79 FJ40 Build

[fj40fillet]

Thought I would would start a post of my 40 restore project. FJ40 Powersteering Box Type
Brakes were shot. Ordered new rear disc conversion kit and new calibers for the front. Had the beefy front stock rotors recut. Engine ran okay, a little rough.
So far I have completed the following:
- Removed front fenders, grill, radiator & bracket.
- Sandblasted front clip frame, axle, tie-rods and repainted.
- Desmogged the motor.
- Welded exhaust leaks.
- Removed old steering box bracket from frame. That was more difficult than expected.

Right off the delivery truck from Alabama.

Stripped down for blasting.

Carburator is grime.

Manifolds after cleaning and painting.

Brake system refinished.

- Degreased and wire wheeled, brake booster, motor, alternator, power steering pump, ac pump, and repainted.
- Removed intake/exhaust manifold after breaking a stud during desmog.
- Fabricated new power steering pump brake.
- Replace all heater and cooling hoses.

In progress:
- Remove firewall items, clean, and repaint.

To Do:
- Reinstall intake/exhaust manifolds.
- Rebuild and clean carburetor.
- Flush motor/heater core cooling systems.
- Remove power steering pump and send out for rebuild.
- Install new brakes.
- Complete undercarriage refinishing.
- Start body work.
- Interior restoration.
- New factory wheels and tires.

I'll post the progress as it goes.

 

[Varty Yo]

Nice!!!!

Welcome!

 

[78fj40mg]

Nice rig!

 

[fj40fillet]

It's coming along. Still working in the engine compartment. Tonight I cleaned and painted the heater hose steel tube on the block. Removed the heater valve to clean it. It was stuck and full of corrosion. Dropped it in the Chem Dip tank for the night to see if it is salvageable. Chem Dip is awesome stuff. 1st time I've used it on a project. Anyone know where I can source firewall rubber grommets for the two AC hoses that currently have plumbers putty on them? AC was aftermarket on this truck as is the power steering. Sanded cooling fan with 120 grit to restore it. Also, have new lower sheet metal patch panel for the front bib rust. Keep plugging away a little every day.

 

[fj40fillet]

Grill wire mesh and sheet metal was kind of a mess. I tried to dolly it straight so I could paint it. Just couldn't get it straight. Going to install a new piece of flat bar there with some new mesh I have in stock. More fire wall cleaning and parts removal in prep for paint.

 

[AdamKFarmer]

The heater valve is still available OEM.

 

[DTSkyCop]

Nice looking 40, Subscribed!

 

[fj40fillet]

Yeah, I'll check the valve out tomorrow. It's moving now. If I can't Weld Bond the thin spots and paint it, I'll replace it. I really like these ABA hose clamps. First bought some from SOR. Just ordered more on Amazon for cheaper. The cooling system hoses tee was a mess too. Soaked and Epoxied it. Surprised how much hard deposits blockage both had.

 

[samc2447]

Cruiser Corps has a good selection of firewall grommets.

 

[fj40fillet]

Thanks I'll check it out. Picked up some 1/4"x1/4"x1/8" angle to fabricate a new radiator screen. That should sort that out pretty well.

 

[fj40fillet]

Heater valve is junk. Cosmetically okay, but does not flow water through the valve. I'll order a factory replacement.

 

[oldschool4wheeling]

Before installing manifolds, make sure you get them RESURFACED and SPOT FACED.

 

[fj40fillet]

Will do. I have a buddy that does machining that I think can handle that for me.

 

[oldschool4wheeling]

Pardon me if you already know this.... but spot facing is as important as surfacing.

Spot facing levels the manifold where the bolt goes. So that the bolt has the same clamping pressure across both aluminum intake and the cast iron exhaust.

 

[tstepp920]

I didn't know that, just like I don't know crap about most of this stuff. That's why I'm here. Thanks. Keep it coming

 

[fj40fillet]

My exhaust and aluminum intake ports as if sits on the bench right now are not aligned flat. When they spot these manifolds and redeck them, do they jig them up as they would be mounted on the engine block, and them mill them flat?

 

[oldschool4wheeling]

I'm not a machinist....but when they resurface the deck.... I'm sure they would spot face 90 degrees to the resurfaced deck.

They also tack your exhaust horns to the main body of exhaust manifold so that they get squared up too. Your exhaust horns #1 & #6 have a couple of gasket rings going back into main body.

Note: As I was told..... if your machine shop doesn't know what spot facing is... then go find one that does.

I called 4 reputable hot rod machine shops and they never spot faced " son I've been doing this for 35 years and I have never done that".

So finally I found one that does tons of diesel engines and he was well versed in the subject of spot facing and how to do it.

The pics below..... the red line show the spot faced bolt holes.
The blue shows where the gaskets are for the horns.

 

[oldschool4wheeling]

All of this knowledge is from @FJ40Jim .
I highly recommend him to rebuild your carb too. And if you desmog it, follow his desmog thread.

 

[oldschool4wheeling]

Red lines, look closely where the bolts go... Notice how shinny they are. That's spot facing...

Blue lines, is where the gaskets for the horns are

 

[MOTOV8R]

Is spot facing needed on the outer two holes in the exhaust manifold or just the other 4 that are shared between the two manifolds?