1974 FJ40 through the Sahara and sand dunes!

[midknightc3]

Just a thought that I think you could adapt to your own application here, though I understand the picture you have of your radio is the entire radio (super cool, I need that thing for my motorcycle!). I put my VHF faceplate to the dash with strong magnets. PO had already drilled a convenient spare hole, but you can probably working wiring however you want. The whole dash is steel, so magnets work great for mounting things and allows for great flexibility +/- the wiring. I will say that I'v found the magnets need to be bolted to the faceplate/radio mount rather than glued (I've used every epoxy I can find, they all fail to hold the magnet despite my being careful about prep).

The extra magnets you see in this next pic are just there as spacers.

Clark

 

[flx]

Just a thought that I think you could adapt to your own application here, though I understand the picture you have of your radio is the entire radio (super cool, I need that thing for my motorcycle!). I put my VHF faceplate to the dash with strong magnets. PO had already drilled a convenient spare hole, but you can probably working wiring however you want. The whole dash is steel, so magnets work great for mounting things and allows for great flexibility +/- the wiring. I will say that I'v found the magnets need to be bolted to the faceplate/radio mount rather than glued (I've used every epoxy I can find, they all fail to hold the magnet despite my being careful about prep).
View attachment 3792733
The extra magnets you see in this next pic are just there as spacers.
View attachment 3792734

Clark

Thanks, yes I just ordered some magnets to bolt them to the provided bracket and see if I can find a better place to install it... The suction cup really need a large flat place. Would try under the dash at the right of the heater.
Oh and your extra hole I'm pretty sure it's factory, I have it also and it had an original Toyota blank on it. Now I have bolted a ram mount ball through this hole and use it for my smartphone holder (very sturdy but anytime I could go unbolt it and put back the blank to look factory).

Another option I'm considering is to install it inside the radio place as I have the blank currently... It's quite smaller so would fit inside and I could just bolt the bracket to the ground bolt there is behind the plate or just tape the VHF someway in there.

Note that the VHF is there only for the trip, I don't have a regular need for it in the FJ40 outside of this specific trip so it will most likely go in the Hiace after Tunisia.

 

[flx]

Today I installed some insulation on the back, hopefully slightly reducing the noise level (and heat). It's a mix of cork and rubber. If I have time I will also try to make a piece for the front and shape it like the original vinyl.

Allows to equalize the level with those annoying body bolts

With the original vinyl back... Yes it's in poor shape

Side benches will go to have more space, but I still need them tomorrow so they are still there for now.

Next step will be to build the platform to have 2 levels of stuff, but before that I test fitted what would go under... I had planned it on paper for a long time but the measurement I had for the rear were wrong, I thought it was larger so I had to rearrange a bit.

Empty space is for my clothes bag, it's slightly too small in this configuration so I have to see what I do there.
Brown tote is for non-refrigerated food + everything to eat (I only need to carry food lor lunches).
The 2 most rearward totes will be for spare parts.
The black&red tote is for my toolbox + my nut&bolts box and a few miscellaneous.

I'm hesitating to drop the vacuum to gain some space, planned to take it to clean the airbox of sand... but as I have succeeded to install a prefilter not sure it's necessary (but I don't know how confident I am that this prefilter install survives the whole trip ).
Note that I won't be able to charge the vacuum battery but I have 4 of those and they are the same than my impact that I take (and spot light and grinder if I have th espace for them).

On top of the platform will go my fridge and my swag.
Left wheel well will have my drinkable water.
Right wheel well may have 2 fuel Jerrycans... hesitating also on those 2 considering it is planned for our guide to carry 140L of extra petrol for me in his pickup. I like the idea to have a little bit of spare fuel on my own but it's a bit of hassle for something not really needed or enough on its own. Would free space for the compressor and vacuum to move out of under the platform.

Table, chair, and flat things like that will go behind the passenger seat vertically.
Recovery gear and Maxtrax will go in the trasheroo on the spare wheel.

And finally I will have a big water bladder at the passenger feet for water used for anything else than drinking (or in backup of the drinking water).

 

[Green Bean]

Looks amazing. Can you specify what your spare parts and nuts/bolts inventory consists of?

 

[MatthewMcD]

Note that I won't be able to charge the vacuum battery

Is there a cigarette lighter (12V or 24V) charger option for the batteries? Even if it takes all day it could save some weight and space.

 

[flx]

Looks amazing. Can you specify what your spare parts and nuts/bolts inventory consists of?

For the nuts & bolts I use an old Toyota Loomwork box, that I reconverted with small plastic boxes inside.
I have 1 plastic box per size M4&M5, M6, M8, M10, 1 for plugs, 1 for wheel nuts & studs, driveline bolts, various clips & hose clamps, a few electrical bits, some carb parts, etc.
All hardware are either OEM or Overland Metric.

For the spare parts I'll have to see what fits in the 2 totes but considering what I usually carry and what I bought specifically for this trip I'm thinking on :
- Paper FSM
- Birfield (1 or 2 depending of available space)
- Complete carb kit
- Wheel bearings front & rear
- 2 U-joints
- Thermostat
- Fuel filter
- Oil filter
- 6 spark plugs
- Points & condenser
- Accessory belt
- Hoses from all classical sizes (vacuum, fuel, small water, big water)
- Flexible brake line
- Various fluids, grease, carb cleaner, etc.

I'm probably forgetting a few things...

I have a brand new spare fuel pump... generally I don't bother carrying for trips but if I find some space for it I may.

 

[flx]

Is there a cigarette lighter (12V or 24V) charger option for the batteries? Even if it takes all day it could save some weight and space.

It exists but I don't have it. As a direct cig lighter for Milwaukee 12V I would have to use the 18V charger which is bulky...
There is also a usb-c topoff for those batteries which I was looking to at some point but couldn't find it in stock in Europe or too expensive so I didn't get it for now.
I could even just bring the AC charger and plan on squatting an inverter from another vehicle if really needed but I really think that it's overkill.

But The 4 batteries I have should be plenty and not much problem to carry, 1 in the vacuum, 1 on the impact, 1 on the spot light and if I take it 1 on the grinder. In case of issue I may be happy to have more than 1 battery for any of those but the probability that I need all of them is very thin...
The vacuum lasts ~12min on 1 battery and even if I need to use it daily to clean the airbox it should be very quick each time just removing the sand accumulated at the bottom.

 

[flx]

Yesterday was wood mission and did not make progress on preparation.

Today I arranged a new setup for the totes, more adapted to the real width of the 40. Compressor and vacuum moved out of under the platform and will go on wheel arch. I'm dropping the 2 fuel jerrycans... There is really no point carrying those around for the entire trip while I have my personal service station following...

And started the creation of the platform.

 

[MatthewMcD]

Yesterday was wood mission and did not make progress on preparation.
View attachment 3794399

Today I arranged a new setup for the totes, more adapted to the real width of the 40. Compressor and vacuum moved out of under the platform and will go on wheel arch. I'm dropping the 2 fuel jerrycans... There is really no point carrying those around for the entire trip while I have my personal service station following...
View attachment 3794401

And started the creation of the platform.
View attachment 3794404

I was going to ask if you should remove the Jump Seats.

I think any time you are "out and about" with purpose, you are preparing.

 

[diesellibrarian]

Birfield: I need at least one, my FJ40 being 10/73 built I need to find a coarse spline birfield... which are non existent in Europe... Will post a classified but if anyone has a correct one (or a pair) and ready to ship to France, I'm interested.

I have one from my 12/71 FJ40 that I will not be using, but I'm sure shipping to France from Canada would be prohibitive. Nevertheless, if you'd like to pursue that, send me a DM.

 

[flx]

I have one from my 12/71 FJ40 that I will not be using, but I'm sure shipping to France from Canada would be prohibitive. Nevertheless, if you'd like to pursue that, send me a DM.

Thanks @diesellibrarian, I actually already found a pair! And yes shipping was expensive

I also found the bracket for the jack rods so I'm all good on the parts side.

 

[flx]

Today progress:

VHF got a new spot, holding with a magnet. Mic holder is simply zip-tied to a ram mount. Very easy to unmount and reinstall (for border crossing).

Finished the platform. It is deliberately shorter than the full length of what I put behind to allow an easier access to the lower floor totes without having to completely remove them from the vehicle.

And a long overdue replacement of the accelerator rod boot. It's theoretically very easy to do but the access to this place requires really small hands

 

[flx]

Not many pictures on the progress today.

Did this cork insulation for the wheel well, it's both to have a little more sound insulation but also have something between the metal and what I'll latch on top.
Did the right side but still need to do left.

You can also notice the new jack rods clip

Otherwise today I did:
- Checked level and topped off engine oil, washer, and radiator
- Wheels rotation
- Fluid filmed the under side (I may encounter salted road on the way to/from the ferry)
- Greased all zergs
- Got the swag tent out and up to check it, air it, and change sleeping bag, pillow and light that I let inside.

Tomorrow I need to fit everything inside and verify everything has a spot and is latched down, fill up the water.
Friday I'm leaving my place with the FJ40.
Saturday I'll board the ferry in Genoa, Italy.
Sunday I'll arrive in Tunis, Tunisia.
Monday I'll arrive in Douz, will be the last civilization for a while (and probably the last network access).
From Tuesday 24/12 I'll be in the desert for 9 consecutive days.

Will try to keep live updates up to Douz (but not sure I will be able to) but from there I will be totally offline so will give news once back.

 

[diesellibrarian]

Je vous souhaite un bon voyage!

 

[MatthewMcD]

Safe travel! Take lots of photos!

 

[RevISK]

Can’t wait for another of your amazing adventures

 

[flx]

Well I think I'm ready to go. Only need to fill the water bladder tomorrow morning.

 

[peesalot]

All that packing, sizing, rethinking, arranging will pay off when the time comes, looks like a great adventure begining.

 

[charliemeyer007]

That's what I tell people Elsie will haul 2 people and hunting camp - don't shoot anything bigger than a few grouse if you are bringing it home. On the other hand I hauled six people and a dog from McCall up to Brundage Ski area. All the skis and poles plus 2 army duffle bags were on the roof rack. We 3 pinned cross country ski from the top back to McCall. 90mph on a 6' wide cat trail - you better know how to ski.

 

[bj70bc]

epic! morocco looked amazing