Build 1978 US Market FJ40 Factory Restoration

[dmaddox]

Hard top sides (installing loosely, so I can align the top when the time comes.)

It helped to run an M6x1.0 tap through all of the holes.

Vent window gaskets:

I have some 1/4" thick weatherproof foam I used on the ends of the rear hard top support rail.

 

[dmaddox]

...continued.

This mess look familiar to anyone?

 

[dmaddox]

Being a home resto in a 1 car garage, I took the hood, hard top sides and a few small pieces to a paint shop. I was tired of battling bugs, dust and other debris and it was critical I get the hood right.

Having issues with the fuel door, and I will likely re-spray it, it came out "too yellow" and sticks out like a sore thumb.

 

[dmaddox]

I have a small list of things still to paint (including the hood hinges you can see in the photos) and a few small areas to touch up. However, I hope to be driving this very soon!

Next, after the top and front end were aligned, I had to re-align the doors. Again, NOT a very fun job.

Vent windows installed:

The old weatherstripping on the windows was so hard, I couldn't get it off the glass! I had to cut it off.

New rubber and cleaned up glass!

New rubber on the corner windows = patience tester! I got to a point I was just laughing at myself trying ot get the corner glass done.

Another mess...

 

[OlYellr]

I can see how many would give up with "close enough",

I’m in that bucket! Just got mine lined up, and resorted to use washers as shims to get it to line up and tighten.

 

[dmaddox]

Hardtop windows installed (thank's honey). Took it for a test drive around the block - no exhaust but still fun!

 

[SteveH]

That's Mustard glory right there. That hood paint job (and the rest) is sexy.

 

[Andrew S]

Dallas, that hood turned out beautiful, especially considering what you started with. A+ on the whole project!

 

[dmaddox]

Thanks fellas!

I’m apprehensive to start gluing in the headliner. I’m prepped and ready to go, but even after laying this out for two hours it has creases in it. I’m not sure if those will smooth out, but I’m not gambling.

Anyone else glue one in like this?

Thanks!

Also, before I glue the headliner in… I hope T.A. And C.C. have had continued love since February 4, 1996. Good to know my cruiser housed some good times.

 

[dmaddox]

Turned out ok!
A couple of small areas that are wrinkly but will hopefully smooth out over time.

Top is dirty from sitting, but will receive a buff and polish when I get to it. Its looking like an FJ40!!

 

[greenEFSI]

Looking good! What brand headliner did you go with?

 

[dmaddox]

I ended up going with the SOR headliner - and I have to say I'm not 100% happy with it. The rear corner geometry was off a bit, and made for a giant hassle in getting them right. I hate resting on a "good enough" solution, but yeah....the SOR headliner is "good enough". I'd have preferred it to be more perfectly contoured to match the curve of the rear hardtop.

Anyway... long story short, I'd give it a 6.5/10.

 

[greenEFSI]

Thanks for the input for sure. I am ordering a ccot headliner today. Hopefully the thick padding covers up any mishaps on my first headliner install lol. BTW that hood looks incredible! Did you sell that aftermarket one you got?

 

[dmaddox]

Thank you! Yes, I sold the hood to a local here on Long Island. It was a win/win. His hood was so rusted, even with the aftermarket one being "off", which I disclosed.

I would think the contour of the rear corners just needs to be right on any headliner. If that is right (which SOR doesn't have right) the rest is pretty easy to install.

Next, I just need to buckle the roof down, build/setup the ambulance doors, build the exhaust, mount the spare tire carrier and go!

 

[dmaddox]

Finishing buttoning down the roof and assembly of the rear doors. I had to scrap aftermarket weatherstrip in lieu of factory. Nothing fits like oem when it comes to weatherstrip. Or hoods. I've paid the price of trying to cut corners and have learned that lesson.

Then, onto the hinges (reading the lower hinges received this rubber stop). I also employed a rubber insulator for the hinge to the body.

 

[dmaddox]

Rear doors fitted and latches adjusted. (I found it easiest to adjust the depth of the latches with the hinges loose, then with the doors closed, I could shimmy the doors square and then snug down the hinges).

Rear license plate frame, new lights and covers:

 

[dmaddox]

Spare tire carrier mounted (with some cut out inner tube as a gasket, I have the cushions yet to install on it) side mirrors and the windshield sprayer "dummy" - as the nozzle on 78's is up on the windshield.

 

[CondeCruiser]

The tire carrier cushion should be there tomorrow through UPS.

 

[red66toy]

Amazing work and attention to detail

 

[Aloha Jen]

Finishing buttoning down the roof and assembly of the rear doors. I had to scrap aftermarket weatherstrip in lieu of factory. Nothing fits like oem when it comes to weatherstrip. Or hoods. I've paid the price of trying to cut corners and have learned that lesson.


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Then, onto the hinges (reading the lower hinges received this rubber stop). I also employed a rubber insulator for the hinge to the body.

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PM me if you have an interest in selling that aftermarket roof/hardtop gasket, I’m in need of one. Thanks! Your 40 build is looking phenomenal by the way!