67 FJ40 Overhaul (Burned Up...)

[kevos37]

Thanks ! The sandblasting cabinet was a nice addition but it required some changes to make it work better. I have a 80 gallon IR compressor. The airline runs underground from another building, I found the line too restrictive for a good flow so I picked up a 8 gallon compressor with a blown motor/pump. I replumbed the tank and located it under the cabinet. Then I ran a large line from the secondary tank to a water trap then to the cabinet. I also installed a inline air vibrator at the base of the cabinet to keep the media moving. And last...I got tired of having to turn on the vacuum separately. I didn't want to spend the $$$ on one of those automatic vacuum switches. I bought a small power bar with a on/ off switch, plug everything into that. Works like a charm now.

 

[vtgbeemer]

subscribed

 

[kevos37]

Made some progress on the front axle, (with the help of orangefj45, thanks again G-man). Thought I would throw a couple pictures out there. Starting on rear axle tomorrow and hopefully get both axles under the frame next by next weekend.

 

[kevos37]

Wow time fly's!

I have been working on the motor. I am keeping the stock motor, It mic'ed out well, so off to the machine shop for head rework and cleaning. Installed new bushings and rings. I upgraded the starter with a gear drive fj60 and adding a Electronic ignition. Will post pictures of the engine when I get it in. Thought I would throw some miscellaneous pictures out there. Slow but sure.

 

[payney60]

Subscribed. Looking good mate.

 

[kevos37]

Putting the finishing touches on the motor. Here are a couple pictures of the manifold assembly and installation. On engine disassembly I had ended up removing the heat riser. I threaded and plugged the holes with brass plugs and brazed them in. For the heat riser gasket, Remflex seemed to be the product of choice. Then I needed the collars for the intake manifold. I used 1 1/2 dia. stainless steel tubing, trimmed them to 3/8 wide. For the outside holes a saw cut thickness would suffice to make the collar fit into the hole, for the center (smaller) hole it took a little more whittling to make it fit. I used a knife file for opening the gap up, very useful tool.

Once everything was ready, I installed the heat riser gasket and loosely tightened down the heat riser bolts (I used stainless steel socket head bolts). Then I fit the assembled manifold over the collars and installed all of the head to manifold bolts. I alternated tightening down the head and head riser bolts, trying to avoid any binding. Ultimately the heat riser bolts were torqued to 40 lbs. . The Remflex did a pretty good job compressing. I removed the manifold assembly and put a sraightedge on it. It had a couple thousands difference so it took a trip to the machine shop for a shave.

 

[kevos37]

Some manifold pictures

 

[78fj40mg]

Hey Kevin, Excellent work on the 40 and love your shop!

 

[kevos37]

Thanks Mike! I need to get some new pictures up, have had some progress

 

[78fj40mg]

Need progress pics!

 

[kevos37]

Going to drop the motor in some time, I finally got ahold of a 2 groove press on balancer. Once I have that installed I can set up the power steering and alternator.

In the mean time I rebuilt the center arm and installed a new tie rod, cross link and drag link. I had Marlin make up heavier duty arms out of DOM tubing, I installed wrench stops on each end for ease of adjustment. The nuts were a bit challenging to get. I looked all around and located a set from JT Outfitters. When Marlin sent me the arms he included a set he made by hand. What a great guy and businessman !!!

I got into working on the front brush guard and bumper. I had ordered an extra long bumper from 4 PLUS products. I wanted to install some fog lights so I trimmed the bumper down length wise and trimmed back each side to match the contour of the fog lights. Once I had the proper angle I used a hole saw for the opening. Had to go real slow on the mill when cutting a hole at an angle. I found the lights off of a 2015 Yaris (so its still a Toyota product- haha). With the backside of the bumper open and the fog light electrical exposed I decided to box it in the bumper. I used the original triangle bracket design and added on to it. The bottom plate was a little more challenging, but nothing that a cardboard template cant fix! I wanted to maintain the flat shape of the top bracket (not bent like the OEM bracket). To accommodate this I milled 6 x 2 wedges to fit between the frame and bracket, it buttoned up really well. As far as the brush guard I changed over a couple of the lightweight crosspieces with DOM tubing. I plan to recess the fog lights some more and come up with some guards for them.

 

[78fj40mg]

Awesome bumper and lights! Great work!

 

[cult45]

I dream of the patience to have fab skills like yours. Such attention to detail!

 

[tls3601]

Very nice work......looking super!!!

 

[SKULLYOTA]

Holy cow, amazing work. I love the whole table full of plated bolts!

 

[tls3601]

Definately some more axle eye candy!!!!!!!!!!!!!

 

[kevos37]

Getting ready to go to the plating shop with another load.

 

[kevos37]

More zinc plating .....Yea!!!! I also dropped some items off to the chrome plating shop. HOLY GUACAMOLE !!!! Just a few small pieces on the Landcruiser made me think you could buy another fj40 for the cost !(haha)

Going to get back to installing all the brackets back on the motor now that I have all the plating back and get it installed.

 

[notaclue]

Absolutely subscribed! Amazing craftsmanship and attention to detail. I look forward to updates.

 

[65swb45]

Kevin

A question from a newb when it comes to plating. Did you blast ALL your hardware before you had it plated? The plater I talked with locally said oxidation was ok as long as the parts were oil clean.

Also, what are you planning to do for grommets in your headlight buckets where the wires pass thru?

TIA

Mark