Build 1978 US Market FJ40 Factory Restoration

[dmaddox]

With several emails and PM's with photos and measurements. I have a close reproduction of the tar floor pads.

Again, I am using EVERCOAT 100117. It is one millimeter thinner than factory. Do not accidentally buy 100116, which is a vastly different product which I'll document here. Photo's from the sale of @b.crush-a-lot 78 FJ40:

And another's:

I started to work with a chunk of cardboard.

I used painter's tape in areas I cut off too much cardboard.

Finished Driver template:

I did the same thing on the passenger side:

Side by side templates.

 

[dmaddox]

Here is the photos that really helped me with the passenger side:

I then set out to trace the driver template.

Recall I mentioned EVERCOAT 100117, here is the comparison of an accidentally ordered 100116.

Thickness is key:

Yes, that is my fuzzy house slipper.

I then scuffed the floor - as I will be repainting mustard over the tar pads similar to factory.

Cutting out the template with an exacto knife - a bit of a pain, as this tar is pretty heavy duty.

 

[Green Bean]

Here is the photos that really helped me with the passenger side:

View attachment 3177666


View attachment 3177667

I then set out to trace the driver template.

View attachment 3177668

View attachment 3177669

Recall I mentioned EVERCOAT 100117, here is the comparison of an accidentally ordered 100116.

View attachment 3177670

Thickness is key:

View attachment 3177671

Yes, that is my fuzzy house slipper.

I then scuffed the floor - as I will be repainting mustard over the tar pads similar to factory.

View attachment 3177672

Cutting out the template with an exacto knife - a bit of a pain, as this tar is pretty heavy duty.

View attachment 3177674

View attachment 3177673Nice work

Nice work!

 

[dmaddox]

I got the top portion a bit too hot, but when it cools down I'll level it out a bit. I wanted to make sure I not only got a good bond, but that is clung to the factory ribbing in the body work.

I'll work on the passenger side next, but I wanted to share measurements for anyone wanting to do this (probably not, I'm the only nut trying to go back to 1978).

Also, if someone were to want to borrow my templates, I'd be happy to toss them in the mail for you/the community.

Head to toe, about 26.75"

 

[dmaddox]

Not great, not bad - but it still feels good to get that added in there! When its covered in mustard it should look better.

 

[dmaddox]

if i could find some fencing or maybe some chicken wire to make that factory imprint...I'd be the coolest cat in Tar Village.

 

[ToyotaMatt]

when i was a teenager in the 1990's Mr. Dallas ,

In the VIETNAM Hot HOT Summer's here in Maryland , that OEM black Tar would stick to my bare feet !

The BOTTOM of the PEM Rubber Floor MAT would make a Cored-Roy pattern in it , like stripes .




Your box was dropped off and intake scanned today at USPS


thanks

matt ....

 

[waiting for time]

Thanks for your pics an measurement info.
Just a tip for others going the same route, rough cit the card board and use a block with sandpaper to finish the edges.
Leave a bit extra for the ridges, it will stretch into them but this will make the material thinner.
For the extra mile, use a small rubber roller and cut some imprints in the rubber to generate a patern, heat the sheet and press roll it to the floor while creating the patern.

 

[dmaddox]

Good tip, add some space for the ridges. A rubber roller or roller of any kind would be tough, as this stuff gets sticky. I ended up using a 2.5” chunk of exhaust pipe lightly coated with a little dielectric grease on the bottom half. You can see the difference.
I’ll do the same on the passenger for a cleaner install.

Great tips and ideas!

 

[cruisermatt]

Outstanding

 

[dmaddox]

Been busy with the holidays but was able to wrap up the tar project. Next will be repainting the floor as well as other body parts when the weather turns. Side note, the SOR transmission cover gasket kit is great.

I took my time on the passenger side and used the heat gun and a small piece of pipe to roll in and around the corrugated areas. It turned out much cleaner.

 

[waiting for time]

Looks great.

 

[RevISK]

Amazing.
following…

 

[Goldbug]

Any updates? Inquiring minds…

 

[dmaddox]

Work over the last month or so. I've finished the tar mat flooring, body work on the doors and fenders, and a few other pieces. Having a free day land on a perfect weather day between 75 and 80 degrees with no wind and bugs is difficult. Wrapping things up for some more base coat:

Even though this is PPG paint, the yellow doesn't cover well and requires more coats than the park lady on home alone 2.

A nice dusting of mustard on my eyebrows, eyelashes and hair.

 

[dmaddox]

Next, clear and wet sanding and some assembly (photos stretch over a few days)

 

[dmaddox]

More assembly and wet sanding.

Starting in on the bezel work. I had to strip the headlight housings. The amount of detail work is just adding so much time.

 

[dmaddox]

I'm waiting on a few things in the mail to finish the bib, but getting close. I also had to strip the grill, prime and paint. That was a hassle!

 

[Malleus]

Simply inspirational!

 

[Malleus]

...and gorgeous