1974 FJ40 BUILD "UNTRNABLE" - JUST GET IT GOOD ENOUGH SO THE NEIGHBORS DON'T COMPLAIN

[DOUGNSTEIN]

The "gold" element you found in your carb is a sintered bronze fuel filter. If you threw it away make sure you have a fuel filter before the carb. Where did you find galvanized replacement rear quarters?

I do have a fuel filter before the carb. In that case, maybe I'll look for a replacement filter.

The PO bought the galvanized rear quarters before I got it. He said they were from CoolCruisers.com or manafrelv.com.

 

[DOUGNSTEIN]

Update: The body inside and out along with the wheels are all painted except for the windshield frame. It still needs patched, filled, and painted. I went back over the body with another coat after some additional sanding of uneven spots or rust pits that remained. The metallic paint shows EVERYTHING... I thought the matte finish would help hide a lot of the flaws that were left. I was wrong. I've enjoyed being able to see the garage floor again for the first time in a while. Waiting on new windshield seals and hopefully new windshield glass? In the process of bolting everything up and checking for anything else that needs to be ordered. Baby is coming soon and I think that I'm still on track to have it done for the summer before she gets here.

Current Project Agenda:
-Install fenders
-Install grill
-Install aprons
-Install hood
-Install new bumper
-Install winch channel and winch
-Cleanup old headlight buckets and install new headlights
-Mount passenger seat
-Rework windshield, paint, reinstall
-Cut chain and install tailgate
-Install new running boards when they arrive
-Install dash pad with cover
-Install new horn

Over the summer I will reupholster the seats or buy new seats and rebuild and paint the hardtop and doors.

 

[DOUGNSTEIN]

Just a quick photo update:

update2

• DOUGNSTEIN
• Oct 24, 2017

update3

• DOUGNSTEIN
• Oct 24, 2017

update4

• DOUGNSTEIN
• Oct 24, 2017

update1

• DOUGNSTEIN
• Oct 24, 2017

 

[DOUGNSTEIN]

Front Update: Got the headlights, winch, bumper, etc installed. I decided I didn't want to use the expanded wire mesh for the radiator screen so I've ordered something a little different for that. Stay tuned...

Front 3

• DOUGNSTEIN
• Apr 26, 2017

Front 5

• DOUGNSTEIN
• Apr 26, 2017

 

[Heron]

Looking good, love the silver grey paint.

 

[David70FJ40]

Great progress! You have about 2 months until the Relic Run so better get busier so you can show off the ride then.

 

[DOUGNSTEIN]

Tailgate complete-ish: I used a 520 motorcycle chain cut to length for the tailgate supports. I will need to add some adhesive backed rubber pads between the chain and the tailgate on the inside to keep down the noise when it's closed. The jeep wrangler hood latches seem to provide enough tension to keep the tailgate closed but if I pulled really hard I'm sure the bands would snap but I just won't do that. Early on I considered putting them on the inside so it would provide more tension to keep it closed and security of having them on the inside but I thought this looked cooler. If you missed it earlier, the tailgate is made up of an old metal shelf, some scrap sheet metal, Jeep CJ tailgate hinges welded to bottom, and jeep TJ hood latches. Only thing left on this part is the TRD emblem needs to be installed.

Tailgate 1

• DOUGNSTEIN
• Apr 27, 2017

Tailgate 2

• DOUGNSTEIN
• Apr 27, 2017

Tailgate 3

• DOUGNSTEIN
• Apr 27, 2017

Paint22

• DOUGNSTEIN
• Apr 24, 2017

 

[DOUGNSTEIN]

Great progress! You have about 2 months until the Relic Run so better get busier so you can show off the ride then.

I had to google what that was.. Sounds great. I'll try to make the final push to have it ready by then... or at least good enough to have some fun with!

 

[David70FJ40]

Google Carolina Relic Run. Uwharrie National Forest in June. The thread is in the ONSC club house.

 

[77TLCFJ40]

Genius idea for tailgate chains! I may steal that for my trailer.

Nice work.

 

[REZARF]

Man, that looks great, "What color primer is that!?"

I really like the work you have done. The paint looks more uniform under the lights than the sun, is that how it looks to your eye? Sometimes the camera's we use can be deceiving. Also, the chain idea is friggen' brilliant. I will be stealing that one for sure, I wonder about a nylon sleeving product over the chain like a good quality nylon wire loom?

And I am a little shocked too that the matte/flat finish didn't hide the imperfections a little more. Either way, I think it looks great man, just wait, you'll have the wind in your hair and the pollen in your face soon enough!

Keep it up, congrats on the kiddo.

 

[DOUGNSTEIN]

Man, that looks great, "What color primer is that!?"

I really like the work you have done. The paint looks more uniform under the lights than the sun, is that how it looks to your eye? Sometimes the camera's we use can be deceiving. Also, the chain idea is friggen' brilliant. I will be stealing that one for sure, I wonder about a nylon sleeving product over the chain like a good quality nylon wire loom?

And I am a little shocked too that the matte/flat finish didn't hide the imperfections a little more. Either way, I think it looks great man, just wait, you'll have the wind in your hair and the pollen in your face soon enough!

Keep it up, congrats on the kiddo.

Drew, thanks for the encouragement! Between some of the earlier painted pics and the later pics i did a little sanding of the trouble areas before putting down a final coat. It definitely takes a practice run to see how it shows flaws and it's also drastically different depending on how light or heavy it is sprayed. There is some magic point where it has a really cool texture in the lighter gray but if you go too heavy anywhere it really gets darker and has a smoother less metallic finish. I liked the texture so tried to maintain that throughout by using lighter coats instead of the 2 wet coats that were recommended by the manufacturer. I don't paint for a living as you can see but luckily I think it will be easy to blend when I have to touch it up or repaint.

I've been wanting to incorporate motorcycle chains into something for a while, this just seemed like a good application. I'll have to keep them oiled to not rust but it shouldn't be too bad. Let me know how your's turn out. I have been trying to add small amounts of color (red) into the project and ebay had red chain for something like $12-15 shipped so I went with that.

Little girl is coming in the next few weeks... getting real, fast.

 

[DOUGNSTEIN]

This stage of the project is almost complete. It made a successful appearance at the 2017 Carolina Relic Run in Uwharrie last month thanks to David1947 and did fairly well. Possibly better than expected but still has some work to be done. I still have some issues to work out mostly with carb settings (not wanting to idle on the trail but runs okay on the street), the transfer case wouldn't go into 4-low, and I would love to rip off the drum brake system but that was about it. I picked up a 4" Skyjacker lift this past weekend from a fellow mud member. Will get that cleaned up and installed soon along with some new seats and eventually new tires (maybe wheels).

Relic Run2

• DOUGNSTEIN
• Jul 6, 2017

Relic Run3

• DOUGNSTEIN
• Jul 6, 2017

Relic Run4

• DOUGNSTEIN
• Jul 6, 2017

 

[DOUGNSTEIN]

Installing a 4" Skyjacker Lift with new 2" lift shackles, greasable pins, . The front is mostly complete. Starting on the rear suspension. I'm thinking 33"x12.50 BFG M/T will be the tire to go with unless someone can recommend a more suitable size or tire.

update6

• DOUGNSTEIN
• Oct 24, 2017

update5

• DOUGNSTEIN
• Oct 24, 2017

 

[jamesurq]

looks good. I'm running a 33x10.50xr15 (tall skinny) with factory steel rims and hubcaps. (all available aftermarket and fairly cheap).. I like the look.

 

[77TLCFJ40]

I have a similar lift and I'm running 37s. Go 35x12.50. The 33s will look way out of proportion with that much lift.

 

[DOUGNSTEIN]

I have a similar lift and I'm running 37s. Go 35x12.50. The 33s will look way out of proportion with that much lift.

I was really wanting to go with 35's but from everything I've read indicates that I will have to chop my new rear fenders... If I had realized this before I painted them then I would have resized the openings. I thought about it over the last few months and finally decided it wasn't worth the extra stress of having to hear the tires crush the fenders or rub on the steering linkage. Did you have any of these problems? Do you have cut rear fenders? Power steering? Other thoughts?

Thanks

 

[77TLCFJ40]

Yes. My rear fenders are cut with flares added. I also have Saginaw PS. I previously had mini truck PS when I had 33 x 10.50s and it was plenty of assist.

If you don't want to cut the rear fenders, then a tire width of 12.50 is not advised. Maybe the 4" springs and +2" shackles will provide enough clearance to keep the wide tires out of the new fenders. How it will look is another thing entirely.

If you plan to keep the rear fenders factory, I'd go with a 33x10.50. 2.5" springs is plenty of lift for 33 x 10.50 and 2.5" springs ride better than 4" in my opinion.

 

[DOUGNSTEIN]

I finally got the lift complete and new tires installed. Went with 33x12.50R15 BFG MT and so far so good. I'm happy with the appearance and the stance and so far no rubbing. A little bit of driveline vibration so I'll be looking at that next. I assume it's a big reason not to go over 4" lift so it was a little expected I guess. Engine still hesitates a little but around 2K RPM or so when accelerating. Refinishing the hardtop will be next big project for this. Maybe the hardtop will be complete in time for Summer!

FJ40 COMPLETE-ISH 1

• DOUGNSTEIN
• Dec 28, 2017

FJ40 COMPLETE-ISH 2

• DOUGNSTEIN
• Dec 28, 2017

FJ40 COMPLETE-ISH 3

• DOUGNSTEIN
• Dec 28, 2017

 

[greenbeasty]

That is a nice build, and a great writeup.
Thanks for sharing.