Builds 1978 FJ40 Crawler Build (1 Viewer)

DangerNoodle

I'm bored
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Divide, Colorado
Everthing but the tub just got finished being blasted, and the tub is going to the blaster today.

I spent a while stripping as much of the bed liner as possible with a wire wheel, as the blaster cannot really get it off without a ton of work.

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Cage coming off.

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Pulling the tub was a bit of the pain, as the backhoe is on a job right now, so we used the skid instead.

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Tub off

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Back to a bare frame.

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DangerNoodle

I'm bored
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The blasting exposed a ton of cheese in the middle of the floor pan by the transmission hump, and overall I was not happly with the quality of the patches I put in earlier, so I decided to properly replace it. The fuel tank I'm building is going to go all the way across the cab, so I am wanting a good, flat surface to mount it on.

The tub started like this today.

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Patch panel made. I decided to go with a bunch of holes to fill instead of butt joints for the panels.

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Replacement rear sill going in.


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Test fit.

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DangerNoodle

I'm bored
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Final fit and partially tacked. I will finish weld the rest tomorrow.

20201016_224201.jpg


Wiring harness finally showed up too, so another project to get started on once everything is painted.

20201016_221943.jpg
 

DangerNoodle

I'm bored
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If your building a fuel tank consider adding the bowl to the floor like factory, that will add a couple more gallons. If you did the bowl on both sides that would add even more.
I can already get about 26 gallons with my old design with a flat floor, and I am moving some stuff around, so I may be able to get about 30 max. I may dish the floor a little, but it makes building the tank a lot more of a pain.
 

DangerNoodle

I'm bored
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I got the cage painted to keep it from rusting in case it needs to stay outside at some point.
20201017_142637.jpg


The transmission hole got cut in and welded.

20201017_222055.jpg


Bottom of the tub got primed.

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I also managed to do this. Not really sure how, but the grinder kicked it back into my finger. Not the most fun thing to pull out.

Wear your gloves.

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Last edited:

rkymtnflyfisher

Big Government Sucks
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I got the cage painted to keep it from rusting in case it needs to stay outside at some point. View attachment 2469382

The transmission hole got cut in and welded.

View attachment 2469383

Bottom of the tub got primed.

View attachment 2469385

View attachment 2469387

I also managed to do this. Not really sure how, but the grider kicked it back into my finger. Not the most fun thing to pull out.

Wear your gloves.

View attachment 2469384
Tis merely a flesh wound, pour some Jameson on it and move along.


In all seriousness, that looks pretty gnarly.
 
Joined
Mar 24, 2002
Messages
538
Location
Calgary AB Canada
 
 
 
 
I used a painless harness when I re-wired my truck, so nice to have each wire tagged the entire length. I re-printed the from/to table and write extra details as I went to help with future troubleshooting.

Wiring harness finally showed up too, so another project to get started on once everything is painted.

View attachment 2467518
 

DangerNoodle

I'm bored
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Divide, Colorado
I used a painless harness when I re-wired my truck, so nice to have each wire tagged the entire length. I re-printed the from/to table and write extra details as I went to help with future troubleshooting.
Did you reuse factory connectors when you did yours?
 
Joined
Mar 24, 2002
Messages
538
Location
Calgary AB Canada
 
 
 
 
Did you reuse factory connectors when you did yours?
I didn't reuse many factory pieces, but where I did, I plucked the Toyota connector off the old harness and added it onto the Painless harness. This would allow me to replace any Toyota parts and have them connect into the harness. I think the only electrical bits I used from the original truck was the steering column and the wiper motor. I didn't re-use any switches, nor the heater.

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DangerNoodle

I'm bored
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Divide, Colorado
I finished up the body work on the tub, so all of the po's hacks are gone.

He completley cut out the mid crossmemember and body mount.

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I had a piece bent to match so I could replace it.

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Tacked in

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I forgot to take some pictures, but that was all spot welded in and the body mount replaced.

I also replaced the rocker panel that he replaced with 20 ga steel. It was wavy, and not very square.

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DangerNoodle

I'm bored
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Divide, Colorado
Lots more getting done, I'm just slow to update.

Lizard skin ceramic coats on. It lays down really nice, but coverage is worse than the sound deadening. The texture really came out nice, with small bumps, kinda like lizard skin :doh:. Its not at all like the rough truck bedliner texture.

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All my front frameside brackets gusseted and finish welded.

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I decided that this needed to go.

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Some good ole CAD. I'm using 2×2 ×1/4 wall square stock. Tube would be stronger, but my little Hazard Freight bender would not be up to the task of bending 1/4 wall, and neither would my arms.

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Bent and gusseted up.

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