Builds 1977 FJ40 Build Thread (1 Viewer)

[brianrb100]

The small bracket holds the windshield wash fluid resovoir. It bolts on drivers side fender down near firewall.

The longer piece almost looks like a windshield to roof header. If so, it is held up inside front of roof using rivets. It bolts to windshield. Perhaps a picture from different angle might help.

Thanks! You're correct about the longer piece.

 

[Tlb]

Thanks! You're correct about the longer piece.

 

[Tlb]

What size battery should I use for fj40. The battery in there now is too long. Overhangs battery tray buy 2 or 3 inches. Optima battery fits but not suite what type, red top blue top

 

[brianrb100]

TLB is my dad. Additional to what he's asking, can someone post some pictures of the braces that mount between the A and B pillars over the windows? We can't figure out how they attach. I have two small angle brackets, which I believe mount to the windshield, but we can't figure out how the bolt to the B pillar. We're trying to get the hard top on today.

 

[brianrb100]

I'm also missing the rear gussets. Does anyone have a source for them?

 

[thebigredrocker]

I have seen quite a few posts about Optima's not living up to expectations. One explanation I dredged up elsewhere, is when Johnson Controls was bought out "bean counters" sourced cheap guts from Mexico. Have read lots of good on the Odyssey batteries. For just a regular lead acid battery I've heard Deka still uses quality lead plates.

On the front door headers. The L brackets are for the windshield. The headers are 2 piece, slide them apart and screw to the hardtop. Don't recall any screw that goes from header to b pillar. Could be wrong tho.

I can take pics of how to separate front headers if needed.

You can post up a wanted add for rear header gussets in classifieds. @65swb45 probably has gussets in stock at Marks Off Road.

 

[brianrb100]

I have seen quite a few posts about Optima's not living up to expectations. One explanation I dredged up elsewhere, is when Johnson Controls was bought out "bean counters" sourced cheap guts from Mexico. Have read lots of good on the Odyssey batteries. For just a regular lead acid battery I've heard Deka still uses quality lead plates.

On the front door headers. The L brackets are for the windshield. The headers are 2 piece, slide them apart and screw to the hardtop. Don't recall any screw that goes from header to b pillar. Could be wrong tho.

I can take pics of how to separate front headers if needed.

You can post up a wanted add for rear header gussets in classifieds. @65swb45 probably has gussets in stock at Marks Off Road.

Please post some pictures of the door headers.

 

[brianrb100]

I have seen quite a few posts about Optima's not living up to expectations. One explanation I dredged up elsewhere, is when Johnson Controls was bought out "bean counters" sourced cheap guts from Mexico. Have read lots of good on the Odyssey batteries. For just a regular lead acid battery I've heard Deka still uses quality lead plates.

On the front door headers. The L brackets are for the windshield. The headers are 2 piece, slide them apart and screw to the hardtop. Don't recall any screw that goes from header to b pillar. Could be wrong tho.

I can take pics of how to separate front headers if needed.

You can post up a wanted add for rear header gussets in classifieds. @65swb45 probably has gussets in stock at Marks Off Road.

Here's my door headers and bracket. I have two of each.

 

[65swb45]

Thanks for the ping Mark. I’ve got a box of those at the shop. But I don’t think the OP wants to wait until August for them.
I
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[brianrb100]

Thanks for the ping Mark. I’ve got a box of those at the shop. But I don’t think the OP wants to wait until August for them.

When in August could you have them to me and how much are they?

Brian

 

[thebigredrocker]

Pictured is passenger side header, I think
arrowed are the holes used to secure header to roof drip rail/frame.

To separate, squeeze or compress the lower half. It is thinner metal and has some give. You may need to tap to break free the lower halfs lip from the slot. Then pry and squeeze. I would add some light oil to both seams.

Contour where lower half fits upper half.

 

[tls3601]

Congrats on the rig, what a beauty! Outstanding starting point. Big fan of Sky Blue

 

[brianrb100]

I'm making progress, but found a few more brackets in my box of parts. I have no idea what these are. Can anyone help?

 

[grich575]

Those look like the cover plates that go over the filler for the gas tank when it’s under the passenger seat.

 

[grich575]

Mine are no longer installed but I set them in place so you can see how they go

 

[tls3601]

I'm making progress, but found a few more brackets in my box of parts. I have no idea what these are. Can anyone help?

Shroud that covers fuel seperator as previously mentioned. Should be factory Pewter color like ashtray and glove box door FWIW. Nice work!

View attachment 2034073

 

[brianrb100]

What is the function of the fuel separator? I have it, but it's not installed.

 

[thebigredrocker]

Here are a few informative posts from the owner of TLC Performance of Lancaster, OH

That's the fuel vapor separator (black plastic thingy w/ 4 hoses). The three bottom hoses are vapor from the top of the tank. The single hose off the top, going through a check valve, down through the floor, goes up front to the canister.

The feed and return are on the driver side of the tank and go down through the floor together.

Any vehicle will run without the separator.
But it provides a way for the fuel tank to exhale/inhale when operated off angle.

Put a breather filter in the end of the line up high in the engine bay and be done.

Correct, it doesn't matter what order, just that the 3 tank vent hoses go to the 3 bottom fittings, and vent line to engine bay comes off top.

 

[emac]

This may help:

 

[Tlb]

I have a few electrical questions.
1. Ammeter is reading just below center mark on Gage. This says battery is discharging. Brand new battery.
2. Intermittent turn signals. Sometimes works sometimes not. Passenger side is dim when working. Could this be bad ground. If ground where would ground be located? Could flasher be bad.