Builds My '78 FJ40 "44" (7 Viewers)

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Ok guys, I've been remiss... At the advanced age of 65, I completely forgot I had created this thread - I've been reporting most of my little successes in the "What have you done to your Land Cruiser this week" thread.

I'll list what I've done since I last posted herein and see about posting some new pictures ... and try to remember to continue posting in this thread.

So, since I last posted in this thread, I've:

1. Replaced the tie and relay rods and their associated TREs and set the toe-in to 3/16th" - the old TREs bottomed-out at 1/8". This cured 44 of trying to kill me by turning into curbs, oncoming traffic and off cliffs at 38mph.

2. Removed the bastardized steering gear housing pedestal and replaced it with a Bill Dorry pedestal from Georg. Adjusted the drag link and centered the steering wheel.

3. Replaced the radiator and flushed and replaced coolant a second time.

4. Replaced radiator hoses and belts.

5. Installed a 'coolant burp mod' - thanks handcannon!

6. Replaced plugs, plug wires, rotor, distributer cap and PCV valve and checked timing.

7. Installed a couple of hidden cut-off switches for a bit of thief deterrent.

8. Replaced a 14ga wire with a fusible link from coolerman - thanks!

9. Replaced the oil pan, gasket, oil filter and changed the oil and lubed 44.

10. Helped jetranger and Allan Mann rebuild my knuckles - thanks Riley and Allan!

11. Removed the Jump Seats and added a 'floor' on top of the rear wheel wells. Allows storage under this 'floor'. Created a wooden box in place of the driver's side jump seat - to carry two 20L gas cans and one 20L water can.

12. Bought custom cargo netting and installed one over the roll cage in the back (for clothes, jackets, etc.) and one across the cab, above the front seats (for maps, iphone, caps, hats, etc.).

13. Bought cloth seat covers to protect the new leather seats when out with my dogs.

14. Replaced the speedo gear seal.

15. 44 Developed a coolant leak and discovered a broken water pump bolt behind the alternator. Drained the coolant a third time. Removed the bib, the radiator, the fan, the belts, the hoses and the water pump. Welded double-nuts onto the broken bolt (6 times) and, using liberal penetrating oil, liberal heat and my 12vdc impact wrench, removed the broken bolt. Cleaned up the front of the block, installed a new gasket and a new water pump. Put it all back together.

16. Replaced clutch slave - master was new when I bought 44.

17. Replaced worn out Monroe steering damper with a SOR damper - thanks doug earley!

18. Replaced the worn out shocks (not sure of brand) with Bilstein 4600's - thanks for the recommendation, kruisinkid and fast eddy!

19. Installed jerry can carriers on both rear fenders. Created 'square-Z' brackets to beef up the fenders' bracing to the frame. Added stainless steel U-bolts to the bottom-rail-of-the-top, to tie the top of the jerry cans to 44. Used ratchet straps for this purpose.

20. Mounted Hi-Lift Jack on the passenger running board, using a locking FJMount.

21. Created a locking center console, using the stock console, an ammo can and a lock from a locking hasp, from Home Depot. Thanks ducktapeguy!

22. Created a locking front-bumper-mounted toolbox, from a 40mm ammo can and a lock from a locking hasp, from Home Depot.

Between now and Sunday, I'll be checking compression, checking vacuum and adjusting valves and driving as much as I can before I remove the carb on Sunday and prepare to ship it to Jim on Monday. I told Jim I wouldn't need it back before August 10th - so, I won't be driving for a while.

I have a 'virgin' intake manifold, from Georg, and a new gasket to install while the carb is off.

Picking up a ConFer rack from jetranger (thanks RIley!) on Friday - bought 6 gutter mount brackets from Brian at BTB yesterday - I'm hoping I can get into the garage, with the rack installed - if not, I'll have to store it when I don't need it, in my storage room, with the Surco basket off my Tundra.

Ok, as I said... I'll try to remember this thread...
 
You've been busy... Keep up the good work.

How do you like the Blistens? My Rancho 5000s are 15+ years old, and don't offer enough rebound dampening... Especially now with rear AiRide bags (although there's less roll now).


I find the Highlift makes a winch obsolete... Well almost.
 
Wow very nice prep work for your touring rig. If you can find a Tirfor hand winch in the US its worth the money for vehicle recovery from any angle.

I'll check into it - thanks!

You've been busy... Keep up the good work.

How do you like the Blistens? My Rancho 5000s are 15+ years old, and don't offer enough rebound dampening... Especially now with rear AiRide bags (although there's less roll now).


I find the Highlift makes a winch obsolete... Well almost.

I only installed the Bilsteins yesterday, but they are going to be great! The shocks they replaced only said "Explorer", but they (especially the rear) were worn out.

I had initially planned to buy a winch and then I started watching videos of recovery, using Hi-Lift and realized, for the type of terrain that I will be driving, I would also need a PullPal (or similar anchor - no trees, no natural anchor, much of the time) and that I could use the Hi-Lift to 're-position' the wheels, as well as winch, when needed. Thank you for validating that!
 
You've been busy... Keep up the good work.

How do you like the Blistens? My Rancho 5000s are 15+ years old, and don't offer enough rebound dampening... Especially now with rear AiRide bags (although there's less roll now).


I find the Highlift makes a winch obsolete... Well almost.

BTW I should have said that kruisinkid and Fast Eddy both recommended the Bilsteins - kruisinkid has 5100s and Eddy has 4600s in one vehicle and 5100s in another.
 
"I have a 'virgin' intake manifold, from Georg, and a new gasket to install while the carb is off."

Intake and exhaust normally come as a set. I would take your new intake and your exhaust to a machine shop and have them make sure they match. Otherwise you could end up a leak.
 
I have headers, so they don't mate - but, I will be taking the intake to a machine shop - Jim suggested that right off.
 
This past week, I performed a series of compression tests and valve adjustments and pestered everyone with questions about exactly what the results mean - consensus is that 44's 2F engine, like me, has lived a full life... and should just continue to enjoy every day to it's fullest.

I was gonna get some new pictures, but forgot... and now I've removed the carb and it's on it's way to Jim's for some Cruiser Lovin' - back in a month or two.

In the meantime, 44 will be down, but definitely not forgotten... while the carb is away, Danny will play... I have the following 44-related projects to complete:
  • Install new intake manifold
  • Install t-case to tranny bypass hose
  • Install new fuel pump
  • Install FJ60 Alternator
  • Install FJ60 Gear Reduction Starter - these last three installs will complete my planned parts replacements and will provide the spares I wanted to carry.
  • Cleanup and replace any remaining old hoses
  • jetranger gave me an old ConFer rack and I bought gutter mounts and am modifying the rack to facilitate mounting to 44. Monday, I plan to carry it to Custom Powder Coat, in Las Vegas, and have it blasted and powder coated - the really surprising part of this is that I can mount it on 44 and still get into the garage!
  • Install off road and work lights - need to decide whether I want them mounted to the rack or the bumpers.
  • I bought a couple of rattle cans of 416 (Dune Beige) from CruiserCorp and plan to touch up a few spots on 44.
I'll try to remember to post pictures of each project...

That list should be enough for the summer Vegas heat in my garage, but I'm sure I will find more that I want to do...

Once my carb is back in place, I want to be ready to load up and go - I'm planning the trip now.

In the meantime, I'll take my Tundra and do some target shooting in the desert and do some fly fishing in the mountains of Utah and COlorado.

Thanks to MUD for all the help/advice - without MUD, I would have had to spend a lot of money on labor and would never have enjoyed 44 so much

 
Well, it's been a while...

I sent my carb to Jim C in mid-June (UPS had a delay - didn't get to Jim until Jun 23rd) and told him to keep it 8 weeks, rather than his estimated 4 weeks -I got it back on Wed, Aug 27th...

Our eldest Golden Retriever, Mr Parker (left in my avatar), developed a very aggressive, basketball-sized malignant tumor on his back and right side... I had him euthanized on Jul 11th, at 12.5 years of age.

Then, we took an extended trip...

Dianna (Wife) and I hooked up our Casita trailer to my Tundra and filled the back of the Tundra with camping/fly fishing stuff, solar, generator and two 5 gallon gas cans, loaded the roof rack with chairs, tarps, etc. and loaded Sgt Gunner (right in avatar - he will be 9 years old on Veterans Day) in the back seat and drove to a very remote 10k' area of the Conejos River, in south-central Colorado.

We spread Mr Parker's ashes in a couple of his favorite swimming places on the river, while we camped there for two weeks with our younger daughter and son-in-law. We caught some trout (rainbows and browns), Dutch Oven cooked, enjoyed 10k' of cool, mountain air, hiked and relaxed.

Then, we trekked back home, via Mesa Verde National Park, CO, Arches National Monument(?), UT, Goblin Valley State Park, UT, Bryce Canyon National Park, UT and Grand-Escalante National (something), UT... camping along the way.

We are now back in the heat of Vegas and my carb arrived on Wed, Aug 27th!
  • installed carb on Thursday
  • Replaced all hoses on Thursday and fired it up - it actually ran at 450 rpm, without dying - never would befor
  • Reinstalled Air Cleaner on Friday, adjusted the idle to 650 rpm and fired it up - always starts on first turn of key - hot or cold - now runs consistently at 650 rpm, with 18 inches of vacuum! Excellent job, Jim!!
  • Drained oil and dropped the oil pan (to replace the gasket I screwed up the first time) on Saturday - this job, I HATE!!
  • Replaced Fuel Pump on Saturday - nothing wrong with the old pump, just looked really old.
44 is really running well!! Thanks Jim!!

While my carb was at the spa, during the time I was home, completed a number of other tasks
  • Replaced alternator with an FJ60 alternator, from Georg
  • Replaced the started with N FJ60 GR starter, from Georg
  • Bought a virgin intake manifold from Georg
  • Had Intake manifold milled for $40, thanks for the shop recommendation, Allan Man!
  • Installed intake manifold and reconnected headers
  • Installed Lou's t-case to tranny bypass hose - thanks Lou!
  • Riley (Jetranger) gave me an old Conferr Rack - thanks Riley!!
  • I bought 6 gutter mounts from Brian, at BTB Products - thanks Brian!!
  • Took the rack to Jose, at JOJ Welding and had three 1/4 x 2" crossbars welded on to Make the rack wide enough to accommodate the gutter mounts and mount to 44
  • Cut and rounded the ends of the new crosspieces, cut slots for the gutter mount bolts.
  • Took rack to Custom Powder Coating to have it sandblasted and powder coated for $240
  • Installed the rack and (great news!!) I can leave it mounted on 44 and still get into the garage with 4" clearance!!
  • Installed 2 LED lights on the front bumper and an LED work bar light on the back of the rack - both switched from toggles on the dash.
  • Built a two-gauge cluster from 26ga sheet metal and mounted a tach and a vacuum gauge on the dash, over the radio hole - love being able to see rpm sand inches of vacuum, while I drive!
  • Couldn't get the carb cooling fan to work, so I bypassed it and installed a manual timer (no room on dash, installed it on the firewall, behind the pedal) - thanks "someone on MUD - sorry, I don't recall who's idea this was...
In the next few days, I'll (temporarily) remove the passenger seat back and build a portable sleep platform... The Gunner and I will hit the road for "a while"!!

I have questions... Since I have the old starter, alternator, water pump and fuel pump, for spares, is there anything I should do to protect them as best I can? Like a few drops of oil or something? I'd like to keep them as long as I can... For spares.

Here are a few pictures... Hope you can see some of them

Carb installed - new hoses
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Passenger side - back end of new alternator - can't shoot GR Starter
image.jpg

Front LEDs - one each side - best picture I can do right now
image.jpg

Rear work light - again, best pic I can take right now
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Rack - best pic right now
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Continued in next post
 
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Sorry to hear about your dog Danny .....cruiser is looking good!
Looking forward to hit some local trails when it cools down.
 
Sorry about the loss of your companion, we sure can get attached to our furry friends...

You have been a busy man! That Cruiser is looking great!
 
Thanks Mark! How was that for begging for attention?!?

...and I forgot to mention I bought another spare fusible link from you - still haven't found my other spare!
 
Naw, that wasn't begging, that was pride in what you have done, seeking validation for all the time and money spent doing it... :lol: That spare link will turn up eventually...
 
Really nice rig, I have a '78 too!
 
Hi'ya,

I'm very happy to report that the oil pan gasket is holding - no more leaks!

But, after I cleared up this oil leak, I was able to see that my new (few months ago) water pump had a very slight leak - I was able to re-torque the water pump and eliminate that leak as well!

In order to get to the water pump, I removed the alternator and, when I re-installed it, I also aligned the Alt-Air Pump-Crank pulleys (the air pump pulley was too far forward) and installed a new belt - since my power steering is a conglomeration of mini-truck and FJ60, the standard oem belts don't fit - I found the correct belt at belts4less (or something... model BX61) and it's identical to the oem belts, but the correct length.

The next order of business was a sleeping platform (for those simple overnights - no need to pitch a tent). I removed the passenger seat back and ripped a sheet of 5/8" plywood to two 24" widths and cut the length to reach just past the front of the passenger seat bottom. I laid the doubled plywood in place and found that the front seat bottom is exactly the same height as the rear platform I previously installed.

So, I then shaved the front of the doubled-plywood into a 'sorta' ironing board shape (to allow access to the transfer case gear shift on the driver's side and to allow the passenger door to close) and placed it back in 44 and covered it with a Harbor Freight moving pad, laid my sleeping pad on top and covered it with an old bed spread and placed Gunner's bed on the back platform (next to me - my sleeping bag (and backpack)) travel in the cargo netting above it) and we now have a travelling apartment!!
photo 1 (6).JPG

photo 2 (4).JPG


Now, I needed a new place to carry my Hi-Lift jack base, so I set it up on the driver's side, back door - here:
photo 3 (4).JPG


I asked and received some great suggestions for carrying spares and making them last as long as possible. Then I tried to come up with the best way to carry them and realized that the front-bumper toolbox that I previously installed was perfect (it's an ammo can and is waterproof and the perfect size for the spares I have (alternator, starter, fuel pump and water pump) - so, I now lock them here:
photo (34).JPG


Today, I took 44 and Gunner for a drive and I am amazed at how much better it runs, with Jim's rebuilt carb! I thought I had it running good before, but it's night and day!

I really wanted to do my own carb rebuild, but was worried that my arthritic hands would make it too cumbersome to do a good job. So, now that I have a great carb installed, I found an 8G27 (Aug 27, 1978) carb, that's identical to my Aisin that Jim rebuilt (thanks oestlarsen!!) - I received it today - it's identical... right down to the big EGR port that Jim removed.

Pin_Head recommended the Hygrade 791B rebuild kit (since I wanted a new secondary diaphragm) and joyRidaz (thanks joyRidaz!!) put me on to Standard Motor Products 791B kit (it's the exact Hygrade 791B kit, on Amazon - comes in the same blue box, with the same Hygrade labeling) - On Amazon, it's half the price ($44) of the kit that sells as Hygrade 791B ($95).

So, on a cold winter's day, I will be rebuilding my spare carb - I'm sure I'll have questions...

I will also be installing my aux gas tank this winter... more potential for questions...

Today, I received my new (old) Air Rail Check Valve, from Georg (to replace the one I have that is rusted out) - I'll replace that tomorrow and that is the last repair/replace item on my list!! I'm sure I will find/encounter other issues, but that's all for now.

Gunner and I will load my tent, cot, inflatable pontoon and fly fishing gear (two large roller bags) in the roof rack, fill the two 20L gas cans and the 20L water can and pack up our provisions, for at least a week - maybe two - and hit the road Monday morning - our maiden trip in 44!! No itinerary - just go where we want!!

Life is great!!!
 

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