Builds 1978 FJ40 Mustard Yellow - almost perfect thread.

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Put a coat of paint on the tank first off so it will be somewhat dry when I install it.
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I added the swingout in the 4Plus carrier and installed the tire.
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Passenger side Amby door installed with the hinge that was used to match the powder coat.
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New weatherstrip on these doors makes all the difference in the world. The thing closes like a coffin now. Add the rattle free spare carrier that makes it where the spare does not stick out beyond the tub and you have solid money.

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One of the biggest complaints I have about these old trucks is how damn hot they are inside with the top and doors on.
I added a fresh tcase inner boot and lined all the places that can’t be seen under the fuel tank and City Racer mat with Noico.

Top of tank will get some Noico as well to cut down on any fuel Pump noise.

All the drain plugs are reopened. This truck will live inside and John will be reminded to keep it nice and dry under here. There was no active rust so it should do him great for noise and heat

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The drivers side has a little more rust. I gave everything a good soaking with Rust Converter and left the rusted areas without Noico. Before I put the mat back I hoses the old rust with Fluid Film and covered.

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The drivers side has a little more rust. I gave everything a good soaking with Rust Converter and left the rusted areas without Noico. Before I put the mat back I hoses the old rust with Fluid Film and covered.

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Really enjoying watching this build and all the details. Considering the same tire and wheel combination as you put on this vehicle how different is the ride with those wheels and tires versus the 16 inch? Just kind of curious before I make the decision To buy?
 
Really enjoying watching this build and all the details. Considering the same tire and wheel combination as you put on this vehicle how different is the ride with those wheels and tires versus the 16 inch? Just kind of curious before I make the decision To buy?

These are 16”

I’ve not driven this one yet but I went from 33x10.50-15 KM3 to these 255/85-16 on my FJ-60 and they gave me about a 300 rpm reduction on the road due to being 2 full inches taller. I’m sold on the size.
 
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In-tank pump setups, while very nice and reliable and hopefully, quiet, are extremely labor intensive. Bear that in mind if you go this route.
I found some purple Sniper wire and was able to tie in the pump using the proper Sniper color.
These new crimpers I got are $$. Love them.
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In and working. I’m waiting on a new fill hose to add gas and prime it.
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The harmonic property of these tank covers can me reduced greatly with a barrier. Factory uses some cloth type strips. The fuel pump will likey need more.
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I ended up cutting the entire area where the weld in plate was out of the cover because I did not want anything associated with the pump to hit the cover and produce noise
 
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Next I broke out the 4Plus rear swingout and spent an hour drilling and installing the lower section. Sadly, I got the correct lower and the incorrect upper so I’ll have to wait to finish it up. The rest of the hardware is installed so it will be a 10 minute install once the correct swingout arrives.

New OEM reflectors. Cleaned up an old trailer harness while I was back there.

These little simple swing outs are on everything build. They get rid of all the annoying rattles in the back and really support a heavy 33” tire nicely. I even adapted one to work on my Pig.

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Is the 4Plus rear swingout bolting to the rear bumper/frame only, or utilizing a portion of the factory spare mounts?

I hate how much an oversized tire sticks out on the factory setup. This looks like it could be a good option.
 
Is the 4Plus rear swingout bolting to the rear bumper/frame only, or utilizing a portion of the factory spare mounts?

I hate how much an oversized tire sticks out on the factory setup. This looks like it could be a good option.

It is the 4 stock trailer hitch bolts and you drill 4 more in the frame.
I run them in my personal rigs and man. They never rattle. Always work. Simple. Takes all the strsss off the body
 
These are 16”

I’ve not driven this one yet but I went from 33x10.50-15 KM3 to these 255/85-16 on my FJ-60 and they gave me about a 300 rpm reduction on the road due to being 2 full inches taller. I’m sold on the size.
My sausage fingers got in the way. I have the same 15” set up you had. My tires about 10 years old so as I think about replacing I’m thinking about the 16” option. While I know these things don’t ride like a Cadillac I was looking for some first hand experience on ride, steering, etc characteristics by going to 16” with these tires. I like the look just wondered if any road improvement
Thx
 
I finally limped out of the shop. So much progress.

My buddy Mike @Cruiser Corps hooked me up with 3 proper air cleaner nuts and the fuel evaporator.
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These high pressure fuel systems send a ton of fuel through the tank Sure, it will work without the evaporator and charcoal canister like to arrived here, but you are basically riding around on a bomb. Fuel fumes and tank pressures are not something to play with, especially here in the south.
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All new hoses are on. I am waiting on a new large fill hose. The one on the truck is as hard as a rock.

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I bent the console back toward its normal position. Most all are bent behind the box part from people stepping on them. This one was that way

I also remounted the ECU display where it can be seen when driving with a suction mount on the dash.
 

Deploying the last of the @SMG pins.

The doors are tight. This is a bit more difficult than the others I’ve installed because the door is HEAVY.

I highly recommend anything he sells.

*tip...:

Install bushings, add your loctite to the bottom screw on the stainless pin and tap it up from the bottom.

I’m thinking the best way to remove them will be to loosen the top and lightly tap the pin down until you can get a grip on it and then pull it out from the bottom

Also replaced the gold bolts in the door with SS
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Top Shelf !

the JIS SEMS rocks and looks so timeless too .....
 
Great thread with lots of pictures! Thanks for posting so much.

In an earlier post about heat getting in the cabin: I put a flashlight in the cab, turned out all the lights in the garage, and crawled under the 40 and looked for light leaking through. Amazing how many holes I had in the firewall and tranny cover. Sealing them really helped.
 

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