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Exhaust hangers also need some degree of engineering. I fall back on OEM engineering (once again) to have a system that allows flex, but also securely holds the tubing in place. Nobody wants to hear resonating or rattles coming from under the body of the truck. Hangers made from 3/8" stainless...

Exhaust systems - They perform many functions. Most importantly, an exhaust system should be tailored to the horsepower and torque curve of a specific engine. There is no "one size fits all". Secondly, there's the emissions controls related to controlling chemical components spewed out into the...

With more important things going on in the world today, building trucks seems so not important. Nowhere on the scale of every day essential requirements. Unless you drive a Freightliner for a living or are stuck down in Baja on an epic journey, trying to get back home, you probably don't need...

Just one less thing to worry about later. Thanks guys.

Next up - custom exhaust system. Here's a sneak peek.

I was given a tip a while back from another friend in the industry about the fitment of the GM wiring. It isn't really ideal. I do hate to tear into something if I don't have to, but cutting open the GM wiring allows me to adjust the fit. Yes, it is a time consuming pain in the butt. Again...

Measurements taken, more lines were bent up and brackets were made. One system complete, the power steering system gets hoses and fluid, and then I bleed it with a pulley on a drill.

Eventually, I'll get to the point where I don't need any mock-ups, but I am still developing the process. The main goal is a complete assembly line style process, but for now, the body goes back on the check a few fitment details.

Plumbing the chassis requires moving of all the hard lines. Though most people do not do this, I do this to keep the vital fluids away from the heat of the cramped exhaust that runs along the passenger side frame rail. Looks factory.

Then the drivetrain gets dropped into the chassis, assembly line style.

Here we go! Pics uploaded to Photobucket. Now that the chassis is rolling, the drivetrain gets installed. I mentioned a while back that I make a spacer for the 4L85E transfer case adapter from Advance Adapters. This is done for a couple of reasons. 1- is to put the transfer case nearer it's...

I need to remind myself that the viewers here on ExPo are the silent type. Some forums get a lot of engagement, usually in the form of nit-picking or trolling, but here...it's a much more civil audience. And wouldn't you know it, Photobucket is going through some changes this weekend. I was...

Thanks everyone. I'll get more updates posted this weekend. Thanks for watching and please comment. Commenting assures me that the thread is not in vain.

Thanks Jack. I am against crappy coffee, people who can't drive and gloss black. Not necessarily in that order.

At the front, the axle is located by radius arms from Delta Vehicle Systems. The original radius arms did not provide enough caster for this conversion, but the lifted radius arms solved that problem while keeping the frame bracket tucked nicely to the frame and utilizing standard bushings, not...

With both axles complete, chassis assembly began with the bare frame. This pic shows the scavenged FJ80 suspension brackets on the FJ62 frame. Note the slip in slider mounts in front of the lower control arm brackets. These do double duty as slider mounts and a great place to lift the truck...

The rear axle got matching brakes.

With everything clean and ready to go, assembly began with standard high quality axle parts from Cruiser Outfitters. The front axle was converted to locking hubs, so we needed new outer shafts and locking hubs, both of which they had on the shelf.

So... the parts were dropped off at American Stripping in Sacramento for blasting and coating with a low gloss black. The powder they use is super corrosion resistant and it goes on after a prime coat.

Our front axle required little more than a rebuild. A new brake line was bent (to emulate the positioning of the original FJ62 hard line) and the original breather hose hole was welded up and moved.