36 year old build and paint thread (2 Viewers)

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Joined
Jan 17, 2005
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Location
Southern Colorado
I bought my '78 FJ40 in Aug. of '90 when it was a mere 12 years old. Paid $3500 and it had 78K miles and was a Texas truck with several owners, now in Colorado. On the offroad test drive, it growled through a bunch of nasty ditches and seemed unstoppable, and I scratched the paint on the test drive. I was smitten. It looked ok, but was sandblasted and rusty in various small spots. The rear sill had already been replaced with a 2x2 steel tube. Patina wasn't a thing back then.

In 1991, I painted it myself in my garage, after reading many library books on 'how to paint your car'. I spent $400 on a DeVilbiss JGA paint gun, Kondar primer/surfacer, and Dupont single stage paint, mixed a few shades off by a paint shop that didn't try very hard. I recall spending 80+ hours of time prepping and painting, and it looked great - one tiny run, no fisheyes, decent gloss, etc. I had touched up a few cars before that, but the result was luck over smarts. My sanding and chip filling was pretty awful, and my bondo was lumpy in spots.

First photo is 'as purchased'. The rest show the paint job in my garage (Iikely violating neighborhood covenants). There were no bezel police back then (or Internet), so the bezel is indeed upside down.

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Fast forward though 36 years of FJ40 fun, including driving it to Michigan and back through the upper peninsula, all over Colorado passes, camping up the wazoo, trips to New Mexico and Moab, etc. I buffed the paint several times, but the years just made the paint weary looking. I had rustproofed the truck with grease in the 1990s, and it was garaged and not driven in salt, so the body was still super solid. I should note that the dashboard and interior paint have always been nearly perfect, so I never wanted to repaint the entire truck inside and out.

When I painted it in 1991, I said to myself that '....one day, I will get this thing painted professionally....'. I guess that time had come.

Early 2024, I talked to a (Ford) Mustang resto guy and got the speeches about 'them Jap things' and he put me off literally for a couple of years - 'bring it back in 6 months...(and I'll tell you to come back in 6 months)' - yeah, got it. Another shop sounded good and seemed interested, but ghosted me after a few weeks. 2 more shops seemed sketchy and wanted at least $10K, even if I did some body tear down and prep. Finally, I found a shop that said 'We can do this for ~$6K, in 2-4 weeks, and I think you'll be really pleased'. I didn't really believe the timeline, but I signed up for it. I saw some of their shop's work, and it looked great.

So, in Oct. '24, I spent ~40 hours disassembling the truck (as I did in 1991). I sanded many panels removed all the doors, hood, glass, trim, etc. I welded new metal in all the rust holes, I gutted the ambulance doors and cargo area, as I wanted the rear floor and inner fenders painted. Here are some prep photos.

I removed the ConFerr aux gas tank and welded a plate over the gas filler hole in the fender. I horribly warped the rear fender, so the body guy cut my patch, flattened it, and rewelded it - I paid him extra. I had a perfect 1976 hood in my barn, and prepped and sanded that. All hinges, bolts, etc. removed, sanded, labeled, etc.

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I dolly-towed the truck to the shop in mid November, 2024. By December 11, they had made, well, very little progress. By December 20, a little more. Then, of course, the holidays. Then the painter got COVID, then he had a week of jury duty, then he got hit in the face with a front strut that plummeted from a Jeep Cherokee on the lift.... so the '2 to 4' week paint job was naturally extending into months.

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Now enter the month of 'paint matching hell'. My painter guy was a perfectionist on color match. My home-brew 1991 job was 2 shades off, at least. He uses Axalta (Spies Hecker base-clear system) and the factory 'formula' for 653 Olive came out exactly the same wrong shade that it did in 1991. So, he got out his color matching camera and started matching.

After 2 weeks of trying, he put the corporate folks onto the matching and they spent a week and didn't get much closer. After another week, we had a perfect match - in sunlight. Under different lighting (indoor, LED), it looks a little different.

The painter explained that without metallic flake or pearlescent pigments, there is nothing to fool the eye, so this solid Olive color was just difficult to match. See all the metal sprayout cards? The rightmost one (on the paper) was the winner. I'm very happy with the color match, but this added a month to the job.

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So, to bring this paint saga to a close, in Feb. of '25, they were nearly done with the body and could start spraying. They told me they couldn't bear to paint the shabby inside rear floor without more prep, so they prepped it nicely. I asked for no seam sealer on the side seams, since it always cracks, and they honored that.

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So, in Mid-March, dolly towed the gleaming truck back home, instructed them to repaint some hinges and hood hooks that needed more paint, and brought home the doors, bib, hood, tire carrier, bolts, hinges, and all the other futzley pieces.

The result is that the truck has a nice glow about it, and they left a little orange peel and as many OEM spot-welds as they could. The last photo shows the windshield frame (repainted) versus the non-repainted dashboard and door. Pretty much a perfect match.

The final paint shop bill was $7K (I had told them 6K +/- $1K) and they earned it. Took 4 months and many trips to the body shop for consulting, but they were easy to work with and we had more laughs than scowls. They pointed out that they had two, $500 cans of a base color product into this shoot, along with the clear coat, primer, and other materials.

I put a ton of hours into reasembly, including chasing every threaded hole with a tap, reinstalling the glass and door guts, etc. My final touch was a new OEM headliner, very expensively glued in by a local trim shop. I pulled the roof for that.

I accomplished what I set out to do: a good looking repaint that didn't break the bank, and over which I had some control. Time to go take it camping and get it muddy, I guess!

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You were a wiser man than I. In the end of ‘91 I bought my 40 for $1250. It has been a lot of fun building it into what it now is, but I would have saved a lot of time and effort if I’d spent more initially. I wouldn’t trade it for anything else now, but all that is left of the truck I bought in Dec ‘91 is: the cowl, windshield frame, front bib, rad mount, the dash, and the front heater.

I lost count of how many donor vehicles at about 36. I’m probably up to something like 48 vehicles… especially if I count the better front doors, rear hatch, and snorkel. P/S, using a Scout II box, adds another 6 bringing the count up to 54ish. Fuel injection will add another 2-3 once I convert it to TPI. About 15 years ago I painted it all one colour again… but it will be a few more years till I paint it all a new colour. I expect I’ll paint it myself, because I don’t trust anyone, and have terrible luck with almost anyone I hire.

As great as your 40 looks… don’t be afraid to drive it. They weren’t meant to be trailer queens and die a little each time they never go anywhere and just sit parked. Much like a caged animal that was born in the wild, they deserve to be free to roam and explore.
 
So, in Mid-March, dolly towed the gleaming truck back home, instructed them to repaint some hinges and hood hooks that needed more paint, and brought home the doors, bib, hood, tire carrier, bolts, hinges, and all the other futzley pieces.

The result is that the truck has a nice glow about it, and they left a little orange peel and as many OEM spot-welds as they could. The last photo shows the windshield frame (repainted) versus the non-repainted dashboard and door. Pretty much a perfect match.

The final paint shop bill was $7K (I had told them 6K +/- $1K) and they earned it. Took 4 months and many trips to the body shop for consulting, but they were easy to work with and we had more laughs than scowls. They pointed out that they had two, $500 cans of a base color product into this shoot, along with the clear coat, primer, and other materials.

I put a ton of hours into reasembly, including chasing every threaded hole with a tap, reinstalling the glass and door guts, etc. My final touch was a new OEM headliner, very expensively glued in by a local trim shop. I pulled the roof for that.

I accomplished what I set out to do: a good looking repaint that didn't break the bank, and over which I had some control. Time to go take it camping and get it muddy, I guess!

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Superb! Hard to beat that color, and great that you found the right shop
 
Looks great.
I'd recommend the repro turn signal grommets that City racer sells to avoid the turn signal bases from digging into the paint. And a fresh 51929-90300 :)
 
@bikersmurf

They weren’t meant to be trailer queens and die a little each time they never go anywhere and just sit parked. Much like a caged animal that was born in the wild, they deserve to be free to roam and explore.

Surely the most profound statement of the day!
 
I removed the ConFerr aux gas tank
Very nice write up and a pleasant story for us all!

What'd you do with that tank? (mine is most probably toast, ... will find out later this summer)

Any chance at that tank and fittings?
 
Now enter the month of 'paint matching hell'. My painter guy was a perfectionist on color match. My home-brew 1991 job was 2 shades off, at least. He uses Axalta (Spies Hecker base-clear system) and the factory 'formula' for 653 Olive came out exactly the same wrong shade that it did in 1991. So, he got out his color matching camera and started matching.

After 2 weeks of trying, he put the corporate folks onto the matching and they spent a week and didn't get much closer. After another week, we had a perfect match - in sunlight. Under different lighting (indoor, LED), it looks a little different.

The painter explained that without metallic flake or pearlescent pigments, there is nothing to fool the eye, so this solid Olive color was just difficult to match. See all the metal sprayout cards? The rightmost one (on the paper) was the winner. I'm very happy with the color match, but this added a month to the job.

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any chance you have a clearer image of that paint card/formula?

they really nailed the color
 
I sold the ConFerr 22 gal. aux. tank and all the fixins to a local Rising Sun Club FJ40 guy, because the spectre of shipping that tank across the country was too evil. It went to a good home at a fair price. He had the other brand of aux gas tank that bolted through the rear floor and tore out the floor metal, and wanted a ConFerr style tank.

Attached is a scan of the paint mix for Spies Hecker (Axalta) base coat. The quantities shown are for a 4 oz. sample, and can be scaled up for a larger quantity of paint. The actual color may vary depending on the tint of the base coat, and the painter determined that 4x coats of base were needed to get the proper color.

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I love this whole story!! beautiful truck and great color!
 
From the depths of my records: the original want-ad for my truck from 11/17/90.

Note all the other cool trucks for sale - and the prices - like the one above my FJ40!

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