1981 FJ40 Restore Project

[johnkappus]

Oh yeah...one other question!

When we were putting in the new driver side floor pan we ended up taking off the catalytic converter...it was all rusted to hell anyway. my question is : should i replace the cat, or can i just build a pipe to reconnect the exhaust? The truck still has all of its smog equipment. I am just wonderring what makes the most sense. Should i buy a new cat? Or run filler pipe?

Thanks!

 

[RattSki]

All those pics sure look familiar Just a quick question, do you have a lift on that at all? I'm rebuilding an 81 myself and I put 4" HellCreek springs on and my drag link now rubs my driver side shock. Looking good so far.

 

[johnkappus]

Thanks Rat!
It's got a standard OME 2.5" lift with HFS anti inversion shackles and 33 x 9.5 BFG AT's

 

[FJ40Jim]

John, it will run fine with no cat.

But a new universal hi-flow cat from summit racing is cheap, will pose zero restriction in the exhaust, and will considerably reduce tailpipe emissions.

 

[johnkappus]

Thanks Jim!

Was going to call you tonight and see what your opinion was...you beat me to it!

 

[RattSki]

I really hate having to get rid of the 4" springs. Do you know if they make an aftermarket pitman arm that might drop the drag link angle? How do you like your Tundra? I have a 2007 and after owning a Chevy, Ford, and Dodge I will never drive anything other than a Tundra again.

 

[johnkappus]

some pics of the progress so far







My body guy is doing a great job. The tub has been painted with a high build primer and he is blocking it out and getting it ready for paint.

He did have to massage a few things on the tub:

1. the holes and captive nuts for the spare tire carrier were off. Actually, the top set of holes were too low...the lower set of holes were missing completely!?!?
So my guy fitted up the top and doors AND the carrier and figured out the placement of everything and THEN he drilled the holes and refitted the captive nuts.

2. the lower corners of the rear door sill did not fit the doors. They were sharp right angles, whereas the corner of the doors is a rounded radius. So my body guy welded a nice curved corner to match the doors.

Ill post a few more pics that will hopefully explain what i'm saying.

 

[johnkappus]

more pics

carrier holes re-done

 

[johnkappus]

door corners rounded off to fit door

(for some reason i cant go back and edit the title of this post?)

i should say the lower outside corners of the TUB needed to be rounded to fit the door


More of a radius than a sharp right angle

 

[johnkappus]

oh yeah and the top....

i didnt realize it, but the PO had riveted the lip that you find on the leading edge of the onto the top! it was all smoothed over with bondo so you couldnt even see it. So my guy has fiberglassed it in real good and is going to fare out the top to get rid of the rivet holes

 

[Megadiesel]

Looking great....It's gonna look better than new when ur done!

 

[johnkappus]

Looking great....It's gonna look better than new when ur done!

thanks for the encouragement!

that is what i keep telling myself...."its gonna be SWEET when it is finished!"

 

[johnkappus]

paint is ordered!!!

i'm getting excited to see this thing start coming together again

I've got the paint ordered (freeborn red). I'm hoping that it will be painted and ready for assembly in the next two weeks.

Now im putting together an order of all the other little things that I need to finish the project : headliner, door panels, window regulators, door seals and weather stripping, windshield cushion, top seals and bolts...lots of little detail items.

 

[FJ40Jim]

Weird. 1981-later tubs have rounded corners. Maybe yours is a late 1980? But the rear doors are late model...

 

[Splangy]

1979-later tubs had the rounded corners. The corners were squared off when body work was done at some point. The quarters and inner channels are not flush with the sill from the factory.

Weird. 1981-later tubs have rounded corners. Maybe yours is a late 1980? But the rear doors are late model...

 

[KY Longhunter]

My pilgrim tub has square corners too. Paul's stuff is 99% accurate in every way but does have some inaccuracies if you will. I didn't bother rounding off mine.

To boot I have one rounded amby door and one square amby door.

Still trying to figure out how I will handle that...

 

[ebanden]

Nice build Kappus. I just came on here to see Tom's new ride but got sucked in. I hope the guys at Jeepforum don't see I am straying. It's interesting to see the questions and suggestions for parts. In the CJ world, there are endless options, of great varying quality unfortunately.

Certainly hope to see that thing off road with its shiny new paint!

Cheers,

Dan C. - Tom's buddy

 

[johnkappus]

Nice build Kappus. I just came on here to see Tom's new ride but got sucked in. I hope the guys at Jeepforum don't see I am straying. It's interesting to see the questions and suggestions for parts. In the CJ world, there are endless options, of great varying quality unfortunately.

Certainly hope to see that thing off road with its shiny new paint!

Cheers,

Dan C. - Tom's buddy

Hey Dan!!!

Yeah i can't wait to see it in paint too. I am HOPING in the next week or two?

Oh yeah you WILL see it off road at F-Town. Hopefullly soon!

 

[kling-on]

Looks great

 

[Overlander 80]

Wow John, when you mentioned you were repainting the 40 I had no idea....... This thing is going to be better than new by the time you finish!! Well done! Bunch of Toys from mild to wild in Wellsville today and I am saddled up at the desk