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- #21
I lived at Cubi Pt in 1988 but didn't see much of the country apart from a brief vacation in Baguio. I've been back a few times on dive trips since Mt. Pinatubo erupted. Love diving there, especially Boracay.
1978 FJ40 Stock Restoration – 15 Years Long
- Thread starter unixman
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I lived at Cubi Pt in 1988 but didn't see much of the country apart from a brief vacation in Baguio. I've been back a few times on dive trips since Mt. Pinatubo erupted. Love diving there, especially Boracay.
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- #22
Medium scale...hehehehe...is there such a thing with a '40?
I bet the more you tear down...the more you will tear down...but you really do have an excellent ol' girl to start with! Wish mine was in that good o' shape
Skip
Isn't that the truth? I was initially thinking I could spend $1000 for an inexpensive paint job and be done. I obviously knew nothing about paint and body work. I was not interested in a MAACO-type job and that's why I got the three estimates from other shops. The estimate from the most recommended shop was $3500 and included all the other work I listed. (I'll do the top and doors next year.) As you know, the more you start disassembling things, the more things you find that could be "easily" refurbished. Plus, when you have a good-quality paint job, you can't go putting back things that look 35 years old. Just doesn't look right. That's when I started looking at powder coating other items and my parts list went from about $500 to over $1500 ... and counting.
lol...exactly! It's a bug that gets in your blood, and like ya say...ya just CAN'T put some rusty old something back onto a nice shiny body...that's the main reason I have been putting off doing a 'mild' resto job on mine.
Enjoy it all, and I'm glad you decided to keep it and breath new life back into it!
One day...yes, one day, I'll venture into it...
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- #24
I finally pulled the proverbial trigger and the body shop started on the Cruiser. These pictures are from late May. I stripped the FJ40 down to where I could still safely/legally drive it to the shop and dropped it off.
In retrospect, I wish I'd completely stripped everything I was able to and had a flatbed deliver it to the shop. I learn more and more at each step of this evolution. Note the "Real Steel Cruiser Parts" tailgate being prepped with the rest of the parts. I know it's not OEM, but it seemed to be the most attractive option when the top is off.
In retrospect, I wish I'd completely stripped everything I was able to and had a flatbed deliver it to the shop. I learn more and more at each step of this evolution. Note the "Real Steel Cruiser Parts" tailgate being prepped with the rest of the parts. I know it's not OEM, but it seemed to be the most attractive option when the top is off.
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- #25
Picked up the Cruiser from the body shop. I had them mix up a pint of the new Toyota FJ "Cavalry Blue" with the idea of having a custom color, but it was too gray for my taste. I defaulted to the original 854 Blue. I'm glad I did as nearly everything on her is stock. With the roll bars and seat frames reattached, I can see now that I'm not going to be happy with the mixture of brand-new paint and 35-year-old hardware. Next project is getting the silver/pewter and black items powder coated...
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- #26
Wow, the more you start getting into the smaller stuff, the more you find you "need" to do. I disassembled the rear heater assembly and realized it needed painting. I surfed posts here for weeks to determine the best color code and paint. I finally went with my local powder coater and used a silver-gray that is a very close match to OEM. With that decision, I then "had" to disassemble the instrument cluster as well and get everything (pocket door, ash tray cover, center console, instrument cluster face, seat backs, rear heater, visor mounts, license plate light covers, and fuel filler cover) powder coated together.
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- #27
Now that I'm powder coating the pewter-colored items, I have to powder coat the black items as well. Amongst the numerous black items is the front heater assembly. Disassembling the heater reveals why my heater and defroster only blew out hot dust and disintegrated foam particles. I just can't leave well enough alone and end up disassembling the rear jump seats and front buckets, too.
This awesome I really can't wait to get to this point everything looks great!!
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- #30
Thanks! I'm not an experienced mechanic so I've really enjoyed the smaller-scale projects I feel comfortable with like the heater rebuild, seat recovering, dash knob painting, and other detail items.
Assembling the front heater with the rebuild kit, powder-coated housing, and cleaned core.
I was able to reuse the original foam, but here is the seat with powder-coated frame and new hog rings. I've since discovered that the seat cover is not original, but replacing that is a project for another year.
lol...yep, I knew it would happen
But when you are done (does that ever happen??), you will have a fantastic and beautiful machine to last another 35+ years. She's looking VERY good, and you will know your cruiser inside and out...way to go!!
But when you are done (does that ever happen??), you will have a fantastic and beautiful machine to last another 35+ years. She's looking VERY good, and you will know your cruiser inside and out...way to go!!
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- #32
I think I've finally gotten most of her back together. All of the pewter-colored parts are powder coated as are all of the black items including the rear jump seats frames. I did not paint any plastic parts because I think they're fine as they are; a little sun-lightened but acceptable to me. I like the Real Steel tailgate. Not OEM of course, but looks like it belongs there. Heater rebuild was straightforward and I repainted the lettering. Repainted the lettering on the dash knobs too (didn't get the choke yet).
I've addressed numerous little issues on my TO DO list.
FIXED - Windshield wipers (don't park properly - bad ground)
FIXED - Windshield washer inop (bypassed clogged pipe)
FIXED - Dash light inop (bulb out)
FIXED - Heater box light inop (broken solder connections)
FIXED - Light switch bulb inop (burned out)
FIXED - Seatbelt light inop (burned out)
FIXED - License plate lights inop (bad ground)
FIXED - Water temp gauge inop (replaced bad sending unit)
FIXED - Battery won't hold charge (replaced battery)
FIXED - Turn signal switch inop (broken lever)
I still haven't been able to:
1. find the tool kit tool kit band brackets and clip
2. find someone to replace the webbing on my front seat belts
3. repair the carb fan controller relay.
BTW, the pictures are a little washed out. The bezel is not stark white, it's Dover White and a very close match to the original. The Toyota lettering is Almond.
I've addressed numerous little issues on my TO DO list.
FIXED - Windshield wipers (don't park properly - bad ground)
FIXED - Windshield washer inop (bypassed clogged pipe)
FIXED - Dash light inop (bulb out)
FIXED - Heater box light inop (broken solder connections)
FIXED - Light switch bulb inop (burned out)
FIXED - Seatbelt light inop (burned out)
FIXED - License plate lights inop (bad ground)
FIXED - Water temp gauge inop (replaced bad sending unit)
FIXED - Battery won't hold charge (replaced battery)
FIXED - Turn signal switch inop (broken lever)
I still haven't been able to:
1. find the tool kit tool kit band brackets and clip
2. find someone to replace the webbing on my front seat belts
3. repair the carb fan controller relay.
BTW, the pictures are a little washed out. The bezel is not stark white, it's Dover White and a very close match to the original. The Toyota lettering is Almond.
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- Thread starter
- #33
Here are some interior shots. Almost all of the plastic and vinyl in the Cruiser are in very good condition. My front mat is in very good shape as well for the most part. Dash pad is original and in very good shape, too. Looking for a AM/FM radio for the unmolested radio opening. I know FM wasn't an option in 1978 but I'm not building it for display only. Thought about maybe putting in a Toyota 8-Track.
I have no speakers installed and the stock speaker bracket is missing. Have seen only one for sale on eBay but they wanted way too much. Used my sewing machine skills to make a new transfer care shifter boot from naugahyde.
Anyone see any obvious errors anywhere? Hey, you won't hurt my feelings; maybe I'm just looking for more little projects. Next up is the bumper. I've debated buying an aftermarket one for the Warn 8274, but have decided to go stock. Should be in place by the end of the week.
Any recommendations on who can best replace seatbelt webbing?
I have no speakers installed and the stock speaker bracket is missing. Have seen only one for sale on eBay but they wanted way too much. Used my sewing machine skills to make a new transfer care shifter boot from naugahyde.
Anyone see any obvious errors anywhere? Hey, you won't hurt my feelings; maybe I'm just looking for more little projects. Next up is the bumper. I've debated buying an aftermarket one for the Warn 8274, but have decided to go stock. Should be in place by the end of the week.
Any recommendations on who can best replace seatbelt webbing?
Give me your take on the Real Steel Tailgate. Do have an interior pic? A pic from the top? Is it pretty stout if you push against it?
Cruiser looks great. Is that your original floor mat? Looks super clean. Keep up the good work.
Cruiser looks great. Is that your original floor mat? Looks super clean. Keep up the good work.
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- #36
The inside looks like the outside. It's a pressed panel with a lip on the top. If I could do it again I might have them not attach the mounting "ears" and instead drill it to use my ambulance door hinges. I drilled two holes for the license plate lighting and with new grommets used my original license plate assembly.
View attachment 799310Cruiser looks great. Is that your original floor mat? Looks super clean. Keep up the good work.
Yes, original mat. I spent quite a few hours scrubbing it with a brush and 409. Then a very light mist of Armor All and a cloth. Enough to bring out some shine but not be slippery. Just scored an original cargo mat as well.
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Did you get new straps for your jump seats? If so, where did you get them? I got new ones from SOR 15 years ago, but they are dry rotted now and need replacing, they are no longer available (Toyota parts), so SOR's web site says.
Thanks,
Skip
Thanks,
Skip
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- #38
No, they're the ones that have been on there for the 15 years I've had her. I suspect they're not original, but I don't know.
Thanks, they look OEM, but I doubt they are original...I've had my '78 for 15 years, too, and the originals were toast, but OEM straps were still available then and I replaced them. The years in the sun did a number on them and they are now shredded and broke. Good thing your '40 was in storage all these years! You've really done a super clean build on your baby!
Very impressed. Moar pics please.