FJ40 '82 Diesel Rebuild in progress

[andhikae]

Dear All,
My name is Andhika from Indonesia. I'd like to share the progress of rebuilding my FJ40 '82 Diesel. It contains some pictures taken during restoration. For more complete documentation please go to TOYOTA FJ40 '82 Diesel

Originally was '82 Hard Top version in maroon red (Muleta Red T1454). After 15 years driving pleasure, I will convert this rig into Soft Top Version in desert color scheme. Some goals we plan:
-New look, fresh from factory, military jeep's like.....as possible
-Apply new design for lighting system using LED, especially to replace the bad design of tail-stop lamp.
-Minimum budget........ Is this possible?

It is hard to find but we try to restore the missing parts using genuine one as possible, make some minor modification and adding new better parts. I hope this experience will useful to someone who want to build this rig. Feels free to comment.

Thanks to Mr. Diran that successfully 'break' this car into pieces and put them together again.

 

[andhikae]

Body and chassis condition

This is the condition of chassis and body after 3 years stranded. It was an accident when this car was slipped and hit a tree in the forest at the right side. It shown 3B type diesel engine installed, the original is just a memory.



See more at this link.

 

[andhikae]

Chassis in black glossy

The chassis repaint, we decided to finish in black glossy.



See more at this link.

 

[lostmarbles]

Nice work!

 

[andhikae]

New tires installed

Thanks Tom, like yours. We work day and night in the rainy days.
I keep my old 15 aluminum rims and put new Good Year Xtra Grip. This noisy tires are match for military looks.


See more at this link.

 

[andhikae]

Primer over the body

There is no choice, we must put some putties.


See more at this link.

 

[andhikae]

Body Finishing

We'd like desert color scheme instead of green army, like Deutch Afrikan Korps vs Pink Panther Desert Ratts. We choose Milky Chocolate by Danapaint and Sinkken Varnish.


See more at this link.

 

[andhikae]

Body and chassis are united

Looks better, body mounted on chassis.

 

[Ron B]

Very nice job.

 

[Rambrush]

Very Nice!!

 

[andhikae]

Rear lamp unit

Dear all,
Thanks for the support.

Is this good or bad idea to put new design of LED rear lamp unit? Is there any experience using LED before?
We found the problem of this important part is malfunction by dirt and rust. I'm in progress of making this waterproof lamp unit.
The lens, reflector and back cover already done. Now I'm waiting for PCB and LEDs, this unit should be finished in a few days.
I know this is not OEM. If this experiment resulting a better lamp, I'd like to use it.

See more at this link

 

[lostmarbles]

LED lights do perform better than the old filament-type (generally speaking ...in all applications except for the headlights themselves).

They:

• are more rugged
• are more reliable
• are longer-lasting
• use less current (for the same brightness)

But an unfortunate side-effect of the low current-draw is that an old-style blinker relay may malfunctiuon when used with LED turn-signal bulbs.

Another negative is that they create very little heat .... and I like the way conventional filament bulbs tend to dry out their enclosures (with the heat they produce). .... But this comment only applies to LED bulbs and not the "sealed-unit-type LED lights" you're considering.

Go for it.

 

[Ron B]

A simpler way might be to use these. Mine work great and havnt had any problems. They even ha ve the flasher youll need. Super Bright LEDs – 12 Volt LED Car Bulbs I like your idea though.

 

[Kotekaman]

Andhikae,
Selamat Datang MUD! It looks like you have a pretty good build in progress. I think the military look for your '40 will turn out very nice. Have you considered painting your wheels black? What other modifications do you have planned?
Keep posting your progress pictures!

 

[andhikae]

Vacuum parts LED lamp

The result of vacuum forming........

But an unfortunate side-effect of the low current-draw is that an old-style blinker relay may malfunctiuon when used with LED turn-signal bulbs.

A simpler way might be to use these. Mine work great and havnt had any problems. They even have the flasher youll need. Super Bright LEDs – 12 Volt LED Car Bulbs I like your idea though.

Thanks for the link Ron, the site informs many types LED available. The LED working in the range of 2.8-3.6 volts.
My circuit design is a series of 4 LED's for 13.5 volts, each LED will get 3.38 volts. Also inform that a load resistor required for old-style blinker relay (6 ohm, 25 W)

 

[andhikae]

Andhikae,
Selamat Datang MUD! It looks like you have a pretty good build in progress. I think the military look for your '40 will turn out very nice. Have you considered painting your wheels black? What other modifications do you have planned?
Keep posting your progress pictures!

Hi Kotekaman, glad to see you. Finally you've found the specific nickname.....
I just do some minor modification, it is enough for me to make this big daddy run again. In my opinion military car should:
- Using lamp cover (black out light). No, I need bright light for safety driving.
- Camouflage color. It is not good for this car.
- Jerrycan, big antenna, ammo box etc. I will think about it. My fund resources seems depleted.......
- Tactical symbol and decals. This is the best we can do, unfortunately this vehicle has no battle record in history.
I think I will fail for military's look.

 

[Kotekaman]

- Jerrycan, big antenna, ammo box etc. I will think about it. My fund resources seems depleted.......
http://1.bp.blogspot.com/_78V7SBplOM0/S_zv702bi-I/AAAAAAAAA_o/l7cuIAFropk/s1600/FJ+40+p2.jpghttp://3.bp.blogspot.com/_78V7SBplOM0/S_zv-A5gMNI/AAAAAAAABAA/mbWtxOwenug/s1600/FJ+40+p5.jpghttp://4.bp.blogspot.com/_78V7SBplOM0/S_zv-l6L05I/AAAAAAAABAI/FF-SrnZxLX4/s1600/FJ+40+p6.jpghttp://1.bp.blogspot.com/_78V7SBplOM0/S_zv8liYP3I/AAAAAAAAA_w/BVaaYdhzpvI/s1600/FJ+40+p3.jpg

It appears a common problem of being a '40 owner is being depleted of funds, including me!

I think you got the look for your '40 nailed:



...except yours is nicer, it's a Toyota, not a Rover.

Also remember, in Papua, never judge a man by the size of his koteka

 

[bursabaju]

It appears a common problem of being a '40 owner is being depleted of funds, including me!

I think you got the look for your '40 nailed:

View attachment 423963

...except yours is nicer, it's a Toyota, not a Rover.

Also remember, in Papua, never judge a man by the size of his koteka

Hahahahhaaaaa......

 

[andhikae]

Hahahahhaaaaa......

Also remember, in Papua, never judge a man by the size of his koteka

Wakakaka...... should I put a big koteka to the Cruiser? Like this......http://lh4.ggpht.com/igo.mappangara...VTIMa0O_o/Enak....enak....enak.jpg?imgmax=512
What are we talking about? Wakakakaka......

 

[Kotekaman]

Wakakaka...... should I put a big koteka to the Cruiser? Like this......http://lh4.ggpht.com/igo.mappangara...VTIMa0O_o/Enak....enak....enak.jpg?imgmax=512
What are we talking about? Wakakakaka......

It would make a great hood ornament, or at least hang it on your rearview mirror!

It's great to see the '40's being restored in Indonesia. Your work is very inspiring. Keep up the great work, and keep posting update pictures. Terima Kasih Banyak!