fj40_73 Build Thread

fj40_73 · 07-30-07, 12:01 PM

----Update Most recent Photo --------

----Update-- Start Date 7/30/07-- Last update 6/29/08 ----

Time to bit the bullet and dive in. AA is building an Orian HD for me, and I need a paint job/body work. So yesterday I took my running fj40 apart.

This is at 10AM.

At 12:30pm

12:30 - 1:00 Lunch

At 4:30pm

And around 6pm after cleaning and seperating trans & tc

2 years ago I bought a new NV4500 from AA, it always has had a noise, so AA said they will have a look at it, this is why it made since to gut her.

Goals: Back to orginal dark green. I have new quarter panel patches, and rear sil to tack in. I also have to fix the the dirvers side kick panel, as I already have done to the passenger side.Passenger kick panel

Poser has shipped me rear brake caliper brackets, and I already found cadillac calipers, for rear disk brakes & e-brake.

I need to order a Metal tech family cage this week and possible rock sliders if I get some computer work done this week.

Also need to order new turn lights and side markers from Kurt later this week too. I figure new lenses all the way around will be a nice touch & most of mine are rusted out on the inside.

Not sure if I can fix the drivers side fender. I would also like to run my exhust on the inside frame rail. I am thinking of using some block hugger headers.

ETA- two and a half months of down time.

Edit: Currently 5 months into it, and not done yet. Yikes. Hope to be done before summer.

sneezy · 07-30-07, 12:24 PM

Damn, That's a good amount of work for one day. I'll feel happy when I have enough time to flip my bezel.

fj40_73 · 07-30-07, 12:37 PM

air tools, really help with all those bolts on the hump and every where else. I forgot to mention, I was well tired at the end of the day, and am taking the day off from wrenching today. zzz zzz zzz zz

If only it was as fast to put things back together as it is to take apart.

Downey · 07-30-07, 02:13 PM

When you are choosing your Block Huggers, suggest you get the Ultra-Block Huggers, they tuck tighter into side of engine, better clearance from steering drive shaft.

fj40_73 · 07-30-07, 02:29 PM

maybe if you offered them with a Ceramic Coating(did not see online if you do) and would take a trade in on a pair of your Cantilever shackles I hate.

I will say the Alum Radiator I purchased from you has been the best thing I have gotten from downey.

Also not super stoked you use 1310s on your long slip yokes, I would prefer if u used yota u-joints.

just my .02 cents.

kellyo · 07-30-07, 02:32 PM

Have you got a body guy lined up? I am only asking cuz I need some body work as well and was checking.

fj40_73 · 07-30-07, 02:37 PM

no, I will be doing all the pain staking body work in my drive way with my Pop up tent garage U see in pictures. I have sides too. Here is a picture when i was working on the hood. Can you say super ghetto fab?

fj40_73 · 07-30-07, 02:44 PM

Dose any one on the board sell these?

fj40_73 · 08-02-07, 04:27 PM

Just got my rear disk brake brackets and rotors from poser.

Nice packing, nice items, heavy brackets. Thanks

Should be able to get those on this weekend, if not sooner.
I would do today, but been surfing and drinking beer. mabye later if I get a second wind.

my64fj40 · 08-02-07, 05:58 PM

Very cool, keep up the work.

I added you to the build thread list.

fj40_73 · 08-04-07, 11:24 AM

Last night I got one rear bracket & caliper on. Everything fits nice. Been stewing in my head about running the e-brake lines.

Decided to do more mud searching and found all the threads about how the caddy e-brake sucks. Boooooo. And I am not interested a inline ball valve for an ebrake.

Jim at AA menetioned they had a provision for an e-brake on the HD, and I found a picture of it, but means more money.

So not enough research = Wasted day at junkyard getting caddy calipers. & wasted money buying them . Boooo.

Will be talking to AA about what they have.

fj40_73 · 08-04-07, 11:27 AM

fj40_73 · 08-05-07, 01:12 AM

Went ahead and prodged on. After my tourch ran out of oxigenizer i had to sawzaw the last backing plate off, but all good.

I have to say the rear disk brake conversion is way satasifying feeling and much easier then the front.

Spent the rest of the day helping my brother with his bronco build. He is getting a double flaring tool, this or next week, so I will run my lines then.

Any one need any drum brake parts? Yours for the shipping. The springs are good, and the slave cylinders look good. Drums seem ok too.

73fj · 08-05-07, 01:30 PM

Quote:

Originally Posted by fj40_73

Dose any one on the board sell these?

Try this guy http://www.gasseling.us/InsPnls.htm , I got one , nice work.

fj40_73 · 08-07-07, 11:58 PM

E-brake update.

AA has no e-brake for the orian HD.

High drive line is the one who is developing the one pictured above. Current problem is that the drive train bracket, that AA uses on the back side of the TC, is in the way of the disc of the one pictured above. Moving on to body work for now.

fj40_73 · 08-08-07, 12:12 AM

I am not sure what would of happened if I had rolled.

1. My stock roll bar would of crunched.
2. It would of poped threw the wheel wells.

The body is less then show condition. So I cut out the
offending area above to this.

To keep my patch even, I then welded in a strip on the lip.

Then to Top piece.

The other side was worse so I cut out more.

Above you can see my replacement piece I bent up, ready for
install.
Here is it welded in.

I should be able to tackle the drivers side kick panel on friday, and hope it comes out as good as the passengers side I did
last year. Below are pictures from that.

nspctr1 · 08-08-07, 06:19 AM

Great! Keep up the good work. Oh,, and lose the ugly exhaust while your in there....

fj40_73 · 08-08-07, 09:54 AM

Quote:

Originally Posted by nspctr1

Great! Keep up the good work. Oh,, and lose the ugly exhaust while your in there....

hahaha, yeah, I hope to have time for that, but may have to wait until after pismo(SnT), if I make in time.

fj40_73 · 08-18-07, 07:37 PM

Been picking away at this thing. The Driver's side rocker panel had some serious rust. The Back Center Brace was hosed, along with where it attached, and a couple other sections on the inside.

So I made a new panel, and insides as was needed Then stapled it back together, after dealing with the inside sections and rust. Also made a new back center brace for it.

I then cut the last bit of the back panel, were it was also rust kindom.

Here's the old piece, and the new one, along with the back brace.

Kinda seemed funny to do this part, because most of it gets covered up by the wheel flare, but wtf.

More pictures of of my staples.

My piece was a little short on the top, but I was able span the gap.

Backside:

Hard to see but I have the hole drilled for the body bolt on the bottomish.

I decided I will grind down my staples after I get done with this.

I have a pair of quarter Panel Patches, that if I use wisely, will be enough to replace all the rust parts. And a real sill. I am sure after I cut this up, I will be patching the rear support too.

fj40_73 · 08-18-07, 07:45 PM

Also got a nice box of parts from Kurt.
poly Body mounts
Pair front bib lights
Pair turn lights.

Yeah, I am running a mix of year lights.

fj40_73 · 08-18-07, 07:45 PM

oops got all excited with the finger.
here is the pic.

cronic · 08-18-07, 11:00 PM

Quote:

Originally Posted by 73fj

Try this guy http://www.gasseling.us/InsPnls.htm , I got one , nice work.

good luck getting a hold of him. I called and email him numerous times a few weeks back and never got a response. So I made my own out of .25" aluminum. Looks awesome. I will post a pic tomorrow. I am sure from the looks of this thread that you have more than enough skills to knock one out. Great work on the 73.

fj40_73 · 08-18-07, 11:24 PM

Thanks for the info, I got one at a good price on ebay, eventhough I have to polish it up, because of shotty production.

mikedickbek · 08-19-07, 02:14 AM

Looking good bro. Keep it up! It looks like you've got a lot of work a head of you still, but you seem to be tackling the problems quickly and thoroughly.

I'll be lingering on this one!!

Tarkus70 · 08-19-07, 06:49 AM

This is great keep up the good work and pics. Thanks for sharing

Cruisertime · 08-19-07, 09:34 AM

Good looking build man!

fj40_73 · 08-25-07, 02:04 PM

Last week started out good.

I measured up the rear gap, and sinched it with a strap to meet speck.

I bolted up a thick angle iron and removed strap.

After that I unbloted, and sawzawed off my existing body mount brackets, and set the rear tub up a bit on 2x4s. Frame will come out from under body, after I finish up the body work. Trying not to look too spread out in the Driveway.

Here I have drawn out my cutting marks.

Crap... this was after cutting off the Right , side, support is rusted out. Another thing to make...

Final pic of offending areas cut out.

As I started to make my new support bar for the rear, my crap ass Harbor freight stuff started crapping out.
First the elect shears. Got another one, and it broke too. Returning all, and have a good pair on order, that are made
in the USA, and have a cheap replacement blade.
The problem was most venders were out of these, but the manufacture said, they are still producing them. Must be slow on a production run. but found one.
http://www.tools-plus.com/kett-kd440.html

Then my air system started to crap out. My big ass tank compresses to 180, and all my lower rated crap broke.(hah, go figure.) Ordered a new main regulator, and a new quailty filter form Granger.

Compressor out in shead.

Hose real dangles from celling.

Now that air is back, I can do some work. But I also have a work load next week, so see how it goes.

Massive Love Hate at this Point. But I tried to order a Metal tech cage thurs-fri, but they seem to be out 4x4ing or something. Will order next week.

DomSmith · 08-25-07, 11:20 PM

Looks good! I wish I had some fab skills like that. I ended up paying the cash for the SOR split case P-Brake kit but not sure that would work for you (aside from spendy). I don't know anything about the Orion. I did have some custom exhaust built in the last few months that run inside the frame rails you might want to take a look at. I'm in South O just let me know if you're interested.

fj40_73 · 08-28-07, 09:00 PM

Quote:

Originally Posted by DomSmith

Looks good! I wish I had some fab skills like that. I ended up paying the cash for the SOR split case P-Brake kit but not sure that would work for you (aside from spendy). I don't know anything about the Orion. I did have some custom exhaust built in the last few months that run inside the frame rails you might want to take a look at. I'm in South O just let me know if you're interested.

ya, I am interested. PM sent. thanks!

fj40_73 · 08-28-07, 09:19 PM

snuck out side for a few hours today. Decided since I am waiting on my electric shears, I would start in on the Dash.

I have three ARB switches, and have ordered 4 more switches just like them from: http://waytekwire.com/ for a total of 7 switches. Some time ago I welded in a plate at the stereo hole. I put my dash pads on, and made a template, with illustrator, that would just fit, 7 switches, in that space.

Here you can see I have taped my template on, and did a double check before cutting.

My cuts were not perfect, but, well within tolerance. I was suprised at the strength of it, being that the slits are thin, but it is 16g, metal i put in there, so that must be why, and because of the overall structure.

the switches just fit, with a tiny bit of space in between them.

After that, I ground up some circles to weld in, to fill in about 4 extra holes the POs had put in. I should have a good picture of dash this week. Thanks for watching!!!!!