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View Full Version : FJ40 Hi-Lift Windshield Mounting Bracket


RicardoJM
09-03-2012, 02:16 PM
Welding is one of the things that I have been wanting to learn. On and off, I have been cruising Craigslist for an entry level mig machine. A few weeks ago, I pulled the trigger on a Millermatic 135.

http://www.risingsun4x4club.org/uploads/ricardojm/hibracket/hibracket_001.jpg

The machine came with a cart, bottle and fixed shade helmet. I added some gloves, welding coat, auto darkening helmet, welpers and some small magnets to round out the basic welding tools that I did not already have. I didn't set out to have a flame pattern on everything or Denver Bronco colors - plain fact is that is the one welding coat that was my size:D.

http://www.risingsun4x4club.org/uploads/ricardojm/hibracket/hibracket_002.jpg

I rounded up some 1/8" plate proceeded to start burning some lines. There was quite a bit of tweaking involved (welder settings, helmet settings) but after a couple of evenings I could see the puddle and had good penetration of the metal. They were not (still are not) pretty looking welds. They are welds that are melting and fusing the metal. Perhaps they will get prettier over time.

So I set about to fabricate a bracket that will hold a hi-lift jack on the passenger side of my FJ40. I really think this is a great looking place to mount a jack and the passenger side mirror never really worked that great. I cut out a piece of my plate and picked up a piece of 1/8" by 1.5" strap.

http://www.risingsun4x4club.org/uploads/ricardojm/hibracket/hibracket_003.jpg

I really did not take any photos through the fabrication process. I can tell you that I engineered as I went. My first bracket was not great - it put the top part of jack way too far outboard from the truck. No worries as it was straight forward to cut and fix by making it shorter. Despite paying attention to heat warpage, I did end up with a small amount of that. When I ground down the welds, it is clear the metal is solidly fused.

http://www.risingsun4x4club.org/uploads/ricardojm/hibracket/hibracket_004.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/hibracket/hibracket_005.jpg

For the welds I put tack welds on each side but only welded (and ground) on the outer side. Here are is a shot of the tack welds on the inside.

http://www.risingsun4x4club.org/uploads/ricardojm/hibracket/hibracket_006.jpg

The actual amount of time spent welding was much less than the amount of time spent in prep and finishing. Here are a couple of shots of the bracket in paint.

http://www.risingsun4x4club.org/uploads/ricardojm/hibracket/hibracket_007.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/hibracket/hibracket_008.jpg

The painted bracket mounted to my FJ40 looks like this.

http://www.risingsun4x4club.org/uploads/ricardojm/hibracket/hibracket_009.jpg

The hi-lift jack being mounted in the bracket looks like this.

http://www.risingsun4x4club.org/uploads/ricardojm/hibracket/hibracket_010.jpg

It is a little thing, but oddly enough I feel like it a a huge accomplishment to take raw material and put it together all on my own.

nattybumppo
09-03-2012, 02:57 PM
Nice, Ricardo. How satisfying.

Crash
09-03-2012, 04:13 PM
A Smurf blue Hi-Lift jack with yellow base.. Wow, pretty neat. Good job, Ricardo and I didn't know you had Swedish ties. I wish somebody in my neighborhood would buy a welder and get good at it....hint, hint. Then I'd be satisfied too!

nattybumppo
09-03-2012, 05:56 PM
Garage comes first!

RedCreeper
09-03-2012, 09:10 PM
nice job! and for the record the welding is always faster then prep time.

bigcity25
09-03-2012, 09:13 PM
That's a good lookin' rig buddy

Crash
09-03-2012, 10:31 PM
Got to see the full on style show of you wearing the welding leathers and the mask to make the image complete. Early ideas for Halloween don't you know.

SteveH
09-04-2012, 07:05 AM
Looks great - congratulations.

nuclearlemon
09-04-2012, 08:28 AM
Nice score ricardo....you'll be very happy with the millermatic

Rzeppa
09-04-2012, 09:24 PM
I have always found that a good angle grinder is a weldor's best friend! :weld:

nakman
09-04-2012, 10:35 PM
Nice! I'm sure you'll be a great welder in no time.. :weld:

so is there a bolt through the base of the jack into the running board? Do you have to undo both then? What about using some big knobs, like your windshield bolts, for quick removal?

RicardoJM
09-05-2012, 08:29 AM
Got to see the full on style show of you wearing the welding leathers and the mask to make the image complete. Early ideas for Halloween don't you know.

:eek: No one really wants to see that.

Nice! I'm sure you'll be a great welder in no time.. :weld:

so is there a bolt through the base of the jack into the running board? Do you have to undo both then? What about using some big knobs, like your windshield bolts, for quick removal?

There is a bolt at the base. It may be ok without it, but I feel much better with the bolt. Yuppers, to get the jack off I need 19mm, 12mm and 13mm. I like your thinking on the knobs, it would really simplify getting the jack off. Perhaps it would be good to refer to this bracket as the prototype ;).

corsair23
09-05-2012, 02:03 PM
What about wing nuts vs. nuts? :hill:

For the base, you could fab up a 'holder' to secure the base in...Like what my rear bumper has. Although I like the simplicity of your solution. My only concern would be the off chance that the side the hi-lift is on is the side stuck in 2' of mud or whatever denying you access to that lower bolt/nut.

As always, you are an inspiration :thumb:

FJBRADY
09-05-2012, 02:09 PM
Yuppers, to get the jack off I need 19mm, 12mm and 13mm.



As always, you are an inspiration :thumb:

:brick:

simps80
09-05-2012, 02:55 PM
:eek: No one really wants to see that.



There is a bolt at the base. It may be ok without it, but I feel much better with the bolt. Yuppers, to get the jack off I need 19mm, 12mm and 13mm. I like your thinking on the knobs, it would really simplify getting the jack off. Perhaps it would be good to refer to this bracket as the prototype ;).

:eek: No one really wants to see that.



There is a bolt at the base. It may be ok without it, but I feel much better with the bolt. Yuppers, to get the jack off I need 19mm, 12mm and 13mm. I like your thinking on the knobs, it would really simplify getting the jack off. Perhaps it would be good to refer to this bracket as the prototype ;).


I like this a lot! nice work.

thumb nuts (http://www.mcmaster.com/#thumb-screw-nuts/=j5vv80) might work slick too, maybe the 'through' kind of thumb nut with a hairpin cotter pin (http://www.mcmaster.com/#hairpin-cotter-pins/=j5vxf1) through the welded bolt on the outside of the thumb screw.

30400

30401

nakman
09-05-2012, 03:52 PM
Yeah Mike, or something like that. :thumb: Ricardo, check some of these out http://roganknobs.com/allclampingknobs.aspx

My thought is just a post would suffice for the base- the thing up at the mirror is going to hold it down, so you really only need to keep the jack from sliding off the running board, right? I bet you could get it down to just one knob and still keep it secure, possibly with some rubber pads to dampen the rattles and also add a little load to the clamping?

Speed of deployment, IMO, is all the difference in how useful a hi lift is on the trail. I've actually been in recovery situations where a less than ideal solution was even implemented, because someone couldn't or didn't want to find their keys, or find a wrench, or get it down, or unload everything to pull it out... :blah: :rant:

FJBRADY
09-05-2012, 04:08 PM
What about wing nuts vs. nuts? :hill:



I use wing nuts.:thumb: The bumper mounted hi-lift comes off in a jiffy, saving the day!

I also carry a bottle jack because hi-lifts suck.

Rezarf
09-05-2012, 04:11 PM
Burning steel is a blast, that came out great bud.

Rzeppa
09-05-2012, 05:57 PM
I also carry a bottle jack because hi-lifts suck.

Me too! Ever try to simply change a tire with only a HiLift available? :eek:

Crash
09-05-2012, 07:21 PM
Me too! Ever try to simply change a tire with only a HiLift available? :eek:

Yes, and a bottle jack wouldn't have worked nearly as quickly and efficiently. It's good to have all bases covered. Needing three different size sockets or wrenches is not quick or efficient. On the other hand, it makes it a little more difficult for someone to steal! :thumb:

RedCreeper
09-06-2012, 09:07 AM
I used wing nuts for mine on my roof rack. Works great. Now if it could be lower......

Bruiser
09-06-2012, 01:45 PM
: Perhaps it would be good to refer to this bracket as the prototype ;).

One other thing that you may consider if you ever build a version 2, is where the weak point is. If by chance you ever test how well your running boards work as sliders, I might be concerned on the damage it could cause to your hinge, body or windshield. Of course you could just snap the bolt that is holding the lift to the car, which would be fine.

Looks good though, I likes me some inspiration to build new things. I might have to come by and test your welder myself.

Justin