Builds 1965 FJ40, What Have I Gotten Myself Into?

[Krondor]

More rust and rot removal...

Cut out and scab on.

 

[Krondor]

Starting to POR 15 the inside.

Inside is complete. Now for the body filler.

Just smoothing out the rough parts.

Next up.... Primer!

 

[Krondor]

I used the U-POL Raptor Primer. Stuff worked pretty nicely.
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[BrianSanDiego]

Dang, that's beautiful! Nice work man!

 

[Krondor]

While I was working on the body. I was also cleaning and rebuilding the engine and drive train. I have not done much more on the body besides install it on the chassis to make sure everything fits. It will probably be another 6 months before I disassemble the body and paint it the final color. If you guys have any suggestions on period correct FST colors, please let me know.


Anyways, here are some pictures of the engine.

The valves look pretty good. Rockers are not rusted, everything freely moves and no rods are bent.

I also pulled the exhaust off to unseized the heat riser flap, clean it up, and clear out any excess carbon build up.

 

[Krondor]

The thermostat may need to be replaced and I have a little build up in the coolant system. Looks like a coolant flush is in order…

Pulled the engine with a little help from my friends. Wasn’t too bad.

So much room for opportunity. Will I replace the engine with a V8 or will I restore the original engine? Stay tuned to find out.

The pilot bearing was shot. You can see some random floating bearings….

 

[Krondor]

I didn’t take any pictures during the wire brushing. But I used an angle grinder, a case of brake cleaner, and a box of wire brushes to clean the old girl up. I then prepped it for paint.

I found a dark blue engine enamel that I though looked nice. It’s not an original Toyota color but I still thought it looked nice.

I glass bead blasted the thermostat housing and cleared it. Rebuilt the mechanical fuel pump and replaced the water pump. I also replaced the front and rear seals.

 

[Krondor]

I didn’t have an earlier picture but I did a pressure test on the engine. The compression in each of the cylinders ranged between 120 and 130 psi. This was with fairly dry rings and no valve adjustment. I figured it was good enough to not rebuild the engine quite yet.

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Exhaust put back on and painted with high temp header paint. A new oil pressure gauge and temperature gauge top off the components. I also installed the bell housing back on.

I knew I wanted to add power steering so I found a press on double pulley harmonic balancer. This thing was a bitch to install…

So so so fresh and so clean.

 

[Krondor]

Figured I should replace the clutch while I was at it. Yes, I did replace the pilot bearing.

Reinstallation.

Back home.

Look at those new spark plug wires and shiny copper vac/ fuel lines.

 

[Krondor]

Since I am adding power steering to the old girl, I had to make a custom alternator relocation bracket. Special thanks to @kevos37 for the idea.

I rebent the tensioning bracket later to prevent rubbing with the radiator hose.

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The power steering pump was next. I used the main bracket provided by Georg @orangefj45

 

[Krondor]

Tensioning Bracket for the power steering pump.

Old Girl is just about ready to start.
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[Krondor]

Next project: Transmission and Transfer case.


Nice and ready for a rebuild.

Pulling everything apart and installing all new bearings and seals.

Messy job but someone’s got to do it.

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I wish I took more pictures but here was the final product. The levers and connecting pieces were repainted later.

 

[Krondor]

Drive Train installed. Next up. Axles and brakes.

 

[Krondor]

Drive Train installed. Next up, axles and brakes. The rear axle came with rear disc brakes installed. They were old and seized so they needed replacing.

 

[Krondor]

 

[SteveH]

Great work and pix.

Be SURE to test-fit the hard top and all the doors before you paint. Body geometry can get jacked during such bodywork as you did.

 

[Martyt]

You are certainly multi-talented. I would not be surprised if your next post starts off with you machining a Vader light, doing a quick carb rebuild and installing a harness— all in one day’s work

 

[pistonpete]

Great thread ! Thank you for the story ! Great work !

 

[Wetlandman]

Nice work! I too spent time is west Africa in my 20s and loved all the cool vintage 4x4s there. I did a frame off CJ7 in my garage and im “starting” a 1967 FJ40 build. Have you picked a color yet? I personally like these two colors

 

[toyotaspeed90]

The thread title is misleading, I think you know what you've gotten yourself into!