Project Duragoat: My 1974 FJ40 Build Thread (1 Viewer)

Bsquared · Jan 2, 2012

I picked up this truck in november of 2011, wanted one forever, and finally fell into a deal that I couldn't pass up. I ended up buying this from a guy that I work with; I took my wife to look at it and when we pulled up, I said Wow!, what do you think, she said, "That thing is a huge piece of $hit, I said, yea, its perfect!

Drove her home an hour later with the entire cab filled with gas fumes, and barely able to get it over 45 miles an hr. Aside from nearly running out of gas, made it home with no problems.

I would like to build a super reliable rig that has some road manners, definitely keep a standard shift trans, but would like to couple it up to a 5.3L Gen III engine. Going to take my time and let it evolve.

Here are my plans:

1. [STRIKE]Deconstruction[/STRIKE] Done
2. [STRIKE]Frame rust removal, prime, paint[/STRIKE] Done
3. Power steering conversion
4. Front disk brake conversion
5. GM 5.3L + H55 + Split case
6. 2.5-3" Suspension Lift
7. 35" Rubber all around
8. Bed Liner coating under the tub
9. Paint and body work (thinking stock green or possibly pumpkin orange)
10. Flip Bezel

Here are a few pics from the day I brought her home.

Bsquared · Jan 2, 2012

More Day 1 Pics

Bsquared · Jan 2, 2012

Deconstruction Starts

Without much delay, I began to tear it down, I really can't handle the rust, even if its california rust, it still bugs me.

UZJ40 · Jan 2, 2012

Its actually in pretty good shape! Awesome start to a good project!

Bsquared · Jan 2, 2012

Deconstruction Continued + power wash

Tim71FJ40 · Jan 2, 2012

Congratulations! Great looking 40. Make sure you add "Flip Bezel" to your rebuild list...

Bsquared · Jan 2, 2012

Added it to the list!

Bsquared · Jan 2, 2012

Frame rust removal

I was contemplating having the frame powder coated, but I would need to have all the new stuff mocked up (new motor mounts, tranny mounts, etc), and having a week and a half off over the holidays, I did not want to wait to mock everything up. I decided to rent a compressor/blaster and do it myself in preparation for the paint.

The neighbors were pretty pumped about it. It took about 5 hrs to get it all blasted, that really is an evil process. I had sand/media in places that i didn't know I had....

Pissing off the neighbors

Rust before blast

Post blast

Bsquared · Jan 2, 2012

Frame prime and paint

I have used Rustolem primer and enamel on my 60 with great results, so I went with what I know works. Here are some shots of the prep, primer, and paint.
I did not paint the front frame horns because I will be fabing up the power steering conversion plates. At this point, they had not arrived yet.

cruiserjunkie · Jan 2, 2012

thats sweet great start cannt wait see all the progress

Bsquared · Jan 2, 2012

Power Steering Conversion (Frame mods)

I really liked the look of the 4x4 Labs saginaw conversion kit, it really looks stout especially with the yoke bezel, and the through bolt mounts on the lower side of the frame. I took quite a few pics of the process.

Here are some details on the steering gear box.

Original Frame Pic

Getting ready to cut the 3" hole, measure 2x!

Bsquared · Jan 2, 2012

Power Steering Conversion (Frame mods) contd

Bsquared · Jan 2, 2012

power Steering Conversion (Frame mods) contd

These are the captured nuts for the recovery hooks. It was a little tricky making square holes. i ended up using a jig saw with a metal blade. Go DeWalt! Welded from the backside.

Everything aligned and tacked.

Here is a good picture of the through tubes that mount the lower two bolts on the gear box. Also a good shot of the yoke bezel that supports the cross member where the 3 inch hole is cut.

Bsquared · Jan 2, 2012

power Steering Conversion (Frame mods) contd

Final welds. I know, not pretty, but should hold.

Bsquared · Jan 2, 2012

power Steering Conversion (Frame mods) contd

Final pics of prime and paint.

All said and done, took two full days to get the gear box all installed.