69 FJ40 "Rattle Can Resto." Build up

[jsuthey]

Hi All,Been real busy working on my truck.I have wanted to start a build thread for a long time,as I have photos from along the way.I can't seem to load up the older pics.as they are too big,so here are some new ones from today.I am working on the rear brakes,the wheel cylinders are shot.They are froze up and won't adjust,at least I got the drums off easy!(BFH and a block of wood).My master cylinder is shot,so it's looking like a rear disc.conversion is in order.Lots of info on this here! Poser you will have a PM soon! Gonna pull the trigger on this!

I have alot more questions,but search is our friend! I am also needing a new master clutch cylinder(thinking CCOT or JTO) clutch pedal is froze up also& it won't move..So once I take that off I am going to remove the firewall divider and try to make some room for the new booster/mc.Thats it for now.
Cheers,John

 

[jsuthey]

Hre are some more pics.! Engine bay shot right after I installed the headers,I have a big leak top left on manifold/header.Lots of hot air blowing out there,tryed to re-torque aftr running it hot for a wile but it did not work.Guess I will try a different gasket,I used a new one from SOR.Everything seemed to bolt up nice and flat,guess my header is a bit warped.Maybe a spendy fel-pro gasket will do the trick?

Also did the Herculiner inside,went on pretty nice! Still working on the tranny hump,just got done cutting the holes for tranny and TC.So I saved a little Herc.for that.The one gallon was perfect amount.Still lots to do!

 

[jsuthey]

Got the drums& backing plates off today.Did a real hack job on the plates! Guess I really did not want to take the axle shafts
out.Took the sawsall and grinder to the plates and it was not that easy.
Also worked on the parking brake,I assembled what I had took off months ago and I am missing the 2-smaller springs that go on the top/sides.Anyway I could not get the drum back on? seems like I had the shoes on correctly e-brake off and it will not slip on there.Oh well,going to have to order those springs anyway.I thought about the whole kit from SOR,CCOT or JTO.Well see case I need to order more stuff anyway,it's only money and I don't have much!!

 

[71cruiser71]

looks great! cant wait to see what it looked like when you got it. to resize a picture just right click the pic and there will be an option to resize. just resize it to the smallest one available.

 

[jsuthey]

Hi all,just messing around after work and started her up 1st.try.Let it idle for awile,I have got to fix that manifold leak! Hot air blowing right out the top left side.Do I have to get the expensive fel-pro? gasket,or is there more tricks to seal it up.

1st.pic.is my Newcastle bottle gas can! Works pretty good,my truck has drank quite a few of these so far.My gas tank is getting ready(waiting on $$) to go get hot tanked and sealed at the local rad. shop.

2nd.pic.is my little helper, she is always wanting to get wrenches and help out.One day she even made me a sandwich(she is 5 !)

3rd.pic. is trying out my 33x12x50 tire on the factory tire carrier.Gonna have to modify this a bit to fit,rims are 15x8 with a 4" backspace.I would also like to mount my hi-lift jack on there too somewhere.
Thanks,71cruiser but I could not find the re-size option on my right click.I will try some more later.Also ordered my rear disc.brackets,hardware&rotors from Poser(checks in the mail man!-today)

 

[jsuthey]

Just to correct myself on the manifold gasket,I meant to say use the spendy Remflex one(not fel-pro).What was I thinking.Anyway,are there other ways to seal it up in place? Or take it apart again and use?

 

[bsilva132]

The fel-pro should work. You can always try two gaskets and use brass washers and it may or may not work. I ended up taking the manfold and header to a machine shop and having them trued (header was a little warped). I also swapped the bolts for studs. Seems to be working well.

edit - if you have a straight edge you can always check the maifold and header at home instead of taking it to the machine shop.

 

[Isaacjohnstar]

Nice cruiser... I really like the color!
If you haven't ordered the clutch master, I would not recommend JTO. I ordered mine and it went out after three drives. Then it took them a month to get me another one.

 

[RustyzChopShop]

i love newcastle

 

[jsuthey]

Right on guys,I am stoked on the replys.

bsilva,yea I did not straight edge it,but I did lie the setup on a flat surface and it seemed good.I guess it will have to come apart and check it out.I have lots of straight edge stuff to use(I am a carpenter!).But I am still thinking about using the Remflex gasket,there is a intro.price of $39+s/h.From a guy here on mud,sounds like a good deal if it will work for me.

Isaac,thaks for the heads up on JTO's clutch master/slave setup.Maybe I should try SOR($179+push rod) or CCOT($158 on sale from $189+ $5 for push rod).Sounds like a good deal on CCOT.

Rustyz,yea Newcastle is really good beer!!! We also found it in cans to take on wheeling trips(after a day on the trail!) to pack out easy.On draft also,nice to enjoy a pint or 2!!

Yea right now I am just trying to get all the parts for my rear disc.brake conversion.I have ordered brackets,hardware&rotors so far.Next up is Booster(looking at 81 mini),Master cylinder(FJ80-from Marlin),Calipers(mid 80's Monte Carlo from Napa),Porp.valve(Wilwood,summit,or Russel brake,etc.?),Residual valve,check valve,Brake lines,fittings,pads,ect.s*** this stuff is adding up fast,still need to deal with firewall situation.Lots to do man!!!
John

 

[jsuthey]

Hi All,been lurking a bit on here but not posted up much.It's already been 3-months since I last posted up on my build thread.My camera is messed up rt.now so no new pics. to post up yet.I will try to get some more up soon.
Well I have got some done on my project,but my hands have been tied lately with family,work&the now short days.It's not as motivating with it dark early&cooler temps.
So I have lots of parts now stocked up.Got the rear disc.kit from Poser,monte calipers,pads&rubber brake hoses.Still need lots of fittings& hard lines.Got the brackets bolted up,buts thats it so far.Also got an FJ80 Master,still looking for a booster and rear porp.valve.Got the firewall adapter from JTO.But man it's looking like it will be a real tight fit there with the carb.! Lots to do with the brakes still.
Got the gas tank back from the local rad.shop.Looks great& installed pretty easy.They painted it black with some good paint,(looks powdercoated) after the hot tank cleaning.
Got the new clutch master installed(el-cheapo one from CCOT)
Still LOTS more to do,sucks feeling sick this weekend-bad cold flu.!
Cheers,Johnps no beers for me this weekend!

 

[jsuthey]

Heres a few more pics.Stoked to get rid of that old camo paint job.I also have some shots of the engine bay and interior before shots.Lots more to post up,Just have to figure out how to resize them.

 

[jsuthey]

Hi All,Finally started work on the 40 today.Painted the rear calipers,ready to bolt on with pads/rotors.
Changed the manifold gasket with a Remflex,hope it fixes the leaks.I checked with a stright edge everything looked good.
Did not fire it up yet as the carb.is still out for the master clinder/booster set-up.I had it all bolted up for a test fit and everything fits good.
Can't wait to get it running again.The gas tank is also installed after a hot tank dip and paint job.It looks great.

Also new parking brake shoe kit on the way w/some other goodies.

Lots more to do,I will post up some new pics. soon.

Cheers,John

 

[acollins10]

I think we have the same color cruiser. Keep up the nice work.

 

[jsuthey]

Well,here are some shots before I started my build.My 40 had sat for almost 10 years.It was waiting for a new engine when I found an 80,thats why it sat for so long.
I built the 80 up and the 40 was put on the back burner! I wanted to try and get some engine bay pics. up of the before pics.
I will keep trying.

John

 

[jsuthey]

Dang,two crappy shots of the front disc.brakes.All I can see when I try and load them is the pic.#'s.Loks like I loaded my max of 3-for now.Time to buy a star allready!

Hey nice pics. there acollins10,I had to do a double take there for a moment! I see you have the old school Rancho lift also(gut buster)!
Nice paint job,did you rattle can it or do it right?

 

[jsuthey]

Allright cool,here are a few of the before engine bay pics.I will look for some interior shots also when I tore into it.I pulled the rust trapper carpets up and took off the tranny hump,wow it was looking rough.
Lots of surface rust,but I know because I half-assed it it gonna keep comming back! Oh well,I want a wheeler not a show truck!(it's a low buck build up)

 

[77HesterSue]

wow, you've done a lot of work. looking good

 

[jsuthey]

Thanks for the reply,yes it has been alot of work! But it's taking me way too long,I am really slow at this stuff.I just can't find the time to work on it like I want to,my hands are tied sometimes with all life's other stuff! It would be nice to have a little help here and there,but the few Cruiser folk I see around here are not that into it.So you just have to do everything yourself(and I have!)
But I have started a little work now on the weekends with the days getting a bit longer.
Here are a few more pics.of the firewall,new donor eng.(from a 71 40)getting put in and rust bucket floor!
John

 

[plt2099]

Newcastle resto

Just caught your resto post, love the picks should help me get motivated to finish my 69, maybe even do a post myself also, guess though since Newcastle has already been used, I'll have to use Shinerbock from the great Spoetzel brewery.