Builds 1979 FJ40 Old School Overhaul

Discussion in '40- & 55-Series Tech' started by oldschool4wheeling, Nov 13, 2016.

  1. oldschool4wheeling

    oldschool4wheeling GOLD Star

    Messages:
    1,065
    Likes Received:
    2,320
    Joined:
    Mar 15, 2014
    Location:
    Nashville, TN
    Hello everyone, here is my story and my 40's story. I saw my first FJ40 in 2012, and absolutely fell in LOVE with it. I know, I know where had I been, living under a rock some where??

    Well needless to say after a relentless search I found my baby. An unmolested well slightly molested 1979 FJ40 with premium up grades: 2.5 inch Old Man Emu lift, OME shocks, Warn 8274 with synthetic rope, Hell For Stout Bumper, Safari Snorkel, ARB air lockers front and rear and a set of Goodyear Wrangler MT/R tires, Halogen head lights.

    This thread is to document this trucks "Overhaul" and all the trials and tribulations that go along with restoring a FJ40 Toyota Land Cruiser for the future.

    20150309_161022.jpg
     
    Last edited: Nov 13, 2016
  2. erics

    erics

    Messages:
    1,337
    Likes Received:
    81
    Joined:
    Nov 1, 2004
    Location:
    Iowa
    nice looking truck... for me "unmolested" is a little strong with the tin piece riveted on the rocker panel - I'd vote for slight molestation there :)

    probably too with the antenna mount drilled into the driver rear quarter panel...

    does look like a pretty clean nice truck though... congrats!
     
    FJ43 1980 likes this.
  3. oldschool4wheeling

    oldschool4wheeling GOLD Star

    Messages:
    1,065
    Likes Received:
    2,320
    Joined:
    Mar 15, 2014
    Location:
    Nashville, TN
    Yeah I agree, slight molestation.....I did forget to mention lots of rust too !!:smokin::smokin::smokin:
     
    DSB345 and 78fj40mg like this.
  4. 78fj40mg

    78fj40mg TLCA #23510

    Messages:
    4,479
    Media:
    1,144
    Albums:
    65
    Likes Received:
    3,704
    Joined:
    Sep 13, 2008
    Location:
    PNW, WA.
    Beautiful truck Doug!! Even if it's slightly molested.:hillbilly:
     
  5. jim land

    jim land SILVER Star

    Messages:
    1,274
    Likes Received:
    1,285
    Joined:
    Aug 6, 2007
    Location:
    scott quebec
    more pics :clap:
     
  6. oldschool4wheeling

    oldschool4wheeling GOLD Star

    Messages:
    1,065
    Likes Received:
    2,320
    Joined:
    Mar 15, 2014
    Location:
    Nashville, TN
    One of the first problems I had was chasing rough and poor idle, dying at stop lights and had starts. After digging around under the hood I found a few issues.

    1. Rust in the fuel filter
    2. Intake/exhaust manifold leaks
    3. Bad emissions components
    4. Bad vacuum hoses
    5. etc etc etc

    Repairs made:

    1. I replaced the gas tank with new one. That was pretty straight forward by unbolting the driveshaft and axle springs and jacking the axle back enough to allow the gas tank to clear and fall to the ground. ( No Pictures..... this was before I got the memo about "It never happened unless we have lots of Pictures") From years of sitting with gas/ethanol bend the tank was full of rust.

    2. Followed @FJ40Jim and his desmog thread and removed everything he said to remove. I also sent him my carburetor and had him rebuild it.

    3. Removed I/E manifold and sent it to machine shop to have it resurfaced and spot faced. (Note: IT IS IMPERATIVE THAT YOUR MANIFOLD GETS SPOT FACED!!....... In short, spot facing levels the surface between the cast iron and aluminum where the head of the bolt rests. And allows for even pressure across the two different surfaces.) As @FJ40Jim said "If your machinist doesn't understand what your asking for then go find another one who does!"

    4. New silicon vacuum hoses and manifold gaskets.
    20141021_193949.jpg

    20141025_124600.jpg
    20141105_175625.jpg
    Notice how shiny it is where the bolts go, the machine shop milled it down level... this is "Spot Facing"
    20141108_141938.jpg
    Putting her back together... I used plenty of Anti-seez and VHT paint for exhaust manifold
     
  7. oldschool4wheeling

    oldschool4wheeling GOLD Star

    Messages:
    1,065
    Likes Received:
    2,320
    Joined:
    Mar 15, 2014
    Location:
    Nashville, TN
    Thanks Mike!!
     
  8. oldschool4wheeling

    oldschool4wheeling GOLD Star

    Messages:
    1,065
    Likes Received:
    2,320
    Joined:
    Mar 15, 2014
    Location:
    Nashville, TN
    While I was under the hood, I noticed how the power steering pump was mounted. Uh... the bracket is under the head bolts. Well call me silly but I cant have that!! Notice pump bracket on front of engine.... geez
    20141022_170301.jpg
    So after removing the air pump. Moved the power steering pump to that location and modified the brackets to make it fit.
     
  9. oldschool4wheeling

    oldschool4wheeling GOLD Star

    Messages:
    1,065
    Likes Received:
    2,320
    Joined:
    Mar 15, 2014
    Location:
    Nashville, TN
    IMG_6795.jpg
    Edit: Found this picture of my fab up p/s bracket.
    20141120_163159.jpg
    20141130_183459.jpg


    20141130_183525.jpg
     
    Last edited: Nov 21, 2016
  10. oldschool4wheeling

    oldschool4wheeling GOLD Star

    Messages:
    1,065
    Likes Received:
    2,320
    Joined:
    Mar 15, 2014
    Location:
    Nashville, TN
    So after being disassemble for a couple of months waiting on parts and figuring out what the hell I was doing. I put everything back together and literally turned the key and she fired right up and idled smoothly. Thanks again to @FJ40Jim.
     
  11. oldschool4wheeling

    oldschool4wheeling GOLD Star

    Messages:
    1,065
    Likes Received:
    2,320
    Joined:
    Mar 15, 2014
    Location:
    Nashville, TN
    Few vanity pics... 20150309_161009.jpg 20150309_161046.jpg
     
    davework, DSB345, 120mm and 9 others like this.
  12. Helipilot

    Helipilot SILVER Star

    Messages:
    614
    Likes Received:
    572
    Joined:
    Feb 23, 2013
    Location:
    Arkansas
    Nice writeup and good looking rig
     
  13. oldschool4wheeling

    oldschool4wheeling GOLD Star

    Messages:
    1,065
    Likes Received:
    2,320
    Joined:
    Mar 15, 2014
    Location:
    Nashville, TN
    My future upgrades include 4 - 100w KC Lites facing forward and 2 - 50w facing to the rear, mounted on a Gobi Roof rack.

    With that being said my little factory 55 amp alternator just is not going to haul the mail.

    So I went to our local guy that rebuilds starters and alternators, Todd's Auto Parts. He said my alternator could be rebuilt, but that it couldn't be BEEFED up to put out more amps.

    He said a Ford Escort alternator looks similar and that with minor modifications would fit. He rebuilt one for me 105 - 110 amps worth.

    The only thing its that my amp gauge would NOT work. I will mount a voltage at some point.

    20151004_140929.jpg
    I had to grind the alternator housing on the bottom so that it would fit inside my factory bracket.
    20151004_140758.jpg
    This is a one wire set up... but I left the factory harness in place
    20151004_140822.jpg
    If I recall, it is a #8 awg wire.....
    20151004_140937.jpg
    I know it isn't perfect.:hillbilly::hillbilly::hillbilly::hillbilly::hillbilly:... but you can do yours better
    20151004_140950.jpg
    But the pulley and belt is square and runs true!!;);)
     
    Last edited: Nov 21, 2016
    DSB345 and Solace in Solitude like this.
  14. oldschool4wheeling

    oldschool4wheeling GOLD Star

    Messages:
    1,065
    Likes Received:
    2,320
    Joined:
    Mar 15, 2014
    Location:
    Nashville, TN
    Thanks..
     
  15. erics

    erics

    Messages:
    1,337
    Likes Received:
    81
    Joined:
    Nov 1, 2004
    Location:
    Iowa
    let the "slight" molestation continue :)

    just giving you grief...
     
    oldschool4wheeling likes this.
  16. oldschool4wheeling

    oldschool4wheeling GOLD Star

    Messages:
    1,065
    Likes Received:
    2,320
    Joined:
    Mar 15, 2014
    Location:
    Nashville, TN
    HAHAHA....."Slight molestation" could be the motto of my build. Cause I really have opened a can worms:worms:.

    Its not quite the BIG CAN of WORMS :worms:like others.
     
  17. oldschool4wheeling

    oldschool4wheeling GOLD Star

    Messages:
    1,065
    Likes Received:
    2,320
    Joined:
    Mar 15, 2014
    Location:
    Nashville, TN
    Speaking of BIG CAN of WORMS, like a frame off restoration...... @Vae Victus ride has been stripped down to every last bolt and he is getting his back together...

    V.V. has been one heck of a great friend. He has pushed me along and gives me support when I need it.

    Rust has become an issue with me and I got to where I couldn't stand to look at. I had to do something. So I checked around and priced panels and fender and floor pans, rocker panels and the labor to install, oh and paint........ uhhhh yeah, hello, over 10g's.....clams, pesos, rubles, franks, pounds, euros.... in just labor alone!!!!! This of course is something I couldn't afford. Cost of steel 2500 claims, paint job 3000 clams.
    All of the sudden I'm at 16,000 clams.... I think you get the picture:crybaby::crybaby::flush::flush:

    Then I thought I had found the deal of the century when I talked to the local Votech College. They said they would love to do the body work on my 40 .... and said bring it on over. And to beat all it would cost me ZERO clams!! :bounce:Yeah, well you know the story, I got some ocean front property in Tennessee for sale. After calling and calling and calling, they just didn't have time to do it. "We have too many projects to do". :bang:
    They were even talking about painting @Vae Victus 40 when it was time, (which that might still happen) but anyway

    I have no experience with anything like "BODY WORK". :( It actually scares the heck out of me. I did not have a welder either so, Im out! I'll just have to live with the rust...

    Well this is where the story takes a left turn. My friend @Vae Victus builds up my confidence and tells me I can do this!! Of course I still don't have a welder... so being the kind of guy he is, lets me borrow one of his welders!!!!

    So Scott, I owe you big!! Thanks ;)
     
  18. oldschool4wheeling

    oldschool4wheeling GOLD Star

    Messages:
    1,065
    Likes Received:
    2,320
    Joined:
    Mar 15, 2014
    Location:
    Nashville, TN
    Here are some rust shots
    20150914_105949.jpg
    20150914_110105.jpg 20150914_110131.jpg 20150914_110207.jpg
    Of course... and all the rust you can't see.
     
  19. Jdc1

    Jdc1 SILVER Star

    Messages:
    2,571
    Likes Received:
    2,899
    Joined:
    Sep 9, 2013
    Location:
    Akron, OH
    VV is right, you can do it. I am in the process of rust repairs on mine. We pulled it out of a shop because they wouldn't give us a price to complete the body and paint. Take it slow, watch a bunch of videos (I like eastwoods) and get started. I was using .030 wire and just switched to .023 and it is alot easier to use.
     
    Cbled56 likes this.
  20. 65swb45

    65swb45 Elder Statesman Supporting Vendor

    Messages:
    23,849
    Likes Received:
    8,625
    Joined:
    Apr 14, 2004
    Location:
    818-953-9230
    Do tell. Please elaborate.
     
  1. This site uses cookies to help personalise content, tailor your experience and to keep you logged in if you register.
    By continuing to use this site, you are consenting to our use of cookies.