1HZ install into a 1978 FJ40 (1 Viewer)

[crushers]

thanks for the positive comments guys, appreciated.

on with the show:
when the wife is off then i spend time with her and the weather has been... interesting... so not much to show.

more on the brake lines

 

[crushers]

next, the decision was made to elimate the original side steps (running boards) but we also wanted to keep the original idea.
normally, most guys run the pipe straight off the frame which has the mounting bars crooked to the body and i wanted to have them running straight with the body so a angle cut was needed at the frame end of the supports.
also i wanted to end up with the same area as the factory boards so they were used as a guide.

 

[crushers]

fitting of the pipe to the steps

 

[crushers]

next these goes to the powder coaters

 

[prado t]

Exellent Work, I am speachless, I would like to test drive.
Aaron Kuit

 

[crushers]

the fit of the sidebars to the tub...

 

[crushers]

Next, this truck is getting the Vintage air AC kit.
so a test fit, modification of parts is needed.
reinstall the rad
reinstall the grill

tight fit.

 

[crushers]

the kit is a generic one that is supposed to cover all the years from 1966 to 1984.

the mounting tabs are incorrect...

 

[crushers]

so a quick call to Vintage air to confirm i wasn't over looking anything (i was impressed on how quick the return call was) showed how generic the kit is.
the tabs needed modifying
i tapped the steel rad support
trimmed the tabs
touched up the raw edges and painted

 

[crushers]

i wasn't impressed with the location of the dryer nor with the mount in stock configuration.
the lines would hit the mount
the dryer was over the frame too far
the dryer was too close to the frame
time to modify

 

[crushers]

so a slight modification to the supplied bracket to clear the lines
a better fit to the rad support.

 

[crushers]

in the directions it mentions to take the line between the horn and the rad brace, i didn't like the sharp bend in the line so i took it below.
much cleaner line now
nuts tack welded on the back of the drier support.

 

[crushers]

the factory mount uses 4 bolt the go directly into the mount
the compressor suppied used 4 side mount
i would rather use the factory compressor and another call into Vintage air to exchange for the proper mounts. sad to say this is the only compressor they offer and $75 refund for the compressor back.
so a custom mount would have to be created.
this is the mounts supplied with the kit.

 

[crushers]

the compressor mounted
the custom mount

the fun part is lining up the pullies since they have to be exact.

now a bunch more parts for the powder coaters.

and that is it till the new year.

here is wishing everyone visiting a postive, cheerful New Year.

cheers M8s

 

[tmarx]

Awesome work !

 

[crushers]

preping the bib for install
checking for clearence concerns
the headlight basket is hitting the AC line
the drier is touching the fender

the drier is not a big concern and an easy fix
the headlight basket is a problem. i could move the basket ahead or the rad support in 1/2". i opted for the rad to be moved in since that will give me room for the expanded steel rad protection and clear up the basket issue at the same time.

now the rad has been moved 2" to the right and inward 3/4".
the front issues have been dealt with (for now)

 

[crushers]

test fitting the fenders and the bib for clearence issues noted above

test fitting the front clip together, this is not for the faint of heart. getting all the pieces to fit properly with proper gapping is not small chore. 6 hours for 2 men. spacers were needed for the fender supports since Gozzard fenders have too much curve and pull the front clip off level. these spacers are made with 1/4" plate and drilled to match the fender supports. this allows a whee bit of float to level the front clip properly.
there are very few 40 series parts that Gozzard does not make out of fiberglass and the skirts are one of them. the ones off this donor rig were in perfect shape, bonus.

that is as far as we traveled today. Monday, on to the expanded steel rad protector front and rear.

cheers M8s and thanks for the comments guys. greatly appreciated.

 

[denis]

Nice build !
Its so much more pleasant when you're not wasting hundreds of hours fixing rust
A 40 with no rust is not really a 40 though

 

[crushers]

the 'new' 4 core rad and cap.
test fitting the rad for clearences
setting up for the upgraded radiator armour. this is to prevent stones from bouncing off the fan and into the rad. decades ago i was climbing a nasty loose stone covered hill and a stone bounced up from the tire, hit the fan and into the rad. we ended up loosing a weekend over it. since then i install the rear rad protector when buildign an off road rig, mine or a customers. cheap preventive maintenence.

 

[crushers]

this expanded steel gets sandwiched between the rad support and the fan shroud.
the close fit of the lower rad hose and the relocated, modified fan shroud.
ready for the powder coaters