaft). Machining the flats across

Super tight fit. It almost creates a bit of vacuum when putting together and removing. I got lucky!


Very satisfying. Pumped!

 

[FreshSeaBass]

Putting the pieces back together




Time for test fitment. Orientation for reference on how it sits in the truck



All done. Need to now cut out the small plate section where the 4 old bolts mounted and weld one of these plates in place.

 

[FreshSeaBass]

Here's a catch-up.

Fitting up the shaft and getting an idea of the firewall plate





I gave myself some time to think. Realizing I had a big problem.... Under suspension flex, some major collision potential.

Suspension fitment for confirmation. Steering box has to slide back and tuck up into the frame to give clearance to the tie rod. Time to bust out the ruler.