40 ute conversion

[Boxa]

OK here goes.

I bought her over a year ago, but work has had me away from home for 13months of it, so she stayed in the shed awaiting for my eventual return. Being away enabled me to think how I could change or modify what I have to what it could be. I figured doing a tray conversion would create less panels for rust or damage.

As purchased: 1975 FJ40 soft-top
Holden 253
32"BFGs
Second tank
Sports seats
and of course 30 yrs of rust

What I have planned:
Complete rebuild from bare metal (underway)
Conversion from a tub to tray (underway)
Sports seats/harness (have bought already)
Custom fuel tank to run under both seats($640 alloy)
Full 4point roll cage forming a cab
Semi-permanent 12oz canvas soft-top for the cab
3"Tube tray 1000mm in length with roll bar. (Purpose built for 2 x 33" spares and 1200 x 600mm recovery box)
Full core re-wire running Dual batts from behind seats
2"body lift to clear re-piped dump valves (already cleared with engineer)
33"Simex JT's (mates rates from local tyre dealer - LOL)
2"suspension lift(brand ????)
And other bits and pieces taken from my old GU eg....Compressor, Dual batts....

As purchased and road worthy
http://i18.photobucket.com/albums/b112/boxrox/Rebuild0001.jpg


Finally I could start a complete rebuild. So everything must come out. Seats and carpet

http://i18.photobucket.com/albums/b112/boxrox/Rebuild0002.jpg


Tanks

http://i18.photobucket.com/albums/b112/boxrox/Rebuild0003.jpg


Bonnet, guards, doors

http://i18.photobucket.com/albums/b112/boxrox/Rebuild0006.jpg
http://i18.photobucket.com/albums/b112/boxrox/Rebuild0004.jpg


Using imagination and a piece of wood paved way for the chop

http://i18.photobucket.com/albums/b112/boxrox/Rebuild0005.jpg


The chop, I used a fibre slicing disc on a 125mm angle grinder, just like a hot knife through butter. The sparks only burn for a second. LOL

http://i18.photobucket.com/albums/b112/boxrox/Rebuild0007.jpg


The result being, one cab and one tub

http://i18.photobucket.com/albums/b112/boxrox/Rebuild0008.jpg
http://i18.photobucket.com/albums/b112/boxrox/Rebuild0009.jpg


Now with the cab removed from the chassis I can start getting rid of "old man rust" and replace/repair panels where needed

http://i18.photobucket.com/albums/b112/boxrox/Rebuild0011.jpg
http://i18.photobucket.com/albums/b112/boxrox/Rebuild0016.jpg


With the floor pan removed I can fabricate up a new one to size, the rust has affected the strength of this too much for my liking. Here I have it raised the 2" to see how the clearances are going to be

http://i18.photobucket.com/albums/b112/boxrox/Rebuild0012.jpg


The lower door arches have the normal 40 series rust lines along the floor pan join. Getting them to bare metal for repair.

http://i18.photobucket.com/albums/b112/boxrox/Rebuild0013.jpg
http://i18.photobucket.com/albums/b112/boxrox/Rebuild0015.jpg


The fire wall which will need a slight fab to clear the rocker cover on the engine with the 2" lift

http://i18.photobucket.com/albums/b112/boxrox/Rebuild0014.jpg


So that is where I am up to now and unfortunately that is how it has to stay for about a month as the house is being renovated so my beloved shed becomes storage for furniture. Dont you just hate timing.

Hazza/High and Mighty: keep up the good work

;D

[.::lil-oscar::.]

Looking good so far. Can't wait to see the final product.
Looks like there are currently 3 40's being rebuilt in the build up section hehe awesome :D.

[4xgold0]

looking good Boxa :o keep the pics up dated ;)

looking good mate 8)

I am going to watch this thread very closely :)

[Reddo]

With my floor pan, I simple cut the old one out (as you have done) and traced the whole pattern onto t 5 mm sheet steel. For the fuel tank you simply cut it out and fabricate it to suit, including drain plug. Its near on bullet proof and cut out a lot of rd noise lol not that its going to help. Nice work, looks good.

[Reddo]

Also are you going to keep the fluffy duck? Or go to a 308? 253 goooooood but a 308 with 304 VN heads is evveeeeeen better.

[Boxa]

With my floor pan, I simple cut the old one out (as you have done) and traced the whole pattern onto t 5 mm sheet steel. For the fuel tank you simply cut it out and fabricate it to suit, including drain plug. Its near on bullet proof and cut out a lot of rd noise lol not that its going to help. Nice work, looks good.

Thanks for that, I did use a small section of 6mm to patch a 12 x 12" section for road worthy. Knowing that someone else has it that thick makes me feel better. Yeah it would be bomb proof. I probably will take your advice and trace the old one onto 5mm ;)

[Boxa]

Also are you going to keep the fluffy duck? Or go to a 308? 253 goooooood but a 308 with 304 VN heads is evveeeeeen better.

Now Reddo, its not about the size, its about the way you use it. LOL

I am staying with the little fella just to see how the weight to power goes without the rear end. I dont want to be wheel standing or needing ladder bars for wrapped axels at this stage either. But I will defianately be on the look out for something bigger later on down the track ;)

I really should think about changing my Avatar pics too

come on you have been slack ;)

[Boxa]

come on you have been slack ;)
I know, too much time in chat rooms. LOL.
Nah, moving house down to Townsville at the end of the month so it has taken a back seat till the new house is built down there. Atleast 7 months till I can get my hands dirty with it again >:(

come on you have been slack ;)
I know, too much time in chat rooms. LOL.
Nah, moving house down to Townsville at the end of the month so it has taken a back seat till the new house is built down there. Atleast 7 months till I can get my hands dirty with it again >:(


bugger :(

[HLX40L]

http://i18.photobucket.com/albums/b112/boxrox/Rebuild0007.jpg


Great project, reminds me off a 4x4 is born. BTW love the safety boots. :)

[Ozjunk38]

http://i18.photobucket.com/albums/b112/boxrox/Rebuild0007.jpg


Great project, reminds me off a 4x4 is born. BTW love the safety boots. :)



At least there is no possibility of sparks setting the overalls alight like I did :-[ Love the progress so far ;)

[-BJ-]

You have been busy :D Keep up the good work ;)

[Mashed]

its gonna be one sweet looking 40. ;D