FJ80/Volvo Portal Build

[TiredIronGRB]

Here's my '91 TLC that I'm putting Volvo portals under.
http://tired-iron.mounet.com/Grace4X4/GRBTLC/default.htm
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_01.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_35.jpg
Fujitsu Tablet PC with Delorme GPS (TOPO USA)
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_42.jpg
Used the 3rd row seat brackets for a quick release for stowage box.
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_45.jpg
ARB and MileMarker 12,500 winch.
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_50.jpg
Portals Axles from a Volvo C303, vacuum activated lockers, 6:1 gearing.
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_48.jpg
The portal gives 5" of lift in itself.
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_60.jpg
These are the valves from the Volvo that operate the lockers.
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_62.jpg
38.5X11X16 TSL Boggers
Will start on dropping the axles and cutting off the brackets Tuesday.

[TiredIronGRB]

Got the front axle in with the steering all hooked up and all the brackets on the rear one, now to get my yokes mated up and brake lines made up. Off to the machine shop in the morning for flange adapters.
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_69.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_70.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_71.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_72.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_73.jpg

[TiredIronGRB]

The wheels are the stock Volvo wheels they are 16"x8" with 8" backspace, and the axles are the 5.99:1. Here's some pics from today, I only got to work on it a few hours.
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_78.jpg
These are the flange adapters that I had made at Universal Machine & Tool Co. in Kingsport. They do awesome work but they also charge for it :shock:
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_80.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_81.jpg
This shot was taken with the full weight on the axle, the lift in only holding up the rear of the truck.
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_82.jpg

[TiredIronGRB]

I pretty much finished today, I still need to put the new shoes, wheel cyls, and springs on. I also ordered a rear panhard adjustable insert fron Slee because even with all the measuring I did my rear axle sits to the right about 1/4" to 3/8". I took it out for a test ride through the pasture, in low range it crawls really good and the vacuum controls for the lockers work great. In high range it's seems a little lower but not too low.
The ride height worked out even better than I had hoped, 17" to the dif, 25" to the rocker, I may have to keep this thing :wink:
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_87.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_86.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_88.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_89.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_90.jpg
This is a utility light for a tractor (mounts on the fender), I thought it would work as a winch light instead of using the headlights.
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_91.jpg

I started on it Tuesday at lunch, then all day Wednesday, half a day Thursday and Friday, then all day today.

[TiredIronGRB]

I had to mount the MileMarker upside down, the ARB is made so you can run the winch either way.
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_57.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_59.jpg

[TiredIronGRB]

Some flex shots...
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_97.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_98.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_99.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_100.jpg

[TiredIronGRB]

I put the new springs and shocks on today, OME 2" Heavy in the front and OME 2" Medium in the rear, the shocks are also OME. It gave me about 3" more lift in the front and 2" in the rear so it almost sits level now.
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_111.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_112.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_105.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_104.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_106.jpg
Fully stuffed there's about an inch of clearance.
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_107.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_108.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_109.jpg
http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_110.jpg
As for the road speed I was running 2550 rpm at 60 mph, 2700 rpm at 65 mph, and 2900 rpm at 70. I'm very pleased with how it handles, it's very smooth with the new shocks and springs. The front approach angle is 41 degrees and the rear is 45.

[TiredIronGRB]

Here's some pictures of my sliders, Brian (HotRodYJ) and I designed these and made them from scrap metal from a local salvage yard. The round tubing is 1.5" and is 3/16 thick as is the 1.5 square tubing They bolt in the rear and will be welded in the other connecting points.

http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_122.jpg

http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_123.jpg

http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_124.jpg

http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_125.jpg

http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_126.jpg

http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_127.jpg

http://tired-iron.mounet.com/Grace4X4/GRBTLC/TLC_128.jpg

[TiredIronGRB]

I got rid of the huge rockgrabber muffler today :grin:
http://www.4x4grace.com/Coppermine/albums/userpics/10001/64.jpg
Replaced it with a Flowmaster 40 knockoff.
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_TLC_129.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_TLC_130.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_TLC_131.JPG

[Bluegill]

Wow...tha muffler was huge - looks like you've got a flowmaster style muffler now, right?

George, your FJ80 is sweet :smokin:
The only thing from my view that it could use is wheels with less backspace, but I bet the Volvo bolt pattern is hard to find :?

[notbarbie678]

Now this is the kind of truck I want. :cry:

[TiredIronGRB]

New MRW wheels and BFG Krawlers (to be replaced with Iroks).
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Krawler01.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Krawler02.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Krawler03.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Krawler04.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Krawler05.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Krawler06.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Krawler07.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Krawler08.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Krawler09.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Krawler10.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Krawler11.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Krawler12.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Krawler13.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Krawler14.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Krawler15.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Krawler16.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Krawler17.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Krawler18.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Krawler19.JPG

[TiredIronGRB]

I got the Iroks (39.5X13.50X17) on and the fender flares trimed, I really like the way it feels now.
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Irok_01.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Irok_02.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Irok_03.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Irok_04.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Irok_05.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Irok_06.JPG

[TiredIronGRB]

I finally got a good winch for the Cruiser, Ben saw it on Pirate and gave me a heads up.
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Winch01.JPG
It's a Warn commerical 12K made for the Civilian H1 Hummer.
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Winch03.JPG
It has a narrower bolt pattern (8.5") than most standard winches (10") so I had to design some adapter plates to make it work on my bummer.
The original mounting bolts are 1/2" :shock:
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_Winch02.JPG

[TiredIronGRB]

Started building a new rear bumper, got tired of patching up the stock one.

http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper02.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper03.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper04.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper05.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper06.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper07.JPG

I plan to make some hoops out of 1.5 tubing that will go up from the sides of the wings and up over the maker light and back down.

http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper08.JPG

I have my template for the bumper center section and hope to get it bent up tomorrow.

http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper09.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper10.JPG


I also made a better transfer case skid plate while I was at it.

http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_skid01.jpg
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_skid02.jpg
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_skid03.jpg

[Gordon]

Definitely adding more protection. Sounds like a great plan.

[r1ng3l78]

your strong 8) you might want to make some gussets that rest against the frame (shouldn't be necessary to weld it) to keep it from wanting to flex into the body. towards the back, the rear piece should brace it fine but you might want it on the wheelwell side.

[TiredIronGRB]

your strong 8) you might want to make some gussets that rest against the frame (shouldn't be necessary to weld it) to keep it from wanting to flex into the body. towards the back, the rear piece should brace it fine but you might want it on the wheelwell side.

Yea, I'm cutting a piece that will brace it two the frame and in the bend (should also keep mud out of there).

I plan to come over and see you for my hoops :wink:

[Bluegill]

;-) Looking good!

[LoOnaTik]

Nice! Looks real clean.

[TiredIronGRB]

Got the cross piece wittled out.

http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper11.JPG

http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper12.JPG

Still need to make my hoops for the wings and some braces for the hitch.

http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper13.JPG

[BillM]

Looking good man.

[Dino1967]

kool

[duke_lover_13]

I like it!! :grin:

[yota31]

u should make it a swing away tire carrier? you should see mine i made!!!

[TiredIronGRB]

u should make it a swing away tire carrier? you should see mine i made!!!

My spare weights more than you do :shock:

I'm going to paint it black :wink:

[Want2Wheel]

Me Mucho liko.

[BroncoMike]

Nice work George. I like how you've done the corners!!

[Jeep07]

Looks good george.

[TiredIronGRB]

Got some more pieces of the puzzle today...

http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper14.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper15.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper16.JPG

[SamuraiGuyTN]

George You're deffinitley tallented. :smokin: Keep up the good work.

[Bluegill]

:smokin: I like the tucked in tailpipe too :wink:

[TiredIronGRB]

Got Jarret to bend me up some hoops and help me finish welding it up, Drake tigged the caps on the horizonal pieces 8) this evening after I mowed and worked on the mud pit I painted it, will try and get it bolted on tomorrow.

http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper17.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper18.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper19.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper20.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper21.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper22.JPG

[BillM]

Looking great.

[pplblazerdude]

Looking good.

[BroncoMike]

sssaaaaaawwweeeetttaaaaaaaahhhh!!!!! :wink:

[Gordon]

Lookin' real good, George.

[limegreenyota]

Very nice work!! You got metal tallent!!

[Rtaylor]

Looks great George! You're gonna' need some beefier springs to carry that chunk of metal!!!!! :twisted:

[TiredIronGRB]

Done, ready to bang it up now.
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper23.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper24.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper25.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper26.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper27.JPG
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_bumper28.JPG

[Simo]

something about those hoops just makes me wanna grab on and lift up the back of your landcruiser :lol: (if i could squat a few thousand pounds) i like it. well done.

[Jeep07]

He designed those to replace the strap.

[Hokie_YJ]

:laughing1:

[TiredIronGRB]

http://www.4x4grace.com/tiredirongrb/sept_oct_07.jpg

[Bluegill]

http://i81.photobucket.com/albums/j226/shepherdskeep/Miscellaneous/smle/pimp.gif

[Hadfield4WD]

that's awesome. just need to find where I can pick up crawl around here.

[Gordon]

Sweet!

[Want2Wheel]

:shock:

[Hokie_YJ]

that's awesome. just need to find where I can pick up crawl around here.

Try Advance Auto, or some of the major bookstores.

[SamuraiGuyTN]

That is too cool. Congrats on that by the way.

[R.E.C.O.N.45]

cool deal with the mag cover. I was just thinking (outloud here) Have you thought about puting some shackles on the rear. i know you got the pinicle (spelling) hitch part, but shakles could be a good idea especially pulling up on angles. I have seen a few times when the pin breaks on those receiver and it flys open. Besides that looks good.

[BJack]

I see Pheery's buggy on there too. It's nice to see them giving some east coast guys some attention.

[TiredIronGRB]

cool deal with the mag cover. I was just thinking (outloud here) Have you thought about puting some shackles on the rear. i know you got the pinicle (spelling) hitch part, but shakles could be a good idea especially pulling up on angles. I have seen a few times when the pin breaks on those receiver and it flys open. Besides that looks good.

I've restored military vehicles for over twenty years and have used pintle hitches for everything from towing trailers to recoveries and have never seen one fail. The pin (cotter key) is only a safety device, the hitch has a locking lever that keeps it locked.

Ask Ben how strong it is, he was there when I recovered Dave's YJ buggy after he rolled seven times down cremepuff.

[Hokie_YJ]

Yeah that thing ain't going anywhere.

[R.E.C.O.N.45]

Maybe thats what I saw. now that I think about it. It was on construction sites is where I saw the failures. I watch one idiot trying to something stupid and then I see a strap and chain sling out. O well. Thats cool I forgot about the locks that (should be working to where the pin is not needed) Anyways looks good.

[Green96D1]

A quite amazing build.

[TiredIronGRB]

A quite amazing build.

Thanks, I was really blessed it worked out so well because I'm not that good of a fabricator :oops:

[Andy's01]

George, that looks awsome. I should have had you over here helping me with my build. lol

[admar2]

awesome deal on the cover George.


your rig is definitely wicked cool.


I like it because its not a cookie cutter rig like most everything else out there.

[TiredIronGRB]

Thanks, I can't wait to read the article...there's also a piece about Harlan in this issue.

[BroncoMike]

We have a celeb amongst us! :wink:

You da man!!!

[TiredIronGRB]

You da man!!!

No...but I know Him :wink:

[amgraham]

I finally found this issue of Crawl yesterday.. Nice write up they did George. It seems they sought out some portal'd rigs since they have that TJ on portals in there too (which is also pretty cool... I like when a Jeep is unique which, sadly, is rare).

Congrats on the 15 min of fame :wink:

[TiredIronGRB]

Thanks :grin:

[BroncoMike]

I wonder if those that don't have a subscription yet could still get the one with you in it George? If not think you could scan the article for use to view?

[TiredIronGRB]

I found that I was loosing 3" of travel on the rear axle so I redesigned the shock mounts which gave me the 3" back and a little more clearance.

This is what I had.

http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_DSCF0014~0.JPG
This is the extention, made from 1/4" flat stock.
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_DSCF0013.JPG
You can see where the old post was cut off and relocated.
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_DSCF0016~0.JPG
Finished.
http://www.4x4grace.com/Coppermine/albums/userpics/10001/normal_DSCF0017.JPG

[Want2Wheel]

That should do much better.

[Hokie_YJ]

That should keep them out of the rocks too. Looks good. Did you weld that with your welder? If so, that's impressive. :shock:

[TiredIronGRB]

Yea, it does pretty good for what it is.

[Gordon]

That looks great. I have had the similar thought with mine hanging so low. Just have to get around to it.

Doug, that may be something to tackle on Lisa's, too - as evidenced at Stony last weekend on Pinto.

http://i55.photobucket.com/albums/g125/gme1951/1989%20XJ/04-07-07XJ010x.jpg

[TiredIronGRB]

Gordon, I've got some extra shock posts...we could weld them right on the axle tube.

[R.E.C.O.N.45]

I like your thinking good job with the inivative shock idea.

[Bluegill]

Nice fab work! 8)

[admar2]

nice job george, that oughta help alot.


what welder you have anyways?



I REALLY want a millermatic 210 for Christmas, but I'm probably gonna end up with something a little smaller and a new air compressor setup.

[TiredIronGRB]

It's just a little Century 110v, it does ok on small stuff.

[Bakpack]

I'm heading over to take a look at this Cruiser on 11/27/07, can't wait to see it. :grin: Think I'll bring the camera, I'm sure there will be some Kodak moments. :grin: