Builds 1979 FJ40 Old School Overhaul

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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.

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erics

 
 
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Iowa
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 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.

View attachment 1350984
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!
 
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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.
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Notice how shiny it is where the bolts go, the machine shop milled it down level... this is "Spot Facing"
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Putting her back together... I used plenty of Anti-seez and VHT paint for exhaust manifold
 
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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
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So after removing the air pump. Moved the power steering pump to that location and modified the brackets to make it fit.
 
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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.
 
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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.

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I had to grind the alternator housing on the bottom so that it would fit inside my factory bracket.
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This is a one wire set up... but I left the factory harness in place
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If I recall, it is a #8 awg wire.....
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I know it isn't perfect.:hillbilly::hillbilly::hillbilly::hillbilly::hillbilly:... but you can do yours better
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But the pulley and belt is square and runs true!!;);)
 
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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.
 
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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 ;)
 

Jdc1

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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.
 

65swb45

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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.
Do tell. Please elaborate.
 
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