72 FJ40 Chevota Build (1 Viewer)

[Tokamak]

Hi,

I think it is finally time to introduce myself and document my build. I picked up this '72 FJ40 from my daughter in law in 2006. She needed to get rid of it and had always wanted one. I was in the middle of a house remodel and had no garage. So she sat waiting for me to get done. I started reading builds on ih8mud in the tech links and learning about the options. Didn't know about FAQ but sure wish I had. Finally finished the remodel and the wife let me build a garage.

I started picking up parts here and there but committed to disassembly in Oct 2011.

Thanks for all of your help so far with your build threads, posts and answers to my sometimes anal questions. This is a great source of knowledge, and I want to learn and contribute too.

John

 

[oldmuddog]

Welcome. Looks like a nice project My 78 has been in my shop for 2 years without a body , Take your time and you'll be happy with the results.

 

[Tokamak]

Catching you up on the work already done

I decided on the GM 350 TBI. Went looking for a donor vehicle. I opted for a used engine and the safest was a low milage complete vehicle. Wasn't sure about the LS1 so I went with the Gen1. To do it again I would probably go with the LS1 for the lap top computer interface.

I found an 88,000 mile GMC 3500 Sierra running strong was originally owner by the city of Santa Barbara. Figured I would be safe.

Removed the engine, and the complete wiring harness to the tail lights, fuel pump, sending unit, fuel lines, computer, fuse box and relays.

Cleaned the exterior of the engine, removed the covers, intake manifold, and oil pan. Painted everything and re assembled.

 

[nspctr1]

Nice and Welcome. Keep the pics coming...

 

[mruff]

Looking good. Like others have said, take your time. I raced through my to get it done and it took 75% of the fun out of it

 

[Tokamak]

NV4500 Transmission

Still catching you up on my build.
I found a used NV4500 from a 1995 Tahoe rollover. Installed an AA Adapter and painted it.

 

[Tokamak]

More catch up

Removed old bell housing pins to install offset pins.

Installed new flywheel, clutch and pressure plate.

Checked and centered Bell Housing.

 

[Tokamak]

Catch up

Install NV4500 Transmission

Finished my Orion and installed it

 

[Tokamak]

Still catching up

Rebuilt the front axle. New bearings, old gears, new ARB.

Made my own knuckle centering tool to complete the job.

Added GM Rotors and Brakes

 

[ElHefe]

Subscribed, this is going to be a beast.

 

[BigRed40]

Looking great! Keep up the good work!

 

[Diskord]

Damn fine job. I'm taking notes

 

[Pierps]

Gorgeous so far! Subscribed indeed!

 

[Griffin]

holy smokes that looks clean, well done sir!

 

[Tokamak]

More catch up

Thanks for all the good feedback. Would have liked to keep you updated as I was doing it.

This is the rear axle. When taking it apart I found that the PO had not staked the pinion nut. It also had a crush sleeve installed. Found small tooth chips in the bottom of the housing. So I replace the R&P with a Nitro with solid spacer.

I couldn't picture what was good and bad in the pattern (first time doing this) so I used a .020 and a .010 to see what the two ends of the adjustment looked like. I could see the flat and curve in the pattern. Then split the difference with the .014 and could still see a little flat in the pattern. Looked like I needed a little more. So I settled on .017.

Installed a Spartan Locker. Was going to use a Lock Right but they didn't have any at the time. Don't know if one is better than the other.

Installed the disks and brakes.

 

[SSCR]

Very nice work! What color and type of paint is that, that your spraing on the motor and other parts? I like the cast iron gray look.

 

[Diskord]

Agreed, very good work, and love that color on the engine/trans

 

[Tokamak]

Dupli-Color Cast Iron and Low Gloss Black

Seems to be pretty tough banging around during assembly.

 

[Tokamak]

Frame Catch up

The PO had hit the right front bumper hard enough to rack the frame 1/2" back on the right side. After calling around and getting crazy quotes to straighten the frame I figured I could do it cheaper. HF hydraulic stuff.

Got it straight and square without much trouble.

Sandblasted it. Then rattle canned it Dark Bronze hammer tone. The hammer tone didn't show up too good. Fine line between hammer effect and runs and I nobody wants the runs.

 

[terrx]

What are you using to support the rear of the transmission/tcase? I see you haven't removed the crossmember (yet)...