I was thinking of doing a similar setup, but when the wife goes and picks up the kids from daycare where does she put the gun? I can break into the LC quicker than I can open the refridgerator. The day care place gets a little nervous when she walks in to pick up the rugrats carrying the 9mm...
I used POR-15 and while it was still tacky sprayed it with the 3M undercoating you buy at Advanced autoparts. After a year and a half I've had no problems at all. It took about 6 cans of the 3M at $4.50 a can on sale to do the complete underside.
Did you have to trim your fender in order to fit it around the gear box? The brackets I bought from OrangeFJ40 were all pre drilled so I had no room to adjust the gearbox location.
Just completed my mini truck p/s install. Works great, turns easy, runs smooth. The question I have is why does the pump and gearbox get so hot? Is this normal? Using stock manifolds without headers. Is this just a by product of engine heat absorbtion? I know the pump is not working hard...
I just finished my mini-truck p/s installation yesterday and it should fit snuggly. It sounds like it is the wrong fitting. the fitting should be 16mmx1.5 the other is 17mmx1.5. The low pressure fitting is the port closest to the firewall.
Look in the classifieds here...I bought one with the gearbox, pitman arm and both hoses for $60. It had been in the classifieds for a couple of months with no takers.
I used OMNI Base/Clear, its made by PPG but much less cost. ITs been a year and the paint still looks perfect. It has a perfect freeborn Red match. If I remember right I had about $500 into all the materials. If you have a shop buy it for you its probably cheaper. I also do not take it off road...
It seems like you are putting a lot of $$$$ in to paint and body. I would suggest in case you are not doing it, is to remove the top, fenders, aprons and doors and paint separately. I would change out all the hardware and use all new seals. Their is usually rust between the hard top and tub.
I used P0R-15 and then hit it with the 3M spray on undercoating while the POR-15 was still tacky. Its been one year so far with not any indication of rust coming back. People complain about the extra step of prep for the POR, but I think that is why it works so good.