Build 1st FJ40, '76 - SMOKEY - Puttin’ her Back Together

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I checked the items that I had soaked in the parts washer with KSG and had set out to dry without wiping off. They are visually free of any residue. Won't have time this morning to do much with them, as at some point I have to work, but I will report back once I clean them with some soap and water.
 
Working on the stuff to take to cad plating. I forgot how much I hate grinding things. I started off grinding the pair of tail light backing plates, and after about 75% of one of them, said, this is for the birds.

My electrolysis bucket has seen better times - the winter weather was not kind to it, and the electrolysis has left the cathodes almost rusted through (as a matter of fact, one did break off). To add insult to injury, my wife bumped into it and it broke the plastic casing near the 1/2 way point, thus about 1/2 of the liquid drained out, leaving an unsightly rust stain on the driveway. Nice.

But, I thought I'd try it anyway and see if the soda ash to water ratio was still workable, even after all the rain over the past 5 months of non-use.

I attached the negative lead to the other tail light backer, plugged in the battery charger, hooked it to the battery, and voila - bubbles. Yaaa, back in business. I can put away my grinder for now.

Perhaps I'll compare the outcome of the two different versions after cad plating.

Grinder version:
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Sad looking electrolysis tank:
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But - bubbles!
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Started taking apart the doors. Man, the door hardware for raising the window SUCKS! How the :censor: do you get the rail off the bottom of the glass and get that winder mech out?

I figured out the lock and handle parts, but gave up on the glass and winder for the night.

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I'm a bachelor for a week starting today. Just let me know when to come over and and I'll show you. I just fought that battle a couple of months ago. I feel your pain but it's not that hard... after you know how to hold your tongue right.
 
I remember your saying it was a little tricky. Looks like getting it all back in will be harder.

Do I roll down the window first? Does that help any? At what point do I unscrew the piece that grips the glass? Give me steps man!!!

If you have some time saturday, I could use your help.
 
Call me when you want to set up a time for Saturday. I'll be glad to come get you out of that bind. It'll be more clear with that e door in front of us.
 
Rainman said:
Call me when you want to set up a time for Saturday. I'll be glad to come get you out of that bind. It'll be more clear with that e door in front of us.
Click to expand...

But what about the rest of us?

@Vae Victus: Don't start skimping on the overly detailed posts! There's a reason I'm letting you win the bet. Doors are in my future too, and, as usual, any insight, tips, and tricks, will be much appreciated.

Also - was the inner door panel just held on by tabs, or is that some sort of adhesive?
 
RWBeringer4x4 said:
But what about the rest of us?

@Vae Victus: Don't start skimping on the overly detailed posts! There's a reason I'm letting you win the bet. Doors are in my future too, and, as usual, any insight, tips, and tricks, will be much appreciated.

Also - was the inner door panel just held on by tabs, or is that some sort of adhesive?
Click to expand...

Ah, ok. I have been skimping a bit, but I'm jumping around a lot. I'll get details on the doors.
 
When taking the doors apart, I took out the hinge pins while Jr held the door. I tried doing it alone and quickly found that the door is heavy and off center once you get one of the pins out. Much easier for someone to hold it while you beat the pins out with a punch.

Then I set a door upright to remove the guts. I had taken the panels off a long time ago and yes, @RWBeringer4x4 they were held on by several clips. There is an adhesive left on the door. I believe that might have held some plastic sheeting in place to keep moisture out/away from the panel if it got inside the door. The clips will rip thru the fiberboard if you aren't careful. Use a flat screwdriver and carefully pry the out from the metal door. Only remove the clips from the panels if you need to save them for use with a new panel.

Taking the guts out of the door. I first removed the 6-8 10mm bolts from the door in the panel area, and 3 screws from the door catch on the side of the door. Also, I removed the two nuts from the door handle by using an extension and 10mm socket thru the access holes opposite the door handle. I think there was one more 10mm bolt inside holding the door handle to the release mechanism that is inside the door that you must remove first. Once you do that, you can remove the door handle.

Screw to remove is to the left where the holes are. Screw is already out. Lock is in the center of the photo, clip already removed.
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Door handle screws seen from the inside.
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Then you can pop the plate off the door lock. It simply slides over the lock to hold it inside the door. I'm showing it partially removed, towards the outside of the door.

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The you must pop the long door release and locking rods carefully out of the plastic retainers that attach them to the release and locking mechanisms. I broke one, shown below.

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Once the rods are disconnected from the door release mechanism, it should come out.

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Along with that, the inner release and lock handles and rods will come out.

I guess I should consult the FSM now. I've not even looked. I'll detail the window mech removal once I get some help on that.
 
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Looks much simpler here:

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EDIT: To remove the window, first push it down toward the bottom of the door until you can access the two bolts attached just below the glass to the winder mech. Remove those.

Remove the window felt channels at the bottom (held in by metal friction pins, removed by prying out with a screwdriver carefully), and the channels along the side and top (one continuous channel that can be reused if you CAREFULLY pry it out, but realistically is almost impossible to get out cleanly). Both my felts and channels were trashed so we yanked without much concern for safekeeping.

Window can now slide up and out by rotating it where the angle in the bottom corner that is cut off of the glass comes out first. This is the only way the glass can come in or out.

Window notch on lower right:
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Channel:
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Felts:
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Window coming out:
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One year in, I'm actually sitting in front of my grinder wire wheel, cleaning up bolts. Sigh. What joy.

Just about ready to take my and @Rainman 's parts to the cad plater.

Instead of boring you with a photo of a box of parts to be plated, I'll show you Rainman's friend's '53 Hudson Hornet. It is a BEAUTIFUL car. He surprised us by driving it over on Saturday. Even my non-car loving wife enjoyed it.

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Cleaning up after wire wheeling more parts for cad plating tonite. I dug out my handy dandy big a:censor:ed magnet, put a plastic bag over it, and gathered all the wire shards that had been beating on me all night.

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This is why you wear a full face shield folks!

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Then invert the bag a voila! No more shrapnel.
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You just taught an old dog a new trick.
 
That's not a magnet...

...THIS is a MAGNET! AHaHHhaahahAhAhAa

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Need recommendations on the front springs and shackles. Rainman and others have me convinced to just do OME Medium springs and struts, and normal shackle height with greasable pins.

Any desenters? Other recommendations?

Finally took a box of stuff to CAD plating. That's another milestone for me, as now I can continue with the front end rebuild.
Also @roma042987 is bringing me my final 3.11 3.73 (EDIT: Oops) diff today. Door to door delivery - that is what the TLC community is all about. I won't get to meet him unfortunately, as I can't be there when he comes by.
 
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You mean 4.11.

Maybe 3.73 but most likely 4.11
 
Vae Victus said:
Also @roma042987 is bringing me my final 3.11 diff today. Door to door delivery - that is what the TLC community is all about. I won't get to meet him unfortunately, as I can't be there when he comes by.
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Agree 100% after decades in Honda's, Miata's, BMW's, and Audi's. This community is SOOOO much better - not even close. I would guess the average age here is a bit higher than those others and it's helps a good bit. I've meet some really great people in a very short time.
 
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