Build 1979 FJ40 Old School Overhaul

[oldschool4wheeling]

I'm reusing the body mounts.. They are held on by a Phillipshead screw that I had to drill out.

 

[oldschool4wheeling]

 

[oldschool4wheeling]

Cleaned up spot welds at front of bed

 

[oldschool4wheeling]

Got another shipment from @beno ... thank you !!

 

[oldschool4wheeling]

In between all my projects "chores" I noticed antifreeze leaking into the floor board. The leak was from the rear heater lines at attach at the fire wall.

I decided to dig a little deeper and you'll never guess what I found.

MORE RUST!!!

 

[oldschool4wheeling]

Transfered all hardware and brackets to new bed pan.

First where the body mounts.

I put the bushings in my drill press to cut the rubber so I could install a bolt in the bushing.

 

[oldschool4wheeling]

The rear ones install nicely.

The front ones not so easy... I had to cut and weld the front cross member because the body bushings set 3 inches from the edge.

I like to use a lot of antiseeze!!!

 

[oldschool4wheeling]

One more

 

[oldschool4wheeling]

The other brackets welded on.

1. Gas tank
2. Evap hard lines
3. Muffler heat shield
4. Gas tank access cover nuts
5. Rear heater nuts

 

[oldschool4wheeling]

To help weld it all up.

I drilled holes every 2 inches along the front and rear.

When I do get ready to spot weld I will be able to access everything going from the top.

 

[want2wheel]

Keep up the great work.

 

[kiley7483]

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.

What kind of steering gear box are u using. I am trying to swap mine to power steering I pit 350 in it so I already have a good pump. But not really sure where to go from here. Definitely the Least expensive way. If u have any info I could sure use it. Nice 40 by the way love it.

 

[oldschool4wheeling]

What kind of steering gear box are u using. I am trying to swap mine to power steering I pit 350 in it so I already have a good pump. But not really sure where to go from here. Definitely the Least expensive way. If u have any info I could sure use it. Nice 40 by the way love it.

Thanks for the kind words Kiley. My power steering was already on my rig when I bought it. Being that it still works, I don't know much about it.

One thing I did not like about it was the pump bracket was mounted under the head bolts. So I made a new bracket and installed it where the smog pump went.

 

[oldschool4wheeling]

Rhetorical question, but am I the only one who HATES broken bolts!!! Damn aggravating!!!! And of course not to mention getting out the rest of the bolt.

Many moons ago, we'll let's say mmmm over 20 years ago, our mechanic showed me a trick. He welded a nut on the end of the broken bolt!! By gosh it worked like a charm, for him anyway!

It only took me about 10 tries, then sucess

 

[oldschool4wheeling]

Cleaned up back half of frame... for some POR 15.

 

[oldschool4wheeling]

POR 15

Wanted to paint as much as possible while I still could access everything.

This is what ya get when you don't do a frame off restoration!

 

[oldschool4wheeling]

If fixing the 40 was as easy as ordering parts...

Well anyway I got some stuff today!

 

[oldschool4wheeling]

Welded a patch on the passenger fender where it was spot welded to the bed pan.

Mounted bump stops on frame. ( Just noticed I put them on backwards.. I change them tomorrow. )

Mounted the shocks.

Used some lithium grease on shock mount.. and LOTS of anti-seize everywhere else.

 

[oldschool4wheeling]

I have read that some people are reluctant to drill holes in their new quarter panels.

Well, I'm not one of them.

Had to make sure my rig was properly branded!!!

 

[oldschool4wheeling]

I also cleaned up passenger floor board looking for more rust. And I was pleasantly surprised!! I have some work to do, but it was in pretty good shape.