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

[Michael B]

Thanks Michael! How are your projects?

Scott, my 45 is still running great. Unfortunately it spent spring, summer and most of the fall season in storage while my shop building project was under construction. The shell is complete, now I get to finish the inside. I have a thread in the “Work shop” section if you have time. All of my other projects are on hold until the shop is finished. Keep up the good work on your 40. It will be done before you know it!

 

[Vae Victus]

Au contrare. By 1991 two of my friends were driving survivor 1971 FJ40s and they were just SO clean that I was won over.

Survivors in ANY color rock.

Ha. Well, I assume you mean they were driving Spring Green versions?
Happy Thanksgiving to you.

 

[Vae Victus]

Scott, my 45 is still running great. Unfortunately it spent spring, summer and most of the fall season in storage while my shop building project was under construction. The shell is complete, now I get to finish the inside. I have a thread in the “Work shop” section if you have time. All of my other projects are on hold until the shop is finished. Keep up the good work on your 40. It will be done before you know it!

Very nice! That will be a great asset.

 

[ToyotaMatt]

As far as updates go:

Began to work on installing the @Racer65 version of the electronic steering. Very nice kit. Very solid. High quality parts. I've heard about but have not yet looked up the "Prius electronic steering conversion" - heard it was available. Anyone know anything about it?


View attachment 2845654

View attachment 2845655

Started taking apart the steering column, removing the ignition cylinder and cable module. Got into the ignition lock cylinder to find out that I needed to replace my current one due to the fact that:
- It has a single sided, non toyota looking key-cut.
- the retaining pin on the side of the cylinder is broken, and the cylinder was held in by a broken off small screw (not even a grub screw)

I'm not even sure this is a Toyota cylinder.
View attachment 2845665


Retaining pin bent (I already tried to straighten it - it was bent down enough to allow it to enter the module without engaging the pin itself). And, key detail. Doesn't look like a Toyota pattern.
View attachment 2845666

I also realize that I will need to get all my cylinders (ignition, doors, ambulance door, gas) keyed the same, so I'm reaching out to @ToyotaMatt and his keying expertise to help me with all that.

Of course, I also remembered that on the day I purchased the vehicle, the sticking key in the "start" position was what caused the started to continue to run, which caused it to overheat the wire from the battery, which caused it to catch fire, which caused be to start this whole damn rebuild in the first place. Thus I took out the Ignition Switch Key Lock cable and found that it indeed has a "catch" in it when I turn it to the starting position with a screwdriver, and release it. So, it too needs to be replaced.

View attachment 2845667

There will be very few original parts on this when I'm done that have not been replaced.

I swear that EVERY screw on this truck will be touched when I'm done.

That IGNITION LOCK CYLINDER , is / was a oem unit , however ?

its been damaged / destroyed , that pin is crushed and NEEDED to retain the LOCK inot the alloy reciever housing you restored to be clear





that ELECTRICAL key switch IS a CHINA one , and the stripped JIS Philips head screws holding in place is proof it was removed and replaced at one point , a while back

TOYOTA Never used a WHITE connector plug on the end likethat NON locking type

always a LOCKING GREEN OEM Sumitomo one ...........


like so ...........


this IS a OEM Toyota GENUINE Parts JAPAN Made assy , and looked same back then too , as of 10/72 - Later 40 series with a 2F

 

[Vae Victus]

Pleased to say that Toyota Matt has put together my lock set and made it a star in its own movie.

 

[Vae Victus]

Been finishing the electric steering install. it's neatly done. Waiting on some industrial Velcro to stick the control box to the side of the inner driver right footwell above the fuse box. Had to remove the mounting plate as it was useless - no where for it to go. They changed the mounting bracket - it's different than the instructions state. They show an L-shaped bracket, but it has just a rectangular bracket on the back. It's nice, but not usable. Once I get that I can complete the wiring and be done except for testing.

Received the lock kit from Toyota Matt. Was great. Custom touches. Extra keychains with hidden Easter eggs, and a vinyl banner of Matt's company (cool). Installed the ignition lock cylinder. Seems to function ok (won't know for a while). Also installed the new wiring harness and the new turn signal and high/low headlight control. OEM and nice to have new.


The angle of the electric motor on the shaft will change such that it is close to parallel with the floorboard. I wish it could angle up like this but it can't due to the pedals and such.

You can see that the control box will need to go above the red wire clips on the inner side panel, above the rib. The mounting plate has to be removed.

 

[Vae Victus]

Started installing the wiring harness. Coolerman did a fantastic job on this. So many custom upgrades. Dakota Digital wiring harness, amp harness, trailer hitch circuit, fog light harness, USB power port harness, Vintage Air accommodation (I think - that may stand alone). Everything cleaned and replaced as needed. Also upgraded to handle the 85 amp alternator - new connector installed for that.

Ordered the Dakota Digital dash - 20 weeks for delivery! HDX version ordered. I thought I bought that a year ago but I didn't. Regretting that.

 

[Vae Victus]

Started the Vintage Air ac system install. It's going smoothly, but it'll take some hours to finish. More on that later.

These projects will all proceed simultaneously for a bit.

 

[Vae Victus]

Some random stuff:
Got a batch of rubber bits and small parts from Racer65 and more from ToyotaMatt. Grommets, cushions, odd bolts, etc.

Working to refinish the steering column cover. Prepping it for paint. Also repairing the inner screw posts that are cracked with some magic powder and liquid glue. You are supposed to drip the liquid in the powder, pick up the ball of goo, and put it where you want to form the part using a needle. But that doesn't work. It's like picking up biscuit dough with a knife point. In the end I just wet the crack and dump the powder on it In layers. Seems to work.

I cerakoted the steering column firewall plate as well. Turned out nice. It's a much tougher coating than spray paint.

 

[Honger]

Been finishing the electric steering install. it's neatly done. Waiting on some industrial Velcro to stick the control box to the side of the inner driver right footwell above the fuse box. Had to remove the mounting plate as it was useless - no where for it to go. They changed the mounting bracket - it's different than the instructions state. They show an L-shaped bracket, but it has just a rectangular bracket on the back. It's nice, but not usable. Once I get that I can complete the wiring and be done except for testing.

Received the lock kit from Toyota Matt. Was great. Custom touches. Extra keychains with hidden Easter eggs, and a canvas banner of Matt's company (cool). Installed the ignition lock cylinder. Seems to function ok (won't know for a while). Also installed the new wiring harness and the new turn signal and high/low headlight control. OEM and nice to have new.


The angle of the electric motor on the shaft will change such that it is close to parallel with the floorboard. I wish it could angle up like this but it can't due to the pedals and such.
View attachment 2879659

You can see that the control box will need to go above the red wire clips on the inner side panel, above the rib. The mounting plate has to be removed.
View attachment 2879660View attachment 2879661View attachment 2879662View attachment 2879663

Whoa, is that padlock keyed to your ignition key? Is that a standard ToyotaMatt upgrade for his lockets?

 

[Vae Victus]

Whoa, is that padlock keyed to your ignition key? Is that a standard ToyotaMatt upgrade for his lockets?

That would have been a great idea for it to be on the ignition! But it is for the spare tire.

 

[Vae Victus]

Update on the reassembly.

In another thread I asked what order to do things, and then made a list. Here's that list.

1. DONE Harmonic nut (Mark )
2. DONE Spark Plugs after dropping a bit of lube in the cylinders.
3. DONE Seat distributor
4. DONE Manually rotate the engine a couple rotations to distribute the lube
5. DONE Replace the leaky freeze plugs noted when I flushed the block
6. DONE Purchase Bolts for the valve cover
7. Water system
   1. replace the rubber water pump seal that is already cracking.
   2. MOSTLY DONE Put on water hoses and clamps
   3. Radiator will wait until a bit later after belts are installed and AC system is installed
8. DONE Belts
9. Vintage A/C
   1. DONE fit it up before body goes to paint
   2. DONE install compressor and brackets
   3. install wiring
   4. install vents and hoses
10. DONE Vintage Air Bracket - Modify alternator bracket as needed (larger alternator being used)
11. Fluids
    1. DONE Oil & filter
    2. DONE Transmission
    3. DONE Transfer cases
    4. Coolant
12. Rig an engine starter test system
    1. Temp battery
    2. Temp wiring
    3. Temp fuel
13. DONE Wiring loom set in place pre-body install
14. DONE Put body back on post paint
15. DONE Wiring post body
16. IN PROCESS Gauges rebuilt and replaced (Dakota Digital gauge cluster)
17. IN PROCESS - Pedal bucket
18. IN PROCESS - Power assist steering (the electric assist unit, not the full hydraulic type) - installed and installed - forgot pedal bucket
19. Fuel lines
20. Carb
21. Master and clutch cylinders
22. Brake booster (after paint)
23. Brake lines (some after paint)
24. Fuel tank and lines
25. Seats and belts
26. All weatherstripping seals around doors, including windows, top
27. Window reinstallation
28. Door and door glass assembly
29. DONE Steering wheel refurbish
30. Heating lines inside cabin
31. Headlights
32. Hood
33. Doors
34. Top
35. [Edit] Exhaust system

 

[Vae Victus]

Quick update:

1. I have installed wiring harness and learning what is what on that. This is a Coolerman rebuild with the Dakota Digital harness built in (fantastic work), and some other goodies for future use (amp circuit, additional exterior lighting, fog lights, USB power, etc).
2. Vintage Air AC system install is going on simultaneously. About 25% done with this. Wiring needs to be complete before this is finalized.
3. Pedal bucket blasted and Ceracoted, installed. Now what do those darn springs connect to?
4. Racer65 Electronic Steering installed (& uninstalled, and reinstalled after forgetting to put the pedal bucket in first). Nice unit.
5. New matching keyset for all locks, as well as new ignition module for steering wheel purchased and installed.
6. Steering wheel finished and waiting for install.
7. Roof restoration is finally complete, along with remaining small parts from the painter. Wow, this was the most over the top expense I have had, and am grateful that I did all the metal work to the body that I did or there would have been another $10K in cost there I'm sure. (And I don't know if they would have gotten the work done to be honest - he's had a heck of a time with staffing due to C19). Final paint price tag ... $23K. Gulp.
8. Updated the cost spreadsheet that I've been keeping. It is listed below. Yes, for you purists, theres a few $K in tools in the list, but overall that doesn't make much difference in the total cost.

FJ40 Running Costs
Model	FJ40LV-KCJA
Date of Manufacture	10/1975
VIN	FJ40.211442
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 - the main reason why I was able to do this project.
3/28/2013	$65.00	$4,901.00	Starter - Used (ha, which wasn't used on this truck)
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 Car 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 bushing, 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	$200.00	$9,144.64	Amazon for jack, jack stands, transmission jack
4/25/2013	$142.00	$9,286.64	Brake Booster #53-280, Advanced Auto
5/4/2013	$582.49	$9,869.13	TPI Landcruisers, clutch kit, transmission kit, etc
5/4/2013	$539.60	$10,408.73	SOR.com, Door panels, emblems, voltage regulator, flasher module, bunch of little crap
5/15/2013	$150.00	$10,558.73	Distributor from iH8Mudder TrollHole
5/17/2013	$154.00	$10,712.73	CruiserCorps, rear main seal, heater valve, grommets, exhaust gasket
5/19/2013	$28.00	$10,740.73	Air intake hose - from iH8Mudder BTUMAN
5/20/2013	$23.00	$10,763.73	Air intake nozzle - from iH8Mudder "76 fj40"
5/21/2013	$232.50	$10,996.23	3 FJ40 Steel Wheels
5/27/2013	$25.00	$11,021.23	Stepped Output Washers from iH8Mudder OrangeFJ55
5/31/2013	$118.63	$11,139.86	Mirror Arms from iH8Muddr Vintij74
6/1/2013	$30.60	$11,170.46	Flaming River FR1005 Shutoff from iH8Mudder jbadoni
6/6/2013	$100.00	$11,270.46	ZoroTools.com for grinder wheels
6/6/2013	$200.00	$11,470.46	Amazon for Metabo WEPBA14-150 grinder
6/26/2013	$167.15	$11,637.61	TPI for Ujoints and 2 Engine Mounts (front)
6/26/2013	$100.00	$11,737.61	2 FJ40 Steel Wheels from iH8Mudder VtgBeemer
6/12/2013	$0.00	$11,737.61	Fuel Lines free from iH8Mudder TCClark
6/28/2013	$255.00	$11,992.61	LED Tail Lights and 12v relaysfrom iH8Mudder Dancar and Chamba who shipped them from Austrailia.
7/5/2013	$9.00	$12,001.61	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	$12,247.61	Used engine hoist $46, new engine stand, balancer, replacement bottle jack for hoist - $200
7/15/2013	$80.00	$12,327.61	Metric Rear Light Guards
9/16/2013	$50.00	$12,377.61	16 tooth speedo driven/drive gear from Mark's Offroad
9/25/2013	$0.00	$12,377.61	Engine Lift Hooks from mudder LandCrusher99 - thanks!!
10/7/2013	$150.00	$12,527.61	3.71 Diff from super40 on Mud.
10/1/2013	$256.00	$12,783.61	Rear Sill (Pending Transfer of $275) from Awl_TEQ
10/20/2013	$72.00	$12,855.61	TCSTARK for Original '76 Manuals
10/24/2013	$140.00	$12,995.61	Lowe Toyota, Beno, 5 hubcaps, 2 transmission synchros
11/1/2013	$500.00	$13,495.61	TCSTARK Fenders, rear heater and lines, tranny hump, gas cover, fender aprons
11/4/2013	$110.00	$13,605.61	77TLCFJ40 for left side tire carrier, panel style.
11/8/2013	$70.00	$13,675.61	TCSTARK alternator bracket - fuel sending unit - gas pedal - eBrake lever - visors, bumperettes
12/10/2014	$38.50	$13,714.11	Permatex x 3
12/26/2013	$100.00	$13,814.11	Front Windshield from Rainman
2/15/2014	$50.00	$13,864.11	46mm socket and 1/2" adapter Amazon
3/24/2014	$55.00	$13,919.11	Wytovitch TEQ emblem
3/25/2014	$50.00	$13,969.11	$50 Gold Membership to MUD. It's saved me thousands.
5/6/2014	$55.00	$14,024.11	CAD Plating round 1
5/6/2014	$50.00	$14,074.11	Various paint stripping disks Amazon
7/19/2014	$197.50	$14,271.61	PartsGeek.com Centric booster (160.88103)
9/25/2014	$11.33	$14,282.94	Nalley toyota - cone washers
10/13/2014	$328.92	$14,611.86	Nalley Toyota - Part #13751-61010, 2F LIFTER Qty 12, List $36.55 MUD discount $27.41, $328.92
10/23/2014	$24.00	$14,635.86	Autozone - grease, oil, startup lube.
10/24/2014	$30.00	$14,665.86	Nalley Toyota - studs, bolts, washers for front diff.
11/5/2014	$164.00	$14,829.86	Nalley Toyota - front disk rotor x 2
12/1/2014	$120.00	$14,949.86	Racer65 OEM Visors
12/12/2014	$36.00	$14,985.86	Welding Gas 75/25 Ar/CO2 for body
12/10/2014	$391.13	$15,376.99	JoeTLC Rear Disc Brake Conversion Kit
12/12/2014	$1,860.00	$17,236.99	CruiserOutfitters.com OME Dakar Suspension Kit 2.5" soft
2/23/2015	$367.50	$17,604.49	Powder coat 5 wheels (Superior Sand Blasting)
5/12/2015	$326.18	$17,930.67	Fuel Tank Floor Pan replacement SOR.COM
8/31/2015	$585.45	$18,516.12	Pair rear quarter panels, driver floor panel CCOT
8/31/2015	$1,036.79	$19,552.91	5 BFG TA KO2s from TireBuyer.com
3/1/2016	$600.00	$20,152.91	Powder coat frame and parts
3/15/2016	$450.00	$20,602.91	Media blasting of doors, hood, other body panels
8/1/2016	$25.00	$20,627.91	Pinion depth shims Cruiser outfitters (wrong ones)
8/15/2016	$25.00	$20,652.91	Pinion depth shims Southwest Toyota
11/2/2016	$150.00	$20,802.91	Rebuilt front calipers and pads - RockAuto
11/6/2016	$194.55	$20,997.46	CoolCruisers Motor Mounts, Bump Stops, Lug Nuts
11/19/2016	$1,095.00	$22,092.46	CityRacerLLC.com - lots of unobtainium.
11/29/2016	$82.98	$22,175.44	Fasteners for motor mounts Toyota South Atlanta
12/6/2016	$52.29	$22,227.73	Fasteners for shocks, Toyota South Atlanta
1/9/2017	$19.48	$22,247.21	Fasteners Beaman Toyota
5/31/2017	$866.00	$23,113.21	Pro90 Seats
6/5/2017	$52.00	$23,165.21	Pittman arm FJParts.com
7/12/2017	$154.00	$23,319.21	Body Mount Kit Cruiser Outfitters
7/19/2018	$240.35	$23,559.56	Helicoil x 4 exhaust manifold
7/1/2018	$900.00	$24,459.56	various OEM parts
7/18/2018	$240.35	$24,699.91	Repair bolt hole in manifold Hamilton Machine
7/19/2018	$87.40	$24,787.31	Helicoil in exhaust flange Hamilton Machine
8/23/2018	$45.00	$24,832.31	Remflex manifold gasket
9/5/2018	$382.38	$25,214.69	Hamilton Machine, surface manifold
9/9/2018	$25.00	$25,239.69	Mark's Offroad - crank nut and locking tab
10/1/2018	$233.45	$25,473.14	Rocker panels, fend bolt kits, tube frame bolt kit
12/1/2019	$58.00	$25,531.14	SOR 4spd shift retainer ring
9/21/2020	$219.51	$25,750.65	CCOT Rain gutter visor set
9/21/2020	$3,500.00	$29,250.65	Automotive Enterprises Paint installment #1
12/29/2020	$90.00	$29,340.65	Hamilton Machine Alternator pulley
1/15/2021	$30.00	$29,370.65	Intake/Manifold gasket
1/30/2021	$38.00	$29,408.65	EGR Blockoff plate
1/10/2021	$50.00	$29,458.65	Cerakoting parts
2/4/2021	$6,000.00	$35,458.65	Automotive Enterprises Paint installment #2
6/30/2021	$2,035.00	$37,493.65	Electric steering City Racer
4/15/2021	$1,300.00	$38,793.65	Vintage Air AC
7/11/2021	$100.00	$38,893.65	Horn & Turn Signal Assy, Raging Matt
8/23/2021	$9,633.20	$48,526.85	Automotive Enterprises Paint installment #3
11/26/2021	$435.00	$48,961.85	Raging Matt, lock cylinder kit - 5 locks.
12/26/2021	$259.00	$49,220.85	City Racer LLC various small rubber bits.
5/2/2022	$4,533.18	$53,754.03	Automotive Enterprises Paint installment #4

 

[Jdc1]

The time and materials needed to do a quality paint job is pretty crazy. Spraying is the easy part it’s the prep and then time necessary to wet sand and buff after the paint is laid down. Props to you for sticking with this project, it’s going to be a great first drive.

 

[middlecalf]

Wow, $23-24k for paint!

Immaculate cost documentation!

 

[RWBeringer4x4]

Wow, $23-24k for paint!

Immaculate cost documentation!

That was my thinking as well. Looks like the Clustertruck is getting painted in my driveway! I’m sure VV’s will be prettier but that’s a pretty penny. I always assumed a good paint job would be in the $10k ballpark so I am, apparently, way off!

 

[Jdc1]

That was my thinking as well. Looks like the Clustertruck is getting painted in my driveway! I’m sure VV’s will be prettier but that’s a pretty penny. I always assumed a good paint job would be in the $10k ballpark so I am, apparently, way off!

VV delete if you don’t want this here but interesting article:

https://www.hemmings.com/stories/article/time-is-money/amp

A 40 is pretty challenging to get looking good because everything shows, the hinges and small pieces are on the outside…..

 

[Vae Victus]

VV delete if you don’t want this here but interesting article:

https://www.hemmings.com/stories/article/time-is-money/amp

A 40 is pretty challenging to get looking good because everything shows, the hinges and small pieces are on the outside…..

Do I dare read it? LOL. Here goes.

EDIT: Read it. Great article breaking down why even a tractor like mine costs so much. So I have a 5’ paint job (looks good 5’ away). A 10’ costs $150. Every foot from 10’ down to1’ (Concours finish) costs about $5000.

 

[Vae Victus]

I just spent 30 minutes with a friend of mine who has been driving his FJ40 since high school, 30 years ago. He knows and has done everything on the Land Cruiser. He straightened out about 10 things on my wiring harness just standing there shooting the crap.

Having you guys on tap is great, but having a true expert in your garage is priceless.

 

[RWBeringer4x4]

Do I dare read it? LOL. Here goes.

EDIT: Read it. Great article breaking down why even a tractor like mine costs so much. So I have a 5’ paint job (looks good 5’ away). A 10’ costs $150. Every foot from 10’ down to1’ (Concours finish) costs about $5000.

I’ll settle for a 20/20 car - looks good at 20ft going by at 20mph .