77 FJ40 restore

[jhunt]

I have wanted an fj40 for as long as I can remember and was finally in a position to purchase one a couple months ago.

I got a 77 the was originally mustard yellow but the PO repainted brown. I have started the process of a complete tear down for a frame up restore. I think I have only broke about 6 bolts so far.

Having a heck of a time getting the tub off the two bolts by the tail lights are near impossible to access and I think one of the heads is rounded now . Any tips on that, probably have to grind it down and take off the tub.

I hope to get the frame sandblasted this week so I can start the process of rebuild. So I wanted to start a thread for help since this is my first restore and I expect to need lots of input and help.

 

[tlc_4play]

For the rear tub nuts - use a tube (box) spanner or an extended socket

 

[timaus13]

Magnificent Site

Here you will if u search the forums find some of the worlds finest examples of full restores allready undertaken by their owners.
I am blown away by the time and effort these guys have gone to.

cheers
Tim
1978 FJ40 shorty
1976 Range Rover 2 door v8
Gadgets.

 

[M5driver]

Having a heck of a time getting the tub off the two bolts by the tail lights are near impossible to access and I think one of the heads is rounded now . Any tips on that, probably have to grind it down and take off the tub.

Hacksaw. Worked for me.

 

[Weedhopper]

Congrats !!! Welcome and have fun. Wal Mart Black & Decker angle grinder will become your friend for bolts like that. I got to the point where I could probably do dental work with mine.

Whats that sticker on the drivers door ???

 

[Ziffdaddy]

Whats that sticker on the drivers door ???[/QUOTE]


Looks like the Warn hub instructions....mine's on the dash next to the light knob.

 

[mikealeus]

Good luck, lots of hours and $$$$!! I know it will be awhile but are you going to go back to mustard yellow?

 

[apeterson]

grinder......... you will break many many more bolts before you are done my friend..... good luck and stick with it.......

 

[jhunt]

The tub is off!

Ok I have finally had some time to work on the cruiser again. After wasting time on trying to get the last 3 bolts for the tub off I rented a saws all for $7 and cut them off in about 30 minutes since I had to remove the two rear tires to get to them.

I recruited two of my neighbours to help me lift the tub off the frame and place it out back for the time being. They did not know what they where getting into so my wife is baking them two pies tomorrow for the help.

Picasa Web Albums - Jacob - tear down

So now to pull the engine, transmission, and transfer case clean them up, clean up the frame and start the process in reverse order.

I am thinking of painting it Dune Beige, that is the colour I have always liked although I am not opposed to the Mustard Yellow I do like that colour two so a little bit on the fence right now.

As for the sticker on the drivers side window, it was something about the wool growers association. It has been removed.

Excited to move on.

 

[kb3gun]

Looks like you have a great candidate for a rebuild. Tub looks to be in great condition!

 

[jhunt]

Finally, more progress!

Ok, between work and home I finally got some time to work on the cruiser again. Like I mentioned last time I got the tub off.


The next thing I got stuck on was removing everything else off the frame. The leaf springs took a while, found out the the PO made/installed one different shackle then all the rest it was about 2" longer thought that was strange.

Finally got the springs off and the steering damper.



I also got the engine mounted in my stand and now in the process of cleaning it, have to admit not excited about that part.

One issue I had was a funny ticking noise when the engine was running, after research and checking for vacuum leaks I was pointed to the rubber damper on the cam gear. Mine has cracks and missing pieces of rubber, so hopefully once that is replaced it will fix that.



So next step, I have all the paint for the engine, transmission, and gearbox now on to the dirty job of cleaning it.

Any tips on cleaning the engine? I have some industrial purple cleaner and some marine clean. Figure I would clean all the grease and gunk off then figure out a way to remove the rust.

 

[jhunt]

Time flies

Wow how time has passed, unfortunately the cruiser set pretty much untouched all winter. I travel for my job and I have been busy, but I have started back up.

Over the winter I had the engine hot tanked and inspected. The PO had a broken piston (#3) and replaced the piston but for some reason didn't clean out all the broken metal fragments so all the bearings had score marks in them. Piston #6 looked like someone had filed on the side of it...so I took the leap and had it rebuilt. I didn't plan on doing that, we will rack that up to the growing list of unexpected costs.

So I have a fully rebuilt 2F motor sitting in my garage in plastic, so that has inspired me to push on. I tore down the rear axle yesterday and wire brushed it, so I can put it back together. Then I will move on to the front one, and have the frame sand blasted.

Then I can put my rolling chasis together and start building up. I may not have done much phyically work on the cruiser over the winter but I did spend some money , other than the engine rebuild.

Painless wiring kit off eBay
parabolic springs from man-a-fre (great deal they where on clearance for $50 each)
weber carb rebuild kit from local dealer
Greasable shackles from coolcruisers
seatbelt kit from coolcruisers
lots of other odds and ends from various vendors.

 

[77HesterSue]

Thanks for the update. Keep up the work and keep the pics coming.

Can't wait to begin my frame off on my 77 - I'm inspired by what you are doing!

 

[johmbie]

how much, if any, lift? Looking great so far.

In broad strokes, what are you planning on doing yourself and what are you planning on farming out? (sheet metal, paint, etc..)

 

[jhunt]

I am not really planning on a lift, I have new shackles from CC and new leaf springs so I would imagine it could be about 2" higher but not much more than that.

Here is the new shackle compared to the one I took off.



As far as work I am planning on doing and what I am going to have someone else do is still up in the air.

I am going to have my frame sand blasted because it would cost me $75, and the amount of time it would take me to wire brush it and clean it up would be a lot. I probably won't have it powder coated as that is $400, so I am planning on putting on a coat or two of por-15.

I am actually very luck in the rust area, I only have 3 or 4 small cancer spots that will need to be cut out and fixed. I would like to try it myself but don't have welding equipment. So I will have either a friend do it or take it in to be professionally done (depending on the cost).

Painting I am still on the fence about, I have never painted a car before but seen some awesome first time jobs here in mud. I understand that a paint job is about 90% prep. So I went in to my local automotive paint store and talked it over. The where very helpful and supportive. But part of me is worried about buying all the paint supplies and screwing it up, so I am still going back and forth on that.

Other than that it's just time and money , and right now I can't decide which one it is more of, changes.

Thanks for the interest, it's a motivator.

 

[johmbie]

Thanks, you're sounding a lot like me, except that you've pulled the trigger and started. I keep trying to take little bites, although part of that is out of neccessity as I drive mine and part of a full restore cost would be a new car for the wife as she drives my truck...

I suppose that, if I were to give any advice, I'd say get a welder and learn to use it. You have a 40; you're going to need it eventually. Why not now and at least take a crack at those little spots? I'm not a good welder, but with patience can get what I need done. Each time I tackle a job I get a little more confident and some day I'll take a shot at my own cancer spots.

As far as paint goes, again, I'm with you. It's always seemed somewhere between art and witchcraft to me. But that simple fact just makes me want to tackle it all the more!

Last, but not least; get that thing together and drive the wheels off of it! The longer it sits the more you forget why you started to begin with. These things are fun to work on, but a lot more fun to drive and if you let life get in the way you miss out on one of the things that make life worthwhile!

Socrates moment over. Have fun friend!

 

[johmbie]

Oh yeah, where's Meridian? I grew up near Coeur d' Alene?

 

[jhunt]

Meridian is right outside Boise, in between Nampa and Boise.

 

[Performance_Tom]

I just ran across your thread and I was surprised you're in Meridian. I'm also in Meridian and I'm getting ready to undertake a FJ40 restoration. Do you have any final pictures of the completed project?