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

[Vae Victus]

Time for a budget update:

FJ40 Running Costs

Date Cost Running Total Item
3/15/2013 $4,000.00 $4,000.00 FJ40 from a guy in the GA Mountains
3/25/2013 $526.00 $4,526.00 Truck Delivery
3/27/2013 $290.00 $4,816.00 TrollHole Carb
3/27/2013 $20.00 $4,836.00 iH8Mud Support
3/28/2013 $65.00 $4,901.00 Starter - Used
3/28/2013 $132.00 $5,033.00 AutoZone - New Fluids
3/29/2013 $169.15 $5,202.15 eBay - Throttle Linkage
3/30/2013 $22.75 $5,224.90 OTC 6296 Pitman Arm/Tie Rod End Puller
3/30/2013 $175.00 $5,399.90 Titan Quatro 4L SUV Cover (EMP832)
3/30/2013 $298.28 $5,698.18 Dash pad replacement from iH8Mudder FJGoober
3/31/2013 $312.00 $6,010.18 iH8Mudder DaveWork JISHardware.com CAD bolt kit
4/3/2012 $159.00 $6,169.18 Battery, fluid pump
4/4/2013 $45.00 $6,214.18 Carb Spacer iH8Mudder rkymtnflyfisher
4/5/2013 $300.00 $6,514.18 2 Rear seats - iH8Mudder 2thDoc/David
4/5/2013 $60.00 $6,574.18 Air Cleaner - iH8Mudder RkyMtnFlyFisher/Ryan
4/6/2013 $203.17 $6,777.35 Advanced Auto - Clutch master, Clutch Slave, Brake Master
4/6/2013 $131.56 $6,908.91 NAPA - hoses, Air Filter, Fusable link, thermostat, fuel filter, belt
4/8/2013 $658.86 $7,567.77 CoolCruisers, Radiator, hoses, 2 front blinkers, 2 headlight globes, 2 door handles, steering rag joint
4/8/2013 $10.00 $7,577.77 Metric - screw set for 2 rear seats
4/7/2013 $103.93 $7,681.70 JDV Impact Screw Drivers - Megadora Impacta and Impact Driver Set 2400
4/10/2013 $228.70 $7,910.40 SOR order for various parts for eBrake, Throttle Pedal, Battery tray, carb gaskets, drain plug nuts and gaskets
4/15/2013 $113.00 $8,023.40 Matco Flare Tool
4/15/2013 $52.00 $8,075.40 Brake line and tools Amazon
4/13/2013 $32.00 $8,107.40 AeroKroil x2
4/10/2013 $22.00 $8,129.40 BG In-Force lubricant
4/16/2013 $69.24 $8,198.64 CruiserCorps - Radiator bushing, accelerator busing, cooling/heater union pipe
4/13/2013 $35.00 $8,233.64 Accelerator Pedal - iH8Mudder Mark Woytovich
4/17/2013 $192.00 $8,425.64 Powder coat fan shroud, skid plate, mesh grille, radiator housing
4/17/2013 $57.00 $8,482.64 Door bushings cruiserbits@gmail.com
4/18/2013 $68.00 $8,550.64 Exhaust Manifold, flange & ship - iH8Mudder HuminaJumina
4/18/2013 $5.00 $8,555.64 Shipping for some free bushings from iH8Mudder FishTaco
4/18/2013 $43.00 $8,598.64 FedHill.com brake fittings
4/18/2013 $145.00 $8,743.64 Water pump, iH8Mudder CDan
4/23/2013 $201.00 $8,944.64 TPI LandCruisers for Transfer Case Rebuild kit, 2 pinion seals
4/24/2013 $440.00 $9,384.64 Amazon for jack, jack stands, transmission jack
4/25/2013 $142.00 $9,526.64 Brake Booster #53-280, Advanced Auto
5/4/2013 $582.49 $10,109.13 TPI Landcruisers, clutch kit, transmission kit, etc
5/4/2013 $539.60 $10,648.73 SOR.com, Door panels, emblems, voltage regulator, flasher module, bunch of little crap
5/15/2013 $150.00 $10,798.73 Distributor from iH8Mudder TrollHole
5/17/2013 $154.00 $10,952.73 CruiserCorps, rear main seal, heater valve, grommets, exhaust gasket
5/19/2013 $28.00 $10,980.73 Air intake hose - from iH8Mudder BTUMAN
5/20/2013 $23.00 $11,003.73 Air intake nozzle - from iH8Mudder "76 fj40"
5/21/2013 $232.50 $11,236.23 3 FJ40 Steel Wheels
5/27/2013 $25.00 $11,261.23 Stepped Output Washers from iH8Mudder OrangeFJ55
5/31/2013 $118.63 $11,379.86 Mirror Arms from iH8Muddr Vintij74
6/1/2013 $30.60 $11,410.46 Flaming River FR1005 Shutoff from iH8Mudder jbadoni
6/6/2013 $53.50 $11,463.96 ZoroTools.com for grinder wheels
6/6/2013 $252.00 $11,715.96 Amazon for Metabo WEPBA14-150 grinder
6/26/2013 $167.15 $11,883.11 TPI for Ujoints and 2 Engine Mounts (front)
6/26/2013 $100.00 $11,983.11 2 FJ40 Steel Wheels from iHMudder VtgBeemer
6/12/2013 $0.00 $11,983.11 Fuel Lines free from iH8Mudder TCClark
6/28/2013 $255.00 $12,238.11 LED Tail Lights and 12v relaysfrom iH8Mudder Dancar and Chamba who shipped them from Austrailia.
7/5/2013 $9.00 $12,247.11 Shipping to Chamba for the lights from his house to mine. Thanks for sending it Express for the cost of standard Chamba!
7/15/2013 $246.00 $12,493.11 Used engine hoist $46, new engine stand, balancer, replacement bottle jack for hoist - $200
7/15/2013 $80.00 $12,573.11 Metric Rear Light Guards
9/16/2013 $50.00 $12,623.11 16 tooth speedo driven/drive gear from Mark's Offroad
9/25/2013 $0.00 $12,623.11 Engine Lift Hooks from mudder LandCrusher99 - thanks!!
10/7/2013 $150.00 $12,773.11 3.71 Diff from super40 on Mud.
10/1/2013 $256.00 $13,029.11 Rear Sill (Pending Transfer of $275) from Awl_TEQ
10/20/2013 $72.00 $13,101.11 TCSTARK for Original '76 Manuals
10/24/2013 $140.00 $13,241.11 Lowe Toyota, Beno, 5 hubcaps, 2 transmission synchros
11/1/2013 $500.00 $13,741.11 TCSTARK Fenders, rear heater and lines, tranny hump, gas cover, fender aprons
11/4/2013 $110.00 $13,851.11 77TLCFJ40 for left side tire carrier, panel style.
11/8/2013 $70.00 $13,921.11 TCSTARK alternator bracket - fuel sending unit - gas pedal - eBrake lever - visors, bumperettes
12/10/2014 $38.50 $13,959.61 Permatex x 3
12/26/2013 $100.00 $14,059.61 Front Windshield from Rainman
2/15/2014 $20.00 $14,079.61 46mm socket and 1/2" adapter Amazon
3/24/2014 $55.00 $14,134.61 Wytovitch TEQ emblem
3/25/2014 $50.00 $14,184.61 $50 Gold Membership to MUD. It's saved me thousands.
5/6/2014 $55.00 $14,239.61 CAD Plating round 1
5/6/2014 $75.00 $14,314.61 Various paint stripping disks Amazon

 

[Stumpalama]

Wow.... I would never do that. I mean I have almost every receipt related to my FJ40, but it would be too depressing (embarassing) to add it all up. You are a brave man.

How do you feel about that number?

I wouldn't count tools in my total, or at least I would break them out seperate since they can be reused for other cars and projects.

 

[Rainman]

I counted up the total on my '32 Ford once. Only once. Never again.

(I think I'm feeling sick again...)

 

[Vae Victus]

Wow.... I would never do that. I mean I have almost every receipt related to my FJ40, but it would be too depressing (embarassing) to add it all up. You are a brave man.

How do you feel about that number?

I wouldn't count tools in my total, or at least I would break them out seperate since they can be reused for other cars and projects.

I've decided to do it for the sake of others. Some will do much more than I am, some will do less, but a realistic accounting (and hobbyist-paced timeline) may help with decision making along the way.

Someone else made the same comment about a year ago re tool cost. I've included about 25% do the tools as direct cost, normally those that I bought specifically for this project. It's my first car project in 47 years - thus it may be my only one.

FYI - I estimate another $13,000 in cost to finish this vehicle. It will be done well, and completely documented here when I'm done.

 

[Vae Victus]

After talking to VtgBeemer today, I heeded his advice, sucked it up, and began grinding off the old paint and rust from the axle instead of taking the easy way out and taking it to sand blasting. I agree with the whole "sand finds it's way into everything" philosophy, so why risk it.

So here it was the other day:

And here it is after about two hours of tedious grinding:

Almost done. Not sure how I'm getting all the crevices clean, but I will find a way!

Also got back round 1 of cad plating:

Some of which I now have to separate out for @Rainman.

 

[Island Hopper]

Wow, amazing work and such patience, something I have to work on. Keep up the great work.

 

[vtgbeemer]

The spendometer is not looking that bad based on the level you are achieving. I am sure someone will disagree with the wirebrushing technique but you can degrease and etch prime the housing (maybe even filler prime any pits that will be in clear view) and move forward. You can even rattle can the finish coat if you want to complete that component before you get your shop set up for serious spraying. Looking very good V V !!!

 

[Vae Victus]

... And here it is after about two MORE hours of tedious grinding. Only this time with a fricking Dremel and some really tiny assed grinding attachments. I don't see how in the name of all that is holy you get into all the slots and crevices without sand blasting this sucker.

Can you see the difference? NO! Because ITS THE SAME PICTURE! You need a magnifying glass to see my work! It's like using a toothpick to paint the Eiffel Tower! But, because I'm fricking OCD, I had to clean it. Jeez.

I'm an expert grinder now. And Dremel loves me - I just plunked down top dollar for a bunch more tiny assed attachments that wear out in about 10 minutes. Even found generic brands from china on Amazon.

At least it is clean.

And I have nearly all of the passenger side knuckle stuff clean. Just lack the caliper and the backing plate, which is about 80%. Some of this stiff is just going to have to be blasted after the fact - I just cannot physically reach all the crevices.

Done pieces:

Not done pieces:

 

[Vae Victus]

Hey where'd my grinder wheel go? This was 6" when I stared.

Oh, there it is. And in my leg, and in my arm...

But not in my face damnit (warning - identity exposing photo ahead):

 

[RWBeringer4x4]

Looking good! I'm dreading cleaning up the axle. Conveniently, I'm NOT that obsessive compulsive, so I'll be doing what I can with a wire brush in the hard-to-reach areas and hitting it with a rust converter.

Did you even get inside the spring perches and steering stops? That is one clean axle!

 

[Rainman]

Will you teach me everything you know?

 

[Vae Victus]

Will you teach me everything you know?

Aaannnddd, One for you -

 

[Vae Victus]

Looking good! I'm dreading cleaning up the axle. Conveniently, I'm NOT that obsessive compulsive, so I'll be doing what I can with a wire brush in the hard-to-reach areas and hitting it with a rust converter.

Did you even get inside the spring perches and steering stops? That is one clean axle!

Uhm, no, why would anyone clean in there? Heh, heh. Hey, look, over there! Topless FJ40!

 

[Weber Sarge]

The Weiler dually stringer wheels work great , just use much less pressure on it - when it stops cutting flip the wheel over .

You might want to seriously consider a good blasting cabinet , saves a lot of bs in the long run - http://www.tptools.com/ . I have an older Snap-On piece of crap but it works ok , seriously need to invest into a good dust collector which Scat makes as well - and their filters are priced much cheaper . I use my cabinet way too often , it just comes in handy for cleaning anything that needs painting or welding (tig) .

BTW-there are adapter collets to run 1/8" tools on die grinders , far more torque than the dumb little Dremel units . Either that , or look into a used/new Foredom as they rule in that mini-tool world . For stuff like that axle , I just disassemble and blast the dumb thing with the pressure pot outside . Quick and clean as it gets .

Sarge

 

[Rainman]

View attachment 895625

Weenie!

 

[Vae Victus]

Weenie!

Am not!

 

[Vae Victus]

The Weiler dually stringer wheels work great , just use much less pressure on it - when it stops cutting flip the wheel over .

You might want to seriously consider a good blasting cabinet , saves a lot of bs in the long run - http://www.tptools.com/ . I have an older Snap-On piece of crap but it works ok , seriously need to invest into a good dust collector which Scat makes as well - and their filters are priced much cheaper . I use my cabinet way too often , it just comes in handy for cleaning anything that needs painting or welding (tig) .

BTW-there are adapter collets to run 1/8" tools on die grinders , far more torque than the dumb little Dremel units . Either that , or look into a used/new Foredom as they rule in that mini-tool world . For stuff like that axle , I just disassemble and blast the dumb thing with the pressure pot outside . Quick and clean as it gets .

Sarge

Sigh - I know. I want, but this just happened to my main storage area:

 

[Rainman]

Sigh - I know. I want, but this just happened to my main storage area:

Is that a "Brentwoood Tornadah"?

 

[Weber Sarge]

That's what happens when I get angry with a building , hope a better one is replacing it .
Sarge

 

[RWBeringer4x4]

I've decided to do it for the sake of others. Some will do much more than I am, some will do less, but a realistic accounting (and hobbyist-paced timeline) may help with decision making along the way.

Someone else made the same comment about a year ago re tool cost. I've included about 25% do the tools as direct cost, normally those that I bought specifically for this project. It's my first car project in 47 years - thus it may be my only one.

FYI - I estimate another $13,000 in cost to finish this vehicle. It will be done well, and completely documented here when I'm done.

For the record, I too, am keeping a spreadsheet on every penny I spend on this project. I don't think it's 100% accurate (haven't accounted for some tooling and small parts) but it provides a good general idea of what each project cost. Honestly, I spent too much on my truck up front, (for what I got) which is going to make this project an expensive one in the long run. I didn't buy it with the intent to profit though, and it is keeping me out of trouble by absorbing every spare dollar I have and keeping me busy. I allow myself around $200 a month (and usually any "windfall" cash I can scrounge up) hence the snail's pace of my project. I think I'm clocking in at about $12,000 and change right now. If I do everything I'm planning to it, I'll be at about $26,000 when all is said and done. Most of my estimates have been WAY low, and constantly evolve though, so I wouldn't be surprised if this thing caps $30,000. Time will tell. As long as never gets a hold of that spreadsheet, I'll consider it money well spent!

Also - Why would you go an demolish a perfectly good barn?