I picked a 40 Series (my second) because of their legendary offroad reputation and because of the memories associated with them from my youth. My first offroad experience was in a 40 and I learned to drive a stick in one. I bought it as a runner project but the 50 year old engine had other plans. I blew a head gasket just a few weeks after the purchase. I decided to tear it all the down and do my first restomod. I call it Project Bighorn in honor of the bighorn sheep indigenous to the Reno area where I live and I am loosely tracking my progress on a blog: https://bighorncruiser.tonyfarson.com I want to keep the core of the build Toyota with logical modernization and upgrades. I found a donor 78 FJ40 rolling chassis with a complete powertrain to leverage the better oiling system of the 2F motor, upgrade to 4-speed transmission, and fine spline axle assemblies. So far I have: Rebuilt and upgraded the 2F with a reconditioned crank, RV cam, small block Chevy valvetrain, .40 over forged high compression pistons. The block and head were heat tanked, magnafluxed, decked, and the block was line honed. The entire assembly was balanced. I am installing a TBI EFI system with OBDII computer and a computer controlled distributor that will all tie into the Dakota Digital HDX gauge cluster for real-time info from the OBD II system and dynamic timing control and air/fuel adjustments for high altitude trails common to the area. I had my H41 converted to an H42 for lower gear ratio and built an Orion twin stick transfer case to go with it. My final crawl ratio will be 82.2:1 which is great compared to the original 54:1. The front axle shafts were replaced with RCV shafts, Toyota mini-truck "outers" were fitted along with Aisin hubs. ARB lockers are installed front and rear and 4-wheel disc brakes backed by a Hydratech hydroboost we also installed.
I am sticking with 410 gears for now, but may bump it up to 488s if I feel the need. I am converting to a Saginaw steering gear and pump, HD u-joint shafts and an ididit column. I have Atlas Springs ready to go on. They area 4" lift spring with their "Expedition" package which means there are two packs in each spring assembly. The primary pack is used for an unloaded/top off configuration to ensure a smooth ride and the secondary packs kick in for a loaded/top on configuration to maintain a good ride and prevent sagging. I am installed extended shock towers up front and the center pins on the springs got pushed out 2" to extend wheelbase, improve steering geometry, and improve ride characteristics. The rear springs are 4" longer than stock to better support the vehicle and increase articulation. I have a full six-point cage with frame tie-in and seat cradles for Corbeau seats and am working with a local shop to reproduce the Toyota backlight pull switches for the lockers, winch, lights, wipers, and other accessories. For paint I opted for a PPG single stage industrial paint for durability and easier maintenance and had an original 1968 Toyota color called T1276 Sundune White (Beige) mixed for both the engine and the exterior. Right now I am waiting for the axles, transmission, and transfer case to be finished and am working on the tub and body to remove some rot and weld in replacement panels. The chassis is about ready for powder coating and then assembly should begin.
