74 '40 Build LM7/NV4500 (3 Viewers)

[h82crash]

Had to wait for an engine part so I worked a little on the TLC. I removed the soft top. It was a Bestop. I thought I just had the ugliest FJ40, but it turns out it was the top.

I also removed the factory engine mounts from the frame.

As soon as I get the engine reassembled I can start mocking up the new mount locations on the frame.

 

[h82crash]

Getting closer with the engine.

 

[h82crash]

Mock up in process. A lot to consider regarding clearances.

 

[h82crash]

I have the engine mounts tacked in place. Built a transmission support crossmember. Then I began the task of removing the Line-X bedliner. It is not a fun process.

 

[h82crash]

Got the body off.

 

[h82crash]

Fixed the tweaked rear crossmember and removed some broken bolts left by the PO. Got all of the undercoating removed from the frame and very happy with the condition. Waiting on some new spring hangers and will cut off the old front hangers from a shackle reversal. They are too short. Have to move the shackle hangers as well. Evolution Powder Coating is not accepting new business due to staffing shortages. I guess I have to haul it down to Farmington.

 

[h82crash]

After lifting the tub and exploring some more, there is rust under the sill cover and corners. Not the worst I've seen on these builds but, it is there. I removed the sill and blasted the tub floor. I have to replace some of that metal.

I received some parts.

 

[h82crash]

Almost time to flip the tub over.

 

[h82crash]

Getting more done. Some scraping, some blasting, some sanding, some hammer and dolly work.

 

[ceylonfj40nut]

Have you tried dry ice on that tar material? On my wife’s 40 I placed dry ice for about 15 minutes and whacked it with a mallet. All that tar material became brittle and cracked to bits and was so easy to remove. Thought I would share in case you want to try it.

 

[h82crash]

Have you tried dry ice on that tar material? On my wife’s 40 I placed dry ice for about 15 minutes and whacked it with a mallet. All that tar material became brittle and cracked to bits and was so easy to remove. Thought I would share in case you want to try it.

Tks. I've read mixed results regarding this asphalt based stuff. Also, its hard to find regular ice in my area, let alone dry ice. Its all off and already got most of the rust removed.
Got the frame back from powder coat today. Looks good.

 

[h82crash]

Started on the rust repair. I'm lucky the only area that needs replacing is the sill area. There is a bit of pitting in the gas tank well but it doesn't go through and is still solid.

 

[h82crash]

Welded up and ground smooth. Some hammer and dolly work as well. This corner had collision damage and typical insurance work repairs, as it had a lot of filler on it.

 

[h82crash]

Sill and cover installed. Been welding dozens of holes large and small. Closed off the already non-functional cowl vent, and I don't have to buy that stupid $50 grommet.

 

[h82crash]

This hole filling is a time vampire. Well, the planning and deciding which holes to fill and which to keep takes time, too. A PO butchered the radio opening. Put it back to a more factory size and will put a switch panel there. I chose not to keep the knee pads, I think it looks clean without them.

 

[h82crash]

Cut the opening and fabbed brackets for the touch screen head unit. And I fixed a PO franenfuk repair and wleded 40 holes on the transmission hump.

 

[h82crash]

Worked on some rust on the rear half doors. Only one is bad.

Driver door was bent/cracked at the forward window channel. Straightened and welded. Also the tabs for the limiting stopper were broken off. Fabbed new ones and welded in.

 

[h82crash]

I got the clutch release arm geometry all worked out and installed. Drivetrain in, hopefully the last time.

 

[h82crash]

I moved the rear axle back about 3.5 inches., in these photos. Final will be 2.5 inches back from factory. I set the tub to see where the wheel arch needs to be. Some adjustment was necessary.

 

[h82crash]

Finally on to bodywork. After a few hours of hammer and dolly work I could almost level the quarters with primer surfacer. But I applied some filler today. No photos of that boring crap.

The other day it was too cold and humid from the rain to prep the bodywork, so I worked on the fuel pump assembly. $300 for a drop in kit is absurd. $55 for a 94 Rodeo assembly with pump. I had to shorten the frame a bit. A friend is milling a mounting ring for me. He has written the file for it but waiting on some end mill cutters. I could have made the ring by hand but he is excited to get to use his cnc mill.