Builds Sweet Caroline: 1977 FJ40 Build

[RustyR]

So here it goes, I just bought a 1977 FJ40 from Arizona. The VIN says it was made in September 1976 which leads me to believe it hit the U.S. market in 1977 thus making it a 1977 truck. Anyone feel free to correct me if that's wrong. I'm pretty new to the cruiser world and hope I can get some good advice as I update my build thread. Anyways, I'm working on a list of what work needs to be done and the current top priority is getting the truck street legal and safe. From what I can tell she runs great, but I'm getting an inspection done soon.

First I'm getting new tires, I decided to go with 31/10.5/R15 size tires so I won't have to worry about a lift kit or any tire rub on the fenders. I might add a lift kit later, but for now I want to spend my money on the more necessary additions to the truck. I am also debating whether or not to get locking lug nuts so my tires don't get stolen. Next I probably will get the door and gas tank locks rekeyed because the key I got with the truck doesn't match the doors or gas tank. Third, I am going to get new brake hoses due to some small tears in the ones on the truck now. This is basically my to-do list so far. After this stuff I need new seat belts, license plate lights, etc. (stuff to make the truck street legal).

Well, Here she is...

I took off the door panel to get the window back on the track

My dashboard seems a little different from the other 40s I've seen on the forum, for example my cigarette lighter is on the far left while the other lighters I've seen are on the right of the dash. Anyone know why?

I noticed an aftermarket fan (bottom right), no idea why it's there, maybe because the engine got too hot in Arizona. The fan is controlled by a manual flip switch on the dash... weird.

Continued on next post...

 

[RustyR]

Closer look on the fan

New upholstered seats

I might like to get new turn signals because these are cracked. Anyone know if metal ones look any good?

All of the doors on the truck don't seem to close all the way especially the ambulance doors. You can see daylight through the doors so I might need some new rubber lining for the doors.

Better look at the dash, anyone know what buttons are missing?

Continued on next post...

 

[RustyR]

Anyone know if the stock window cranks are plastic? These cranks, and handles, seem flimsy

Brake hoses with tears

I'm pretty sure these side-view mirrors aren't stock

I also need new land cruiser emblems (the one on the other side is missing and this one is about to fall off)

Last owner must have had something mounted here

More updates soon...

 

[TheHardWay]

Welcome to the '77 club. Don't take offense, it's the traditional greeting. You pass the bezel test, so you're in good standing there. The bigass fan is a carb cooling fan to prevent vapor lock and carb fuel bowl boiling, and I don't believe was the factory fan for that year. That rectangular thing above your radio is not factory, and the cigarette lighter should be right around that space. Good tire size choice. Why so much primer? How's the brakes work? Heads up, we want lots of pix to drool over

 

[brian]

the model year does not follow the calendar year 100%. in most cases the model year started sept of the previous year. the 1979 model year was one expectation.

the cig lighter was moved, because the hole for it was where the extra square hole is.
window reg are metal with a plastic knob.
mirrors not oem
oem turn signal housings are plastic

 

[sggoat]

Dunno about the cig lighter--
the fan in the front left engine bay appears to be the normal carb cooling fan. My 77 has all the wiring there to hook one up-but it was long gone when I bought the truck. I don't know why, but lots of 77s had the fans, and lots of them didn't. General consensus is you don't need it, based on my research here on MUD.--(especially if you have headers). Sounds like the PO hard wired the fan cause he couldn't get the fan relay to work(prob that little 5 amp fuse hidden under the air duct got him)
Looks like a nice rig to start your FJ 40 adventure--good luck with it--POST MORE PICS!
Welcome--(I like the name--)

 

[RustyR]

Welcome to the '77 club. Don't take offense, it's the traditional greeting. You pass the bezel test, so you're in good standing there. The bigass fan is a carb cooling fan to prevent vapor lock and carb fuel bowl boiling, and I don't believe was the factory fan for that year. That rectangular thing above your radio is not factory, and the cigarette lighter should be right around that space. Good tire size choice. Why so much primer? How's the brakes work? Heads up, we want lots of pix to drool over

Thank you so much for the reply. I'm pretty sure the "rectangular thing" houses a clock which is hanging under the dash by the wires. I wasn't the one who primed the truck, the guy in Arizona I bought from did it. Braking is a little shaky which is the main reason I want new brake hoses. Do you think that small tear is significant? Thanks.

 

[RustyR]

Another question... at first when I saw the bumper on the truck I wondered why the PO bolted so many things to it, but as I looked at other 40s online and I saw what looked like the same holes in the bumper. Is there any rhyme or reason to the placement of those holes? Thanks.

 

[sggoat]

Closer look on the fan
View attachment 1031595

New upholstered seats
View attachment 1031596

I might like to get new turn signals because these are cracked. Anyone know if metal ones look any good?
View attachment 1031597

All of the doors on the truck don't seem to close all the way especially the ambulance doors. You can see daylight through the doors so I might need some new rubber lining for the doors.
View attachment 1031598

Better look at the dash, anyone know what buttons are missing?
View attachment 1031599

Continued on next post...

Dash------here's my 77 when it was first delivered--need to paint the photo so you know the knobs-I'll get a more recent pic for you tomorrow-la

belled--

 

[brian]

small tear in the outer sheathe of the brake hose? no big deal.

 

[RustyR]

Dash------here's my 77 when it was first delivered--need to paint the photo so you know the knobs-I'll get a more recent pic for you tomorrow-laView attachment 1031617 belled--

Thanks! I also have that red display to the bottom left of the steering wheel. Is that stock?

 

[sggoat]

Closer look on the fan
View attachment 1031595

New upholstered seats
View attachment 1031596

I might like to get new turn signals because these are cracked. Anyone know if metal ones look any good?
View attachment 1031597

All of the doors on the truck don't seem to close all the way especially the ambulance doors. You can see daylight through the doors so I might need some new rubber lining for the doors.
View attachment 1031598

Better look at the dash, anyone know what buttons are missing?
View attachment 1031599

Continued on next post...

If you get new signals(esp the lenses) let me know--I would like to get your old ones.( a note here---I have the original lenses on my 77, they have cracks. I thought I would get some better lenses because of this. I bought brand new lenses from CCOT. They were on the rig right at 8 months and the things were so yellowed the light was dim by more than 50%. I put the originals back on-and they are still there--no yellowing-
If yours are original, do whatever you can to preserve them--

 

[RustyR]

small tear in the outer sheathe of the brake hose? no big deal.

Thanks. I guess brake hoses now fall lower on my to-do list

 

[RustyR]

If you get new signals(esp the lenses) let me know--I would like to get your old ones.( a note here---I have the original lenses on my 77, they have cracks. I thought I would get some better lenses because of this. I bought brand new lenses from CCOT. They were on the rig right at 8 months and the things were so yellowed the light was dim by more than 50%. I put the originals back on-and they are still there--no yellowing-
If yours are original, do whatever you can to preserve them--

Will do. I'll let you know if I get new ones.

 

[TheHardWay]

Unless you're losing fluid through the tear (or is it just age cracks?), your braking problem is more likely related to rear cylinders. Check them for leaks and proper operation, then adjust them and they should kick ass when you hit the pedal. Your Amby doors need factory weatherstripping and adjusting to close and seal properly. How about the fronts? The four bolts on the side of the cab are PO inflicted injuries.

 

[Vae Victus]

Welcome! Watching with interest.

 

[RustyR]

Unless you're losing fluid through the tear (or is it just age cracks?), your braking problem is more likely related to rear cylinders. Check them for leaks and proper operation, then adjust them and they should kick ass when you hit the pedal. Your Amby doors need factory weatherstripping and adjusting to close and seal properly. How about the fronts? The four bolts on the side of the cab are PO inflicted injuries.

Thanks. I'll get those cylinders checked. The tear might well be an age crack because some hoses under the hood are also stiff, but not cracked. The front doors have the same lining problem. Do you know where to get weatherstripping?

 

[sggoat]

Closer look on the fan
View attachment 1031595

New upholstered seats
View attachment 1031596

I might like to get new turn signals because these are cracked. Anyone know if metal ones look any good?
View attachment 1031597

All of the doors on the truck don't seem to close all the way especially the ambulance doors. You can see daylight through the doors so I might need some new rubber lining for the doors.
View attachment 1031598

Better look at the dash, anyone know what buttons are missing?
View attachment 1031599

Continued on next post...

Doors--almost looks like the amby door on the right is misaligned--larger space at the top-take this into account when you put new weatherstrip in---

 

[TheHardWay]

I bought mine from Beno a few months ago. Wow, what a difference it makes in the road rattles! Noticed the primer on the rear sill. Wonder what it's covering up? BTW, General-Miscellaneous is where you'll find Beno.

 

[RustyR]

Doors--almost looks like the amby door on the right is misaligned--larger space at the top-take this into account when you put new weatherstrip in---

Still?