1977 FJ40 tub/firewall advice needed, and probably referral for body welding

[RollBar]

Hoping someone may have either advice or a referral, or both… I’m in Fort Collins, CO, and have an October 1977 version of the “1978” FY40. This was apparently the cutover month, as I always have to specify which month when ordering parts… it’s a collection of some 1977 and some 1978 parts. I’m doing a frame-off, and have it down to the frame, with the body ready to lift off. The tub has a lot of rust… more than I know how to fix (or have the tools/setup for). I’ve bought an aftermarket 3/4 tub and (separately) a firewall/cowl that is for a 1978, but it is very different from the 1977… different holes, bracket mounting locations, etc. It’s also missing the mounting plate on driver side air vent for the blower, and missing the attachment “rail” along the top of the dash for the dash pad. So… I either need to find a rust-free 1977 firewall to mate up with the 3/4 tub, or have some work done to the old firewall when I cut it off the old tub, and mate the old firewall to the new tub, which will require some welding of new floor material, etc. If there are any suggestions for someone up here in Northern Colorado (or Denver area) who knows what they’re doing with this kind of work, I’d love a referral!

 

[brian]

Pix of the firewalls.
I didn't think a 77 should be that different from a 78

 

[RollBar]

Here’s what I’ve worked up, comparing old/new. Looking at the differences, one might argue that I could just weld/plug holes that aren’t needed, re-drill new holes where I need them… and I probably could. welding nuts on the backside for mounting would also be good. All of this inquiry is because I just don’t have those skills or that equipment, so my thinking was just find one that’s the same. Pics don’t show rust on inside where it meets the floor, but that would need patching as well (I know there are replacement panels). Anyway… I appreciate the few DMs with suggestions on where to try to find a replacement from the same year, and I’ll look into that. Other option would be get some drilling/welding done, so I’ll keep looking for a local Northern Colorado resource for that. Thanks.

 

[Wasatch Jay]

Here’s what I’ve worked up, comparing old/new. Looking at the differences, one might argue that I could just weld/plug holes that aren’t needed, re-drill new holes where I need them… and I probably could. welding nuts on the backside for mounting would also be good. All of this inquiry is because I just don’t have those skills or that equipment, so my thinking was just find one that’s the same. Pics don’t show rust on inside where it meets the floor, but that would need patching as well (I know there are replacement panels). Anyway… I appreciate the few DMs with suggestions on where to try to find a replacement from the same year, and I’ll look into that. Other option would be get some drilling/welding done, so I’ll keep looking for a local Northern Colorado resource for that. Thanks.View attachment 3979391

I have a July 1978 production FJ40 and the body is all Toyota sheetmetal, and original to this vehicle. You mentioned your replacement tub is aftermarket and if I read your post correctly, your new firewall is as well.

The unfortunate reality is aftermarket sheetmetal has issues. I personally have never dealt with aftermarket tubs or firewalls, but if you do a search on 'Mud you'll find others have fought those battles valiantly.

Comparing my FJ40 to the photos, the clutch master cylinder mounting hole configuration (Number 3) matches the holes in the 1977 firewall pics. The grommet hole (Number 7) is also round, like the 1977. However, the voltage regulator bracket (Number 6) matches the 1978 firewall. The number 9 hole is also similar to the 1977.

My perception is trying to make aftermarket sheetmetal "correct" for a specific period is going to be a lot of work and/or a chunk of money.

Good luck!

 

[RollBar]

I have a July 1978 production FJ40 and the body is all Toyota sheetmetal, and original to this vehicle. You mentioned your replacement tub is aftermarket and if I read your post correctly, your new firewall is as well.

The unfortunate reality is aftermarket sheetmetal has issues. I personally have never dealt with aftermarket tubs or firewalls, but if you do a search on 'Mud you'll find others have fought those battles valiantly.

Comparing my FJ40 to the photos, the clutch master cylinder mounting hole configuration (Number 3) matches the holes in the 1977 firewall pics. The grommet hole (Number 7) is also round, like the 1977. However, the voltage regulator bracket (Number 6) matches the 1978 firewall. The number 9 hole is also similar to the 1977.

My perception is trying to make aftermarket sheetmetal "correct" for a specific period is going to be a lot of work and/or a chunk of money.

Good luck!

Advice much appreciated… The longer I sit with this disconnected tub on top of the frame… eager to “get on with it”, but for sure having similar thoughts about original vs after-market, the more I’m questioning the decision on after-market, of course - after I’ve bought the 3/4 tub and firewall and have them sitting in my garage. The tub has many more issues with rust… rear quarters, rockers, floor pan, and it hasn’t even been blasted yet to remove the very thick coating of rubber spray-on, which will reveal who-knows-what. But perhaps a piece by piece repair of the original, though it may take more time (and somebody else’s hired help)… that’s probably the “right thing to do”. Thanks for the guidance...