Builds ‘82 FJ45 build thread..... no name yet (1 Viewer)

[sloanstavern]

After all of this amazing work, going with an aftermarket generic harness would be a letdown, IMO.

You’ve got your harness off the truck, so you can take it slowly, test frequently, and clean it and repair it in small sections.

I’ll leave you this link (NOT ME) for inspiration:

Thanks for the link, it is inspiring. I will most certainly try and save the OEM harness..... unless it is too "sparky"...

 

[sloanstavern]

I simply could not live with all the flaws on the fenders Hood and aprons so I bit the bullet put some 320 grit on the orbital sander and smooth them all out to fresh coats and it’s much much better now I can sleep at night.

A big day the body mount kit arrived and between this kit and some spare parts I had laying around from other projects I think I can make it all work I just need to get some more grade 8 bolts and it should be a go for tomorrow.

I contacted Daystar to order one of their kits and they said they were 10 to 12 weeks out which was not good news so I quick hopped on Amazon and one of their vendors had some inventory and luckily I got one that wasn’t stuck on an ocean vessel outside of Long Beach

The gasket for the cowel vent was rockhard and cracking. So I tried soaking it in silicone spray wrapped in plastic I woke up this morning and it was plump and flexible and I thought problem solved, then I put it over the plate and somehow hit a grown 2 inches longer! We will have to see if it shrinks back to size if not I’ll start over on something else

 

[Honger]

I simply could not live with all the flaws on the fenders Hood and aprons so I bit the bullet put some 320 grit on the orbital sander and smooth them all out to fresh coats and it’s much much better now I can sleep at night.

A big day the body mount kit arrived and between this kit and some spare parts I had laying around from other projects I think I can make it all work I just need to get some more grade 8 bolts and it should be a go for tomorrow.

I contacted Daystar to order one of their kits and they said they were 10 to 12 weeks out which was not good news so I quick hopped on Amazon and one of their vendors had some inventory and luckily I got one that wasn’t stuck on an ocean vessel outside of Long Beach

The gasket for the cowel vent was rockhard and cracking. So I tried soaking it in silicone spray wrapped in plastic I woke up this morning and it was plump and flexible and I thought problem solved, then I put it over the plate and somehow hit a grown 2 inches longer! We will have to see if it shrinks back to size if not I’ll start over on something else
View attachment 2846613View attachment 2846614View attachment 2846615View attachment 2846616

I may have a CityRacer cowl vent gasket you can have... will go searching for it tomorrow. When we did the rest on my 40 I had the cowl vent welded shut... no need for it and the assembly since I was putting in the Old Air unit.

 

[sloanstavern]

Definitely a mile stone today. She’s back on the frame, the good Lord willing for the last time. I started at the rear bumper while she was lightly supported from the ceiling and started placing bushings and washers one on each side and work my way towards the front. Each side matches its partner exactly for thickness and they lined up very nicely telling me the tub is pretty plum. Finally when I got to the front Where I modified the bracing in the tub I was able to squeeze a three-quarter inch bushing in there and it fit nicely. Then I went around and tighten them from front to back.

I don’t think there’s any binding issues however the clutch pushrod is quite close to rubbing on the tub I’ll need to watch that.

Are used the FJ 40 kit from Daystar for the top bushings, and then I used the generic 2 inch by three-quarter inch bushings for the underside. For some reason they would not except a steel sleeve so I had to drill them out a little bit on the drill press, nothing sketchy about that procedure

There she sits, can you guys tell what is missing from the tub that’s been in all the photos for the last two years and four days?

 

[sloanstavern]

On Wednesday I started fitting the front end on the passenger side. Things were going well and it was really satisfying until I hit the driver side and realized the louvered side panel on the tub was badly bent inward over an inch. Not sure yet how I’m going to fix that. It does flex but I’m worried about creasing it.

This is not the best solution but I might need to add a couple bolts on both sides to attach the side apron to the tub extension

 

[sloanstavern]

Did a little body work on ft doors and windshield frame, but mostly bling work. I got a really small package that cost a lot…. Funny how that works But it is OEM stuff for the light springs, plastic nuts, rubber pads on ws supports and a whipper sprayer that looks oddly like ET….I think I can reuse the WS pad, it cleaned up nice and has no rips or cracks

I said at the beginning I was not intending to do a factory perfect restoration so I simply can’t put a chrome or shiny bazel on this old girl. It’ll be painted white to match the roof.

 

[sloanstavern]

I know it is not a race, but if I don’t set some targets things kind of keep on lingering. I had a goal in mind of have the bodywork done by the end of November. I didn’t quite make it but yesterday I got the remaining loose bits in final paint, and I’m ready to start on the roof assembly. Hopefully I can get that done before the weather turns too cold for painting.

For the first time in two years the roof was outside and got a good bath, so I can see what I’m starting with I did give up a nice flat work space to stage all of my parts

While I am chipping away at that bodywork on the roof assembly I’ll also work on other smaller projects, I just finished a rattle can restoration on the steering wheel and column I need to fix some of the wiring that is booger up on the turn signal and then it’ll be job done. I could not find the dust boot for the steering column but I did replace the bearing and that has made a world of difference

 

[WarDamnEagle]

Very nice. If you haven't installed a new turn signal assembly I would highly recommend it. I have changed the turn signal assembly, the clamshell, and all the lock cylinders on all three of my older Land Cruisers. Toss up between the turn signal and the key cylinders as to which was the best purchase.

Paint is looking good. Exciting I'm sure to start putting it back together.

 

[sloanstavern]

Thanks, good advice. The ignition and turn signal worked great before disassembly and they cleaned up nicely. The part that’s boogered up is only the TS harness, For some reason at midpoint the cut every wire and then twisted them back together?

 

[WarDamnEagle]

All of my turn signal assemblies worked as well. It's just nice, for the relatively low price, to have new parts that you have to touch/operate constantly.

84310-60072 Genuine Toyota Switch Assy, Turn Signal

ToyotaPartsDeal.com offers the great deal for genuine Toyota parts 84310-60072 (8431060072) Switch Assy, Turn Signal for $140.34. All parts are backed by the Toyota's warranty.

www.toyotapartsdeal.com

 

[sloanstavern]

All of my turn signal assemblies worked as well. It's just nice, for the relatively low price, to have new parts that you have to touch/operate constantly.

84310-60072 Genuine Toyota Switch Assy, Turn Signal

ToyotaPartsDeal.com offers the great deal for genuine Toyota parts 84310-60072 (8431060072) Switch Assy, Turn Signal for $140.34. All parts are backed by the Toyota's warranty.

www.toyotapartsdeal.com

10-4, they are my go to place for OEM Parts

 

[sloanstavern]

Ya know how if you pull on a loose thread on a sweater, pretty soon you have a pile of yarn! That’s kind of what happened here. I was all optimistic about just doing a little bodywork and paint on the roof and then realized I made this far I might as well go the whole way.

It will certainly be easier to get a new headliner in the roof when it’s off. I think I may lay a fresh layer of fabric and resin on the inside but just thinking.

I am pretty sure that one piece gasket is not an off-the-shelf item at AutoZone

 

[changingground]

Ya know how if you pull on a loose thread on a sweater, pretty soon you have a pile of yarn! That’s kind of what happened here. I was all optimistic about just doing a little bodywork and paint on the roof and then realized I made this far I might as well go the whole way.

It will certainly be easier to get a new headliner in the roof when it’s off. I think I may lay a fresh layer of fabric and resin on the inside but just thinking.

I am pretty sure that one piece gasket is not an off-the-shelf item at AutoZone


View attachment 2853302

Your shop setup is really nicely squared away. Any thoughts about making restoration a small business? Pretty awesome,

 

[sloanstavern]

Your shop setup is really nicely squared away. Any thoughts about making restoration a small business? Pretty awesome,

Thank you you are very kind that’s kind of the plan. I left my career in a semi conductor business for years ago and while I wasn’t ready for golf and bonbons every day just keeps me busy.
If you guys don’t mind a quick side story, as a young man I loved working on cars but when I got married and had kids that kind of went away. In the late 90s I was watching a fun car show starring Stacy David, a very talented and funny gearhead. He ended every episode the same way saying “ you see what I’m working on, now get out there and work on something yourself“

That really motivated me to get started again I’ve had 2FJ 40s and I restored a couple K5 Blazer‘s with my son and a nice VW bus with my daughter. Plus a vintage type three VW square back and a beautiful Porsche 911. It is so much fun when you can breathe life back into an old classic vehicle. Plus you build a lot of memories with your kids or friends while you’re working on them.

Normally I keep the vehicle and have fun with it for a while and then sell it to move onto the next project. I have a feeling with this one I might cut it loose right away. I’m already starting to daydream about the next project.

 

[WarDamnEagle]

Great that you have restored such an eclectic variety of vehicles. Really cool. We bought our retirement home last year and it has a very nice shop already built. Looking forward to spending my days working at my own pace.

City Racer has that gasket. Just FYI.

 

[sloanstavern]

A big day and big decision made. Hopefully the last of the desert beige paint was applied on the roof side panels and a couple miscellaneous pieces. With that all that’s left is the white top which I’ll start shortly.

After careful and prayerful consideration I have to replace that wiring harness I could not find a single section that was not boogered up and cobble together. I picked up a 21 circuit painless universal kit at my plan is to reuse as many of the factory connectors as I can edit case all the wires and a nice high-quality braided wrap.
I was really concerned that even if I invested the hours to try and salvage that original harness there was a spark in there waiting to get out at the worst time.

 

[sloanstavern]

We had cold rainy weather in the forecast and I knew my days for optimal painting work fading quickly so I rush to get the top and bazel painted yesterday unfortunately the wind kicked up after the first coat and a dust devil went right through my painting area, I had to push everything inside and finish up but all things considered turned out OK. I know it’s not factory but I love that white versus the chrome on the bazel.

I started to tackle the wiring harness but my dining room table just isn’t big enough so I’ll set up a sheet of plywood in the shop tomorrow.

Warning to the purists, you may want to skip my next post

 

[sloanstavern]

Warning - purists proceed at your own risk …….
Today was all about immediate gratification, a lot of jewelry went on. I found some very nice stainless Phillips head screws for the bezel ( they call them cheese heads they must be popular in Green Bay ) and wingnut for the air cleaner, plus I have assorted stickers I want to put in service. I know they don’t match factory but I just think they look cool.

I had to drill new holes for the rear emblems and that was kind of white knuckle I don’t like stuff like that. But I think they lined up OK

 

[WarDamnEagle]

My Troopy has those same plugs or buttons for lack of a better term across the front of the top. Not sure if they match the number and pattern on yours but I had assumed they didn‘t come from the factory. Seeing yours I’m not so sure.

 

[Michael B]

Those “buttons” are rivet heads that hold the front header panel in place. They are stock.