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  #1  
Old 09-09-2017, 12:48 PM
chris@whiterhino chris@whiterhino is offline
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Default FJ40 Build

So I have really fallen in love with these FJ 40's and I have grown to love the shape, well almost. I've always been a Jeep guy more so than a Toyota guy. The more I look at pictures the more I wanted one. The problem was they were either in really bad shape and wanted top dollar or they were in really great shape and wanted top dollar, a kidney, left testicle, a lung and while they were at it the other kidney. Honestly for what I wanted to do with it neither of these options worked for me. Well, they could have worked but what fun would that have been. So I happen to have a friend that bought an FJ 40 that I could pull some measurements from. After spending a little time measuring and researching, boy that thing was JACKED UP. It was a real struggle trying to pull anything constant from this FJ. However for what I was doing, it will work.


The goal for this rig is to make it a 4 seater so me and the guys in the shop can go camping and relax on the weekend. I want it to be a tube chassis, 60/14 bolt, LS with Atlas (if any venders want to donate an atlas I will not say no )

I have gathered most of my parts other than the hydro steering, atlas and King Shocks. I bought some a while back but they were damaged in shipping but I got the springs.

So the first step was to order some cold rolled sheet metal. I ordered some 16 and 18 ga sheet metal, about 10 sheets each. Then I went to the computer and try to draw the basic shapes. With my rough measurements I can cut some blanks to get started with.
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Old 09-09-2017, 12:50 PM
chris@whiterhino chris@whiterhino is offline
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So my thought was I would start with the smaller pieces. I started with the inner fenders on the back. Mainly the upper edge support rail.

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Old 09-09-2017, 12:51 PM
chris@whiterhino chris@whiterhino is offline
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So now I needed to make a die for my Pullmax so I can make the same shape as the FJ40 upper body edge. I think it turned out pretty good.

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Old 09-09-2017, 12:52 PM
chris@whiterhino chris@whiterhino is offline
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There is always a two step process on making a panel. The next part of this equation is to make a guide so I can run that die over edge of the panel. But first I have to make a wooden guide so I can follow without making mistakes in the panel. Here are some of the guides I've made for this project.

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Old 09-09-2017, 12:52 PM
chris@whiterhino chris@whiterhino is offline
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Now I can ride the edge and get a good edge finish. As you may be able to see, I'm making the rear a comp-cut section.

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Old 09-09-2017, 12:53 PM
chris@whiterhino chris@whiterhino is offline
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I guess I should have put this concept drawing up first. The door sides are cut long so that I can cut to height. When running the metal through the dies it had a tendency to curl the edges.

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Old 09-09-2017, 12:54 PM
chris@whiterhino chris@whiterhino is offline
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So I'll make another small piece, the front cowl section I cut. As you see I have the slot for the louvers. Well, crap I don't have a louver punch... Let's make one.

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Old 09-09-2017, 12:56 PM
chris@whiterhino chris@whiterhino is offline
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Basically I wanted a louver tool that I could cut any length louver. I'll just post the pictures. I take a chuck of steel and face the pieces and then put on the index table and machine the shape into the edge with a ball end mill.

Please understand though, I am no machinist. I know enough to get myself in trouble.

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Old 09-09-2017, 12:57 PM
chris@whiterhino chris@whiterhino is offline
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So, fast forward...

Typically you make a few passes first cutting the metal then pressing the shape in with the tool. I used a short cut by cutting the 1/16" slit on the CNC.

Overall I think it turned out great. I'll need to practice a little bit but I got this.

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Old 09-09-2017, 12:58 PM
chris@whiterhino chris@whiterhino is offline
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Cut the other side and let's form it and the louvers. I'm really liking that. I think that will work just right.

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