Builds 1969 FJ40 named Mavis (1 Viewer)

[120mm]

Ground down the generations of booger welds and additional bolts to return the bumper to stock ish configuration. Drilled out and tapped the bumperette bolt holes and slopped some black to inhibit rust. Also did a rattle can restore on the bumperettes and spare tire latch.

 

[120mm]

Miserable hot day progress

Real Steel sill wasn't perfect, but I cut a small section and it fit just fine

 

[120mm]

The real steel sill isn't perfect. The spare tire carrier latch captive nuts we're off by a skosh, but I made it fit by drilling outsized holes on the latch assembly which allowed me to "just" get the bolts in. I've snapped bolts off using this chicanery before but lucked out this time. I'd almost rather they leave the captive nuts off and let the owner use their own captive nuts solution.

The big surprise with putting the bumperettes back on is how much they "shrunk" off the bumpers. Had to put some force on them to expand them back to fit.

 

[120mm]

I was surfing Facebook while having dinner tonight and found someone in town who was parting out a 1970. Had a beautiful correct hood. All it's missing is the ornament. Now to find one of those.

Dude also has the engine/transmission/transaxle for sale in case anyone is looking.

 

[120mm]

Mounted the hood and have to say it looks much better. Just need another section of washer hose to get the dual washer system working.

I now have an excessive amount of spare FJ40 parts and would like to see them go to a new home. A late model hood, restorable radiator and gas tank are the largest bits. I could see them going away for cheap.

 

[120mm]

Finally got around to mounting the troop seats, complete with the new mounting legs.

I don't know if this is normal, but there is only a mild resemblance of symmetry between the two seats. Still, made them fit and it works great.

Also fixed the rear heater and installed it to get it out from underfoot

 

[Green Bean]

Finally got around to mounting the troop seats, complete with the new mounting legs.

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I don't know if this is normal, but there is only a mild resemblance of symmetry between the two seats. Still, made them fit and it works great.View attachment 3414456
Also fixed the rear heater and installed it to get it out from underfoot

Nice! I have a set of Dave’s jump seat supports inbound. Hoping to do the install without removing the seats.

 

[120mm]

Nice! I have a set of Dave’s jump seat supports inbound. Hoping to do the install without removing the seats.

No need to remove the seats. In fact, it's better if you leave them installed. I made sure to mount them so they don't land on a raised bead.

 

[120mm]

Any clever suggestions on plugging all these holes? I know I can cut a bunch of metal discs and weld them in, but am wondering if anyone else has ideas on an easy fix for plugging them.

 

[pb4ugo]

Button head socket cap screws. Or, Can you weld them up with a mig then grind the welds down?

 

[rkymtnflyfisher]

I'm currently searching for similar solutions to various holes in my floorboards.

 

[120mm]

I'm going to put some rubber caps in them for now. Will eventually plug and weld them, but not today.

 

[120mm]

I'd ordered some soft top twists from SOR on the 16th, and as I usually get SOR orders fast enough that I can't use tracking, I realized I still hadn't received this order. Checked the tracking number and discovered the package from SOR has been traveling back and forth from Nashville to Pleasant view 18 times and counting. I'm sure the hard working and efficient workers of the USPS will get this package to me someday.

 

[royal cake]

I'm currently searching for similar solutions to various holes in my floorboards.

Yeah for small holes I went the mig route with a copper backer, for larger had to cut some metal to just fit into the ID. I still forgot a few holes...
I also chose not to do bodywork on the interior floor board so where I welded isn't the cleanest

 

[120mm]

Fixed the holes in a temporary fashion.

 

[120mm]

Then the FedEx truck showed up with a lovely package from Medellin.

 

[Roastchestnuts]

Then the FedEx truck showed up with a lovely package from Medellin.

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Dude! I looks sooo good!!!! I gotta get on that soon.

 

[120mm]

Took 10 days off to sail up the Columbia and Snake rivers. Mostly enjoyed it, but would've rather been doing the driving myself. Realized how much I despise being on someone else's schedule.

Got back to work on Mavis, and now have a fully operational FST.

Only found one kinda sorta serious flaw. This seam is single stitched and not sealed, but will reinforce it and leak proof it using a tent kit.

Overall I think it's worth the price, but like others, I checked the supplies hardware and bought my own from SOR/OEM.

 

[Thechief86]

Looks great man! We need to modify your hinges so it's easy to yank the doors off on hot days!

 

[120mm]

(Insert bad words here)
Just learned something about 40s. Something called a "center arm." Mine is apparently shot and from a bit of research, they look like a PITA.