1978 FJ40 - Ugly but not too rusty - Refresh Thread

[theglobb]

With my experience, leaves get rusty in 2-3 years. This is whether you buy them new or paint them. If you want a clean underbody look on the springs to match the rest of the new painted axles etc etc, then I'd just coat the leaves in fluid film every now and then. In fact you should probably just be coating everything with fluid film underneath if you don't already. Next best thing for rust prevention besides cutting the cancer out and welding new panels in. I would get around to putting new bushings in at some point though, while you have the leaves already out it cant hurt to paint them. Good luck, love the thread.

 

[draker3838]

My wife was out of town for a long weekend and I thought it would be a very opportune time to get some work done on the cruiser. What I thought would take a couple weekends ended up taking almost three months. The majority of the time put into the project was cleaning up the axle, springs, then waiting for paint to dry before reinstalling. Waiting for parts to arrive took a while too. The bushings I have for my leaf springs are not a standard size for and FJ40 and most sites I was looking at didnt have the specs for the bushings. SOR had the bushings I needed with specs. Anyhow, here's a photo dump from the last three months.

When I got into the knuckle, it was pretty apparent somebody had been in here recently with relatively new grease. The bearings and races looked brand new but I replaced them anyways for peace of mind.

The axle seal was bad and was the primary reason I decided to rebuild the knuckles. Most people on Mud say rebuilding the knuckle is a right of passage, which is true, but I really didnt think it was awful. Setting the axle up high made a big difference.

 

[draker3838]

The Bilstein's are a huge upgrade over the old set of shocks. Firm but not as harsh as the 3/4 ton Dodge.

 

[draker3838]

I also decided to go for the 70 series turn indicators. The fenders were replaced by a PO and they mounted to generic turn indicators to the apron. I decided it would end up being more work to mount the period correct lights on the fenders and fill the holes in the apron. I still need to relocate the hood latches but like the way it turned out. Thanks to @devo for a little coaching. The turn indicator housing wouldnt allow the assembly to sit flush on the apron. Instead of drilling bigger holes, I was able to modify the housing to get it to sit flush.

 

[draker3838]

Took her for a spin today for the first time in three months which felt great. The steering is nice and tight. Still need to get an alignment.

But, onto the brakes. PO had the brakes redone recently. I never had any problems with them and they worked great. After tearing apart the front end, I bled the brakes but now I get a hissing sound when I push the brake pedal with the engine running. Sounds like it could be the booster going out. Honestly the booster looks like crap and I would like to replace it, but I also dont feel like dropping $250 for a new booster. Does anybody have thoughts as to why the booster just now started making this sound? Previously it never made a sound.

 

[draker3838]

Finished up the 70 series turn indicators. I could have mounted the hold down latches a little higher on the hood. I think it turned out pretty nice.

As soon as I wrapped up putting the rig back together, the battery died. 8 years old. The original battery had side terminals as well as top terminals. The new battery only had terminals on top so I decided to replace the battery cable ends and use a military style battery terminal. Nice and easy mod. Cleaned things up too.

Realized I got two negatives. Ill have to have a new one sent but this works for now.

 

[draker3838]

Put it to work with a couple dump runs this weekend. Ill have to get a hitch receiver vs. ball mounted to the bumper but this worked well enough. I picked up this trailer a few years ago for $100. It's an old Ben Hurr, 1943 I believe, and I even have a title for it. Its perfect for working around the yard.

Marvin thinks its about time to chase pheasants.

 

[draker3838]

Last week I was sitting at a stop light and looked down where the center console sat and saw a piece of paper sticking out of the grime. It was an insurance card from 2002 or so. Yesterday I emailed the person hoping to get a response. Later in the day, I received an email and after a little back and forth, Rex confirmed he was the original owner purchasing the vehicle brand new in 1978! Pretty cool. I look forward to getting some more information about the rig but in the meantime, here are some photos he sent.

Original color...

San Rafael swell in southern Utah...

How she looked when it was sold...

I guess the lesson learned here is that if you sell your FJ40 and you want to know where it ends up, stash some contact information under the gas tank so the future owner can contact you!

 

[draker3838]

I've been making up for lost time earlier this summer and have been taking near daily drives. Yesterday, I took a little drive around Hayden Lake and exercised the 4WD up a steep hill. The photos never do hills justice.

Towards the end of he drive, my brakes got really soft. I think my booster may be shot....

 

[Vandal FJ]

That looks great! I need to trailer mine up some time and take that loop with you. I have family in CDA, good excuse! LOL

 

[draker3838]

I'm always up for a drive so let me know when you are coming up! The CDA National Forest is pretty cool with roads everywhere.

We did the Wallace to Clark Fork section of the IDBDR in my wife's 4runner earlier this summer. Lot's of downed trees along the route and pretty remote. Very few other vehicles the whole route.

 

[draker3838]

Well the last year has been devoted to a full house remodel due to a flood in the kitchen but finally gearing up to get back at it with the 40.

I picked up some original wheels from Joe at The Land Cruiser Shop - https://thelandcruisershop.com/ in Sandpoint. Super nice guy.

My sandblaster went out of business apparently so used a new shop. Took them in to get blasted and casually asked for them to be primed as I walked out. Ended up costing $700+. Ouch. I found out the hard way that priming costs the same as powder coating. At this price point I probably would have been better off with new from Toyota. Anyhow, these are now mine. I used Massey Ferguson gray and wrapped them with 33x9.5 Kenda Klever R/T. I really dig the look. Steering was noticeably better over the old 11.5s.

It was good getting her out for a spin before the snow started to fly.

 

[draker3838]

I’m looking for a manageable project over the winter. I picked up these half doors on Craigslist a couple years ago and it became apparent that the guy sold them because they don’t fit well. Or at all.

On the drivers side, you can see that the connected for the limiter strap is too far forward for the door to close.

On the passenger side, you can see that the vertical panel is too far to the rear.

These are probably a South American product. Any words of advice on how to approach correcting this?

 

[draker3838]

Been a while since I’ve updated my thread. I stripped my 40 all the way down and just about have the drivetrain reinstalled.

Question on the transfer case drive gear. It doesn’t quite look lined up with the other gear. Do I have this gear installed backwards?

 

[draker3838]

Here’s a photo of the current status.

Body is going to the blaster in a week or two.

 

[Greek Cruiserhead]

...I picked up this trailer a few years ago for $100. It's an old Ben Hurr, 1943 I believe, and I even have a title for it. Its perfect for working around the yard.
View attachment 3089146
Marvin thinks its about time to chase pheasants.
View attachment 3089147

Sweet puppy Marvin and 1943 Ben Hurr trailer!
Rims and tyres too!
PS. Any thoughts about the great original colour (653 olive brown)?

 

[Jackson Hanes]

Been a while since I’ve updated my thread. I stripped my 40 all the way down and just about have the drivetrain reinstalled.

Question on the transfer case drive gear. It doesn’t quite look lined up with the other gear. Do I have this gear installed backwards? View attachment 3884013View attachment 3884015

Yeah, that smooth machined part is supposed to slide into the seal.

 

[draker3838]

Sweet puppy Marvin and 1943 Ben Hurr trailer!
Rims and tyres too!
PS. Any thoughts about the great original colour (653 olive brown)?

Yes, going back to 653. It’s the right thing to do.

 

[draker3838]

Yeah, that smooth machined part is supposed to slide into the seal.

That’s what my intuition told me after looking at it. Hopefully I didn’t Jack up the seal.

Thanks!

 

[Wasatch Jay]

Great project!

I'm curious how you solved the issues with the half doors?