Builds Mike's 1978 FJ40 Turbo Diesel Refit Project and Cross Country Road Trip! (2 Viewers)

[Godfather90]

@Godfather90

Mike, I tried to PM you, but it said your inbox is full, here is what I tried to send via PM:

I've read your thread twice now and have to say, you have some serious talents! I appreciate folks like you talking the time to document and share as much knowledge as you have.

Funny thing - I live in Temecula, CA, but I'm out in Marlboro, NY for work. I think that you mentioned in your thread that you are from Highland? While I'm out here, I was thinking to source a VW TDI for a swap into one of my FJ40's. I've located an 05 Passat with 140k. Recent timing belt before the trans lost all the fluid and burnt up. I can get it for $1500. Did you end up using much other than the engine? I know you pulled the harness and modified for your use, but said you probably wouldn't do it again, instead just buy an aftermarket harness. Would having the donor car be a huge benefit, or would I be better off just sourcing an engine locally in CA when I get back home (pain in the rear to tow car all the way back across the country or strip it here and take everything home in pieces). The TDI's sure seem to be more prevalent out here than they are back home, so not sure how easily I'd be able to find one.

Thanks for any input you have.

Evan

I am in NY right now actually as well. I live in Newport Beach primarily.

Thank you for your kind words!

As for the car, it all depends on how much you want to re-use. 1500 is a good deal. You can just pull the harness or order one.

The initial quality of an OEM harness is very high, but ordering aftermarket will save you time.

You also need the pedal and a few other odds and ends. Its really up to you.

When you get the engine I suggest changing the camshaft and removing the balance shafts while you have it on a stand. It will be very easy this way for you.


The BHW is getting harder to find. They are harder to find in CA as you say. One thing to check is to see how much corrosion has formed on it since its a NE car. They are fairly resilient but having a bit of rust on the block can be annoying in my opinion.

If you're planning AC than grabbing some components from the Passat isn't a bad idea as well.

We should link up at some point!

Mike

 

[EWheeler]

I am in NY right now actually as well. I live in Newport Beach primarily.

Thank you for your kind words!

As for the car, it all depends on how much you want to re-use. 1500 is a good deal. You can just pull the harness or order one.

The initial quality of an OEM harness is very high, but ordering aftermarket will save you time.

You also need the pedal and a few other odds and ends. Its really up to you.

When you get the engine I suggest changing the camshaft and removing the balance shafts while you have it on a stand. It will be very easy this way for you.


The BHW is getting harder to find. They are harder to find in CA as you say. One thing to check is to see how much corrosion has formed on it since its a NE car. They are fairly resilient but having a bit of rust on the block can be annoying in my opinion.

If you're planning AC than grabbing some components from the Passat isn't a bad idea as well.

We should link up at some point!

Mike

Do you have your cruiser with you in NY, or is it still back in CA? I'm here for another month or two working on the Rondout Tunnel project which is a new aqeduct pipeline under the Hudson. Not sure if you're familiar with that project.

I did some searching on the net, and it looks like I can pick up a BHW donor car back in CA for around $2k engine running but with other issues (seems most of these model cars have trans issues? I've found three that run but wont drive). That's probably a better route for me since I don't have the best resources out here to strip the car before heading back West. How much did you get for your donor after pulling what you needed?

Would love to meet up and do some trails in CA when I return from assignment, but I'm currently fighting an issue on my '77 where it randomly shuts off and won't restart for about 30 mins. It is 350 swapped with an early fuel injection kit from Howell and I can't seem to track down why it is doing what it is doing. As such, I won't take it any further than the local starbucks for a cool morning coffee run until I can nail down my issue.

 

[Godfather90]

Do you have your cruiser with you in NY, or is it still back in CA? I'm here for another month or two working on the Rondout Tunnel project which is a new aqeduct pipeline under the Hudson. Not sure if you're familiar with that project.

I did some searching on the net, and it looks like I can pick up a BHW donor car back in CA for around $2k engine running but with other issues (seems most of these model cars have trans issues? I've found three that run but wont drive). That's probably a better route for me since I don't have the best resources out here to strip the car before heading back West. How much did you get for your donor after pulling what you needed?

Would love to meet up and do some trails in CA when I return from assignment, but I'm currently fighting an issue on my '77 where it randomly shuts off and won't restart for about 30 mins. It is 350 swapped with an early fuel injection kit from Howell and I can't seem to track down why it is doing what it is doing. As such, I won't take it any further than the local starbucks for a cool morning coffee run until I can nail down my issue.

The cruiser is in CA.

Is that similar to the shokan tunnel from years ago? Where they filmed dIe hard haha

I think I paid 1900 for my Passat. It was a s*** box from the city. All beat up but ran beautifully. I put 200 miles on it and the transmission blew up. They are the reason that they are such a good deal.

I sold some quick stuff off the Passat and then someone bought the whole car. I probably got 500 back from all that.

Just make sure you can hear it run before you buy it.

Thanks,

Mike

 

[Godfather90]

So a quick re-cap from the past year:

Built a shroud and mounted up a new power steering cooler:

Re-wired most of the truck:

 

[Godfather90]

Deutsch connectors on everything (ouch):

One of many sub-harnesses:

New ambient lighting:

Added OEM signals and markers (converted to LED):

 

[EWheeler]

Sitting in this truck is like sitting in a NASA space shuttle. Everything has a purpose and is thought out and integrated to the Nth degree of detail. Such a cool 40.

 

[Godfather90]

All the ambers up front are wired for running lights and to get brighter and flash with the blinkers.

I especially like these little round guys beside the grills:

Built exhaust/turbine shields:

Went to SAS5:

 

[mattressking]

Sitting in this truck is like sitting in a NASA space shuttle. Everything has a purpose and is thought out and integrated to the Nth degree of detail. Such a cool 40.

Let’s not forget the ice cold - absolutely frigid ac. While he passes you at 80mph when it’s 100+ in Utah.

 

[Godfather90]

Went to Hungry Valley:

Painted the hubs:

Changed all the rock lights to Amber:

 

[Godfather90]

Added some lock-wire to the bolt that came out at SAS4:

Got some chains:

Went to Big Bear snow wheeling (twice):

 

[Godfather90]

Last time down the hill the brakes felt a bit tired.
Went to the dealer and found the biggest 6 lug rotors in stock:

Much bigger than the FJ62 stuff I had.

I didn't want to make the truck any wider because the tires tuck so well right now and the truck works great for the trails I run:

Spun down the original hubs:

Machined the hubs with a shoulder so the wheel studs would press in flush.

 

[Godfather90]

Got to make this happen somehow:

2" thick plate wasn't cheap:

Starting to look like something:

Closer:

Closer:

 

[Godfather90]

Make another but mirror it and don't make the same side twice :

Boom:

 

[Godfather90]

I shouldn't have painted them but I did:

Back together with all the new bearings ect.:

Went through the rear as well:

 

[Godfather90]

Red is a little flashy:

Oh well.

Back up to Big Bear to give the snow another shot:

Super fun.

Then I had the bright idea to wipe down the dirty headlight with snow:

It didn't like it.

I went to change the oil in the winch and nothing but brown sludge came out. I flushed it and then refilled it. It all leaked out over the next few days. Parts showed up:

 

[Godfather90]

Before messing with that I drilled a hole in my radiator and JB welded it back together in time for Cruiser Summit in Oceanside:

1290 on the ramp.

Super fun event!

Next day was a local Landcruiser meet:

 

[Godfather90]

Time to fix this leak before a long trip Snow Wheeling/Skiing to Mammoth Mountain where it surely will be used:

Started cleaning things up. Wire brush and a lot of elbow grease on the drum:

All cleaned up:

 

[Godfather90]

New headlights while its apart:

Painted the grill:

Sitting pretty:

Added grease fitting while it was apart:

And its all assembled and the drum aligned and back together:

 

[Godfather90]

Time to build another radiator since I drilled a hole in the old one and I cant sleep with a JB weld repair (even though it seemed to work)

Pulled the old junk out:

Making the end-tank:

Built a new shroud and got a new fan mounted up:

Re-mounted the PS reservoir:

 

[Godfather90]

Made a shroud to seal the hood up to the radiator for extra air flow:

While it was apart I put in a hotter thermostat:

No Leaks!

While packing for Mammoth I wound up the winch nice and tight:

My landlord showed up in the middle of this. He was not amused. I finished anyways.

Still no leaks:

Hit the road and made it up to mammoth no issue. Snow wheeling ensued.