TCSTARK - My 1981 BJ42 Build Thread - Murphy's Law

[TCSTARK]

I picked up this project in April. I have been busy sorting out all of the parts and determining what direction I will be taking it in. I am using this thread, initially, to document my electrical and engine components so that I can get a quote to put her together.

Here is a list of parts not pictured:

American Autowire Highway 22 harness kit
- ignition switch
- Hazzard
- headlights
- Single and double crimper tools
- American Autowire Copper Ground Kit
- 22 wire bulkhead adaptor

- Ididit 33" Tilt Steering Column
- BTB Products Firewall Adaptor
- Slip Shaft
- DD Ujoint and 3/4 36 spline Ujoint
- Saginaw 4.25 Turn Box
- 2" Drop Pitman Arm & Chevy TRE
- 4x4 Labs Mounting Kit
- Chevy to Toyota Drag Link

Delphi Weatherpack Kit 1505

Digital Dakota Gauge Cluster
- GPS Speedometer
- PSI/Boost
- Diesel Alternator Adaptor
- Electric Fan Controller
- fuel sending unit

- Downey 'Conferr' 22 gallon auxiliary gas tank
- in-tank fuel pump adaptor (if needed)

- Ron Davis Radiator 4 core radiator
- Taurus electrical fan

- 3b Diesel Rebuild Kit
- 13bt turbo
- Racor water separator
- 12v aftermarket high output alternator

 

[TCSTARK]

 

[chappohj47]

Looks great mate nice work

 

[TCSTARK]

I decided to start eating the elephant bite by bite....

I reassembled the front doors thanks to @hindsight well documented thread. The set of doors has new locks, handles, custom door cards and rubber. I re-used the internal hardware. I am pleased with how they came out.

 

[lostmarbles]

Wow. Looks great...

A veritable feast of pics here too!!!

 

[duncanrm]

Awesome photos..

The electrics on these things are so simple.. had you considered a hot-rod type generic harness? I think you'll end up with a neater job.. a bit of smarts to provide the glow and EDIC system if you want to keep them as automatic components or you could replace them with a cable and glow-switch.. not sure what level of originality you're after though..

Best wishes for the project.

 

[duncanrm]

View attachment 1011198

View attachment 1011199 @duncanrm - thanks for the words of encouragement. I have decided to pull all of the unnecessary electronics and go the pull cable approach.

Neat.. I like the cable approach.. whilst its a 2H, here's some shots of my cable, its appearance in the cab, its mounting on the injector pump and a diagram showing its routing.

http://imgur.com/a/NhmO8

 

[TCSTARK]

I am shaking the cobwebs off of this build and trying to get back on track. I wiped down the grime off of the gozzard tub and started assessing what PO drilled holes needed to be filled which lead me to test fitting the Scat seat mounts. I mocked everything up to get a feel on how I would secure them to the tub.

I had to trim off a few sections of the seat frames to position them the way I wanted to secure them to the tub. I have one mounting location that I need to get creative with (the front drivers side bolt). I am pleased with how they are set up (for now). Once I get my fiberglass resin I will fill the other holes.

I decided to use the transmission cover so I cut back the fiberglass and test fitted the panel. I need to get some metric rivnuts to secure it down.

 

[alberta mac]

Nice should look great !
Cruiser seats or are you going with other seats ?
I'm looking for heated lumbar bucket seats now, possibly out of a toyota car.

 

[TCSTARK]

Another small project completed.

 

[lostmarbles]

Another small project completed.

Very nice...

But your LH headlight doesn't seem to be aimed correctly ...

 

[TCSTARK]

I had noticed the LH side didn't seat into the assembly like the RH side. How do I adjust the light so it is aimed correctly?

 

[TCSTARK]

@lostmarbles - closing the loop on this mystery. The outermost bucket the headlight rests in comes in a left and right set. My parts stash had two right side buckets. I switched them out with the set for my petrol 40 and now it looks better.

 

[lostmarbles]

@lostmarbles - closing the loop on this mystery. The outermost bucket the headlight rests in comes in a left and right set. My parts stash had two right side buckets. I switched them out with the set for my petrol 40 and now it looks better.

It was clear to me that your left-hand light wasn't fitted as it should be but I simply thought you'd mocked it together roughly for the photo (because it wasn't on the vehicle) and that you hadn't yet seriously/securely fitted the lights into the bib. (So my comment was "tongue-in-cheek".)

Nice to find that I actually identified a real problem ... although I'm sure you would have noticed before getting it on the road.

BTW... I love your thread here as I'm sure I've said before.

 

[TCSTARK]

I spent a few hours in the garage getting the tub ready for the June deadline. Added rivnuts to secure the tailgate, mounted the fender flares and cut out the opening for the fuel inlet. I will be drilling holes for rivets in the fuel inlet housing then sending it off to be powder coated.

I will be using the primary inlet location for a flaming river cut off switch and the auxiliary location will be used to fill the rear tank.

 

[TCSTARK]

I spent the last two weekends getting the fenders, bib and hood installed.

 

[TCSTARK]

Since I could not use the stock limiters without major cutting I mocked up some door limiters from GA Mountain Cord. They are commonly used on jeeps but I said what the heck... They look good and perform as expected.

 

[OGBeno]

I gotta come up and see this thing. You are in my proverbial neighborhood.

 

[TCSTARK]

It's starting to look like a 40...

The auxiliary fuel inlet has been mocked up but it looks slightly crooked. I need to straighten up the fiberglass opening and add some nutserts so I can bolt it up.

 

[TCSTARK]

I received my steering shaft firewall bracket from BTP this week and realized the hole pattern was different. The PO had used the later model 4 bolt pattern firewall mount. I filled and sanded the holes, filed down the hole to give it a good shape and mounted the BTB mount. It looked ugly so I grabbed an old 3 hole pattern mount and cut it up to make a face plate to cover the gaping hole. It will need to be sandblasted and powdercoated but it looks pretty good.

I also mounted the radiator and battery tray so I have less parts to haul to Trollhole's shop this month. Next up is the dash panel and dash pad retainer clip.