[tlc_4play]

Hi Guys

I've been lurking here for quite a while, stealing with my eyes.

In February of 2007 I bought a 1979 BJ40 in Brisbane Australia, took a while, but eventually got it shipped to South Africa

In February 08 I started stripping it down for a complete rebuild, and as I have a total dislike for diesel engines I decided to swap out the B diesel and transplant the trusty old 2F

Here I will document my rebuild so far

The 40 parked at a friends house in Brisbane Australia


This was the condition of the 2F motor when I received it


Before I pulled it appart, I installed a set of 4" Heystee Parabolic springs and an ARB front bar.


I did a complete rebuild of the 2F before I started to strip the 40
The rebuild involved a rebore and replacing, pistons, rings, all bearings, all oil seals, camshaft reground for torque, fully dynamically balanced, new oil pump, new water pump, reconditioned the dizzie and fitted Pertronix eletronic ignition, skimmed flywheel, new clutch, pressure plate, thrust bearing and spigot bearing. The head was rebuilt and valve seats where changed to ones compatable with unleaded fuel.
The motor just before it was finished


Then I started to pull it all apart.




I sent the body to a friend that has a body shop - for the rust removal and repainting




I decided to repaint the 40 in Rustic green Colour code 631
Here are some of the body parts as the painter finished painting them

[tlc_4play]

The work continued

The naked chassis before sandblasting


The tub once I got it home


The chassis after sandblasting.


The axles where completely stripped sandblasted (outside only) then painted with Rust Bullet


When I istalled the Heystee parabolic springs there was a serious issue with the shackle angles and as I was intending to keep the parabolic springs I decided to move the chassis shackle mount to achieve a better shackle angle as mentioned elsewhere on the forum.



I also removed the standard steering box mount as Im fitting 60 series power steering, this mod also required the removal of the existing front shock towers



And the removal of the diesel engine mounts



More sandblasted components, some with rust holes that needed to be welded up.


The new shock towers that I made up



The completed motor with transmission as used for the laying out and positioning of the new engine mounts



The diffs, after I fitted the ARB Air Lockers



The chassis after it had been Rust Bulleted and blacked.



All brackets, nuts, bolts, washers and pip[es have been re- yellow passivated.

[nodaksn3]

Welcome, neat! A first- diesel to gas. Nice looking truck. You must not have any problems vis a vis import regs and stuff like that, like most of us do? Keep the pics coming! Ned

[tlc_4play]

No real problems, just the normal rego and homologation red tape



The work continued;

Painted chassis with suspension and axles installed.




Then I rebuilt the brakes, and all steering knuckles, bearings and seals in diffs and wheel hubs have been replaced with new.
Unfortunately I only saw Coolermans post on making up your own brake lines after I had a brake shop make up a complete set of new brake lines

Rear brakes.


Notice full floating axle.


The totally rebuilt front axle, with new disks, steering knuckles, birfields, bearings seals etc.



Then last night I eventually got the engine in the chassis



And tonite I got the cogbox (transmission) mounted too.
That is my progress since February this year, I'll keep posting as I progress.

[tlc_4play]

BTW my other truck is a FZJ105 (rigid front axle) 4500 EFI

Fitted with:-
Alloy Roof rack
Roof top tent
4" lifted suspension
45mm bore Tough dog adjustable shocks
80W solar panel
1 x 90AH Cranking Battery
2 x 105AH Aux Batteries
40ltr freezer on roller slide
39ltr fridge fixed mount
roller drawer packing system
Factory lockers fr and rr
VHF radio
Garmi 276C GPS
2 x chassis mount 35ltr water tanks
1 x 100ltr Main fuel tank
1 x 180ltr Aux fuel tank
On board Aircon pump air compressor
rear air springs
dual rear wheel and hilift jack carrier
TJM Alloy front bar with 2 x Lightforce spots
roof rack mount side awning
T-Max 12500lb winch

[CruisinMT]

thats what i call cruiser porn, all those nice shiney parts, looks great.

[romegadave]

Welcome--you're doing great work--liked the mustard color but the green is pretty sharp--Thanks for sharing--wish I was at that beach!!

[DomSmith]

Nice rig. Driving that around JoBerg you'll need flamethrowers from under the running boards if you want to keep it long.

[lostmarbles]

I'd never put a petrol in my diesel - But wow! Great quality workmanship and great photography to boot. ----Well done

[M5driver]

Oom Keith - super work. Now it's my turn to steal from you

Great color choice - I wish I could get work that fine done here in MW. My stuff is stalled again... hope to get it restarted today.

[jimhendrixx]

WOW dudes, that looks so nice, and you better get it dirty!

Have fun my friend

[Teebag]

Originally Posted by M5driver

Oom Keith

Looking good Keith.

[BJEC69]

Nice project and attention to detail. What did you do with the diesel? Keep those pictures coming!

[corbinwelter]

Wow, finally a 79 build! in my color too

Looks Good

[tlc_4play]

BJEC69

the diesel motor is going to a friend in Namibia to be put into a farm truck - a 45 series pick-up

[tlc_4play]

Update;-

Minor hiccup - Ive had a problem locating a suitable alternator. The search continues.

Did manage to get the 60 series PS pump on and power steering box clamped in - busy making up brackets and reinforcing back plate.

I have managed to get the tub on - this feels like a big step forward - although there is a slight problem at the rear a part of the rear panel need to be trimmed a bit to fit properly.

Some progress pics

[ohrly?]

Wow,

That looks really good... I must admit I am surprised that you are putting a 2F where a B belongs. Maybe one of these days I will see it when I go there, for the first time, with my dad, who was born in Uitenhage.

[Josie'sLandCruiser]

Hi All:

Wow dude! You've been busy!!

That is quite the complete rebuild! Awesome work!

Oh, btw - if you need a 2F alternator I have a couple stock Toyota units out in the garage - would be happy to send you one.

Regards,

Alan

[DallasFJ40]

I will be in Jhb in 3 weeks, and might be able to bring stuff. However, with the new SAA weight limits and the stuff I am already bringing is in excess, an alternator will definitely put me over.

[FARMAN33]

Great work - it looks super!!! Would love to hear the story on the rear wheel wells (the before pics were interesting in an unflattering way). Like your remedy though.
.

[tlc_4play]

Originally Posted by Josie'sLandCruiser

if you need a 2F alternator I have a couple stock Toyota units out in the garage - would be happy to send you one.

Thanks for the offer Alan - I'll be sure to let you know if I don'tcome right here.

[tlc_4play]

Originally Posted by DallasFJ40

I will be in Jhb in 3 weeks, and might be able to bring stuff. However, with the new SAA weight limits and the stuff I am already bringing is in excess, an alternator will definitely put me over.

Thanks as well - but I'm sure I'll come right eventually, also it'd be a schlepp lugging an alternator around as luggage

[tlc_4play]

Originally Posted by FARMAN33

Great work - it looks super!!! Would love to hear the story on the rear wheel wells (the before pics were interesting in an unflattering way). Like your remedy though.
.

The original wheel wells were cut by PO in Brisbane to suit a set of fibreglass wheelarch extensions that were for some perculiar reason were curved. I took of the fibreglass extensions as I have a set of flexiflares that I plan to fit and the curves just looked "yech" so I had my mate at the body shop return them as close as possible to original, and once the flexiflares are fitted the corners of the wheel well won't look as sharp.

[tmarx]

Looks great Keith

[M5driver]

Originally Posted by tlc_4play

Update;-

Minor hiccup - Ive had a problem locating a suitable alternator. The search continues.

Keith,

I have a spare alternator. Don't know how much of a flap it will be to airfreight from LLW, but we can work that out. Let me know if interested.

I think you are way ahead of me now. Should be seeing some blue paint at the panel beater's this week, but I'm too busy to go look. I hate it when work gets in the way of my hobbies

Dan

[tlc_4play]

Update

I managed to get one good alternator rebuilt from the parts of 4 Alternators.
Located and installed a two belt crank pulley for the 60 series PS

60 series PS mounted


The reinforcing (anti crush) bracket for PS rack


Alternator and two belt crank pulley


New master cylinder and vacuum booster installed


It broke my heart to cut a huge hole in the freshly painted rear panel for the long range tank filler


Due to the unavailability of most replacement weatherstrip and rubber seals it was necessary for me to cut my own from 3mm rubber sheet.


Mounted the overhauled Aisin carb


Fitment of the kick vents (Zimbabwe Air Conditioning) after installing the self cut rubber weather strip


Main tank filler


More updates to follow as work progresses.

[lostmarbles]

Nice work

[rusty_tlc]

Originally Posted by tlc_4play

BTW my other truck is a FZJ105 (rigid front axle) 4500 EFI

Fitted with:-
Alloy Roof rack
Roof top tent
4" lifted suspension
45mm bore Tough dog adjustable shocks
80W solar panel
1 x 90AH Cranking Battery
2 x 105AH Aux Batteries
40ltr freezer on roller slide
39ltr fridge fixed mount
roller drawer packing system
Factory lockers fr and rr
VHF radio
Garmi 276C GPS
2 x chassis mount 35ltr water tanks
1 x 100ltr Main fuel tank
1 x 180ltr Aux fuel tank
On board Aircon pump air compressor
rear air springs
dual rear wheel and hilift jack carrier
TJM Alloy front bar with 2 x Lightforce spots
roof rack mount side awning
T-Max 12500lb winch

It's official IH8you.
The 105 is pretty much my new dream rig.

[tlc_4play]

This is the current state of the progress on the BJ-FJ rebuild

At one point I became disillusioned with the progress because I was putting in hours and hours of work, but visibly the progress was not tangible

Needless to say a few weeks later and the progress is now at last tangible and visible.

[Michael Hanson]

Very nice!