Builds 77 FJ40 Build, It begins...and may take a while (1 Viewer)

[franklin40]

few more parts..

amazon shipping is really slow so i’ve got time to paint before rebuild parts arrive

 

[franklin40]

starting to plan my brake lines out and it’s been so long since i took it apart i forget where they run. i recall the hard lines run down the right frame rail and there a junction that bolts to the frame but i can’t remember where it goes. can any one take a picture of where this guy bolts? from there i should be able to figure it out.

 

[franklin40]

made a mount for my slave spring. little projects like this are good practice welding aluminum. i need to learn my welder settings.

 

[franklin40]

got my splined winch motor gear for the xp motor. just waiting for the rebuild kits and i’ll get it back together. also got some parts together to make my own greasable spring bolts. little things to keep moving forward.

 

[franklin40]

couldn’t find the right size greasable spring bolts so i made my own

grade 8 bolts sure eat up drill bits!!

 

[franklin40]

got the winch back together. only had to take the brake apart once because i got one of the lower housing gears in backwards. it gave me the opportunity though to replace a seal on the brake shaft i had forgotten to replace.

i used the pipe cleaner technique to hold the bearings in place while compressing the brake spring.

also i’ve not seen any real documentation about actually installing an XP9.5 motor so i put a picture here. there’s a seal and a washer that come with the motor. i tested it with the washer on the shaft and it clearances well so i assume this washer goes here. of course the motor shaft is splined so i bought the splined gear to match

i’m pretty happy with how it’s turned out so far. i want to get an albright contactor for it but am having. a hard time finding one in canada. i might just try a knockoff one off amazon while i’m waiting to find the good one.

and finally with the stickers

ill also likely put synthetic line on it but i’ll do that when i get it mounted on the 40. it’ll be a while yet

 

[Varty Yo]

Ive had my eye onthe amazon albrites. Worth a shot for the price.

 

[franklin40]

Ive had my eye onthe amazon albrites. Worth a shot for the price.

right!!

 

[franklin40]

something like this i think. it’s rated to 500A. and that’s like $20 US right?!!

or maybe this one. still 500A rating and cheaper. connectors are pointing down though which i don’t know if that will be a problem with wiring under the cover.

 

[franklin40]

while looking for a deal i found this.

that seems like a good price. $20 more for the real deal seemed like a no brainer. what’s the point of putting all this time and money into it to cheap out on a part that if it fails will make the winch useless. i just couldn’t find one in canada and most shipping is a deal breaker. this one if definitely worth it

 

[Varty Yo]

Yup go for it! I replaced 2 solenoids inmine for $72 a few years ago

 

[franklin40]

back at figuring out what parts go where. it’s been a long time since i pulled this engine apart. now i can’t remember exactly what goes where so it’s a little slow reassembling. but with every part that goes on there are fewer parts left and spots to fill so ill get there

i got my throttle linkage hooked up and moving smoothly. mercedes made it more complicated that probably was necessary but i removed some unnecessary parts that were for transmission shifting and cruise control.

also got my engine accessories back on.

played with the atlas shifter set up. final adjustment will need to be done when i get the rub and tranny hump on

lastly finished up the lower greasable bolts finished. ill do the upper ones later. it’s a tedious job because i need to sharpen my bits after every bolt or two.

next i’ll start on making my fan shroud and squeezing an electric fan in. it’ll be a bit tight i think

 

[franklin40]

and for some reason this is one of my favourite things about this engine. a manual stop button. my painting around it wasn’t perfect but short of getting a new sticker it’ll have to do

 

[franklin40]

winch contactor arrived today

 

[franklin40]

i started running fuel and brake lines. i wanted to have the lines run clean but did t want to spent $200 on p clamps and then have to drill 15 holes in my frame. so i made my own. sorry for the messy floor n the back ground.

i took some aluminum bar and cut equal lengths and drilled holes. one 3/8 for fuel, one 5/16 for return, another 5/16 for fuel line to webasto heater, a 3/16 for brake line and a 7/32 for air locker line. they seem to be working but fabbing hard line it tough. i ruined a 10 foot length of 3/8. that’s like $90 . ill hopefully be able to use the smaller segments at some point.
here’s my first 5/16 run

also mounted this after repainting the mounting plate

 

[franklin40]

sneak peek

 

[franklin40]

i bought a holset xh30 turbo with adapters from benzforce. i’m just mocking it up now. my plan will be to run a water to air intercooler (due to radiator space) parallel to the intake manifold. before i fully tighten things up i need to drill a hole and put in an EGT gauge. this turbo should be a perfect compliment the super pump and injectors!!

i also had to remount my contractor on my winch. it’s a tight fit and i had to put it sideways. i had to carve out a few ribs inside the plastic as well. should be ok though. mine is a three wire remote socket and apparently they are harder to get around that the five wire. it is possible at least at this stage. we’ll see how it fits with the big wires in there

 

[franklin40]

running brake lines. ill have to get some custom made soft lines. the braided ones are a little too short for spring over.

also here’s a good reason to get rid of the stock diff breather. this was so plugged there’s no way it was working

i cleaned out the breather bolt and will use it to run extended breather hoses. it’s still a nice mount for the the axle hard lines

 

[franklin40]

i’ve been playing with mocking up my lines. here’s the centroid fuel sender i got for my @Downey tank. i went with a 0-90 holm sender because i’ll be going with dakota digital gauges and 0-90 is pretty standard.

one question i had was regarding my return line. as it’s diesel should i have a tube hanging down into the tank? i’ve heard that diesel can foam if its dumped into a nearly empty tank. is that a real thing? or is leaving it just dump back into the tank as my return is set up ok?

i’ve run my return line. i need another 3/8 for my fuel line (i wrecked the first attempt with a kink). i have my brake line and my air locker line in place. and one more 5/16 line for my webasto.

 

[franklin40]

i got my frame lines finished up. here’s a picture of main line on bottom, return just above it with an extra line for dedicated diesel preheater (webasto). then above that is my air line for locker and top is brake line. am i missing anything? . these are the aluminum line brackets i made. they turned out pretty good!!

now its time to clean and organize the shop so i can get ready to put the body on next week when i have some friends come over!!