A South African BJ40 rebuild into a FJ40

Joined
Aug 16, 2006
Messages
437
Location
Cape Town - South Africa
A South African BJ40 Total rebuild into an FJ40

Hi Guys

I've been lurking here for quite a while, stealing with my eyes.

In February of 2007 I bought a 1979 BJ40 in Brisbane Australia, took a while, but eventually got it shipped to South Africa

In February 08 I started stripping it down for a complete rebuild, and as I have a total dislike for diesel engines I decided to swap out the B diesel and transplant the trusty old 2F

Here I will document my rebuild so far

The 40 parked at a friends house in Brisbane Australia
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This was the condition of the 2F motor when I received it
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Before I pulled it appart, I installed a set of 4" Heystee Parabolic springs and an ARB front bar.
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I did a complete rebuild of the 2F before I started to strip the 40
The rebuild involved a rebore and replacing, pistons, rings, all bearings, all oil seals, camshaft reground for torque, fully dynamically balanced, new oil pump, new water pump, reconditioned the dizzie and fitted Pertronix eletronic ignition, skimmed flywheel, new clutch, pressure plate, thrust bearing and spigot bearing. The head was rebuilt and valve seats where changed to ones compatable with unleaded fuel.
The motor just before it was finished
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Then I started to pull it all apart.
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I sent the body to a friend that has a body shop - for the rust removal and repainting
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I decided to repaint the 40 in Rustic green Colour code 631
Here are some of the body parts as the painter finished painting them
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Last edited:
Joined
Aug 16, 2006
Messages
437
Location
Cape Town - South Africa
The work continued

The naked chassis before sandblasting
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The tub once I got it home
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The chassis after sandblasting.
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The axles where completely stripped sandblasted (outside only) then painted with Rust Bullet
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When I istalled the Heystee parabolic springs there was a serious issue with the shackle angles and as I was intending to keep the parabolic springs I decided to move the chassis shackle mount to achieve a better shackle angle as mentioned elsewhere on the forum.

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I also removed the standard steering box mount as Im fitting 60 series power steering, this mod also required the removal of the existing front shock towers

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And the removal of the diesel engine mounts

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More sandblasted components, some with rust holes that needed to be welded up.
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The new shock towers that I made up

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The completed motor with transmission as used for the laying out and positioning of the new engine mounts

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The diffs, after I fitted the ARB Air Lockers

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The chassis after it had been Rust Bulleted and blacked.

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All brackets, nuts, bolts, washers and pip[es have been re- yellow passivated.

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Joined
Jun 15, 2006
Messages
779
Location
Ipswich, MA, North Dakota, Phoenix
Welcome, neat! A first- diesel to gas. Nice looking truck. You must not have any problems vis a vis import regs and stuff like that, like most of us do? Keep the pics coming! :cheers:Ned
 
Joined
Aug 16, 2006
Messages
437
Location
Cape Town - South Africa
No real problems, just the normal rego and homologation red tape



The work continued;

Painted chassis with suspension and axles installed.

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Then I rebuilt the brakes, and all steering knuckles, bearings and seals in diffs and wheel hubs have been replaced with new.
Unfortunately I only saw Coolermans post on making up your own brake lines after I had a brake shop make up a complete set of new brake lines

Rear brakes.
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Notice full floating axle.
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The totally rebuilt front axle, with new disks, steering knuckles, birfields, bearings seals etc.

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Then last night I eventually got the engine in the chassis

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And tonite I got the cogbox (transmission) mounted too.
That is my progress since February this year, I'll keep posting as I progress.

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Joined
Aug 16, 2006
Messages
437
Location
Cape Town - South Africa
BTW my other truck is a FZJ105 (rigid front axle) 4500 EFI

Fitted with:-
Alloy Roof rack
Roof top tent
4" lifted suspension
45mm bore Tough dog adjustable shocks
80W solar panel
1 x 90AH Cranking Battery
2 x 105AH Aux Batteries
40ltr freezer on roller slide
39ltr fridge fixed mount
roller drawer packing system
Factory lockers fr and rr
VHF radio
Garmi 276C GPS
2 x chassis mount 35ltr water tanks
1 x 100ltr Main fuel tank
1 x 180ltr Aux fuel tank
On board Aircon pump air compressor
rear air springs
dual rear wheel and hilift jack carrier
TJM Alloy front bar with 2 x Lightforce spots
roof rack mount side awning
T-Max 12500lb winch
IMG_0623_1.JPG
 
Joined
Feb 26, 2008
Messages
1,256
Location
rome, georgia
Welcome:beer::beer:--you're doing great work--liked the mustard color but the green is pretty sharp--Thanks for sharing--wish I was at that beach!!
 
Joined
Sep 3, 2007
Messages
8,871
Location
New Zealand
I'd never put a petrol in my diesel - But wow! Great quality workmanship and great photography to boot. ----Well done

:beer::beer:
 

M5driver

MUD Addict (Ret.)
Joined
Dec 17, 2007
Messages
686
Location
Taylor, AZ
Oom Keith - super work. Now it's my turn to steal from you :D

Great color choice - I wish I could get work that fine done here in MW. My stuff is stalled again... hope to get it restarted today.

:cheers:
 

BJEC69

SILVER Star
Joined
Oct 26, 2006
Messages
453
Location
Pennsylvania 18350
Nice project and attention to detail. What did you do with the diesel? Keep those pictures coming!:cheers:
 
Joined
Feb 10, 2006
Messages
471
Location
Lillington NC
Wow, finally a 79 build! in my color too

Looks Good
 
Joined
Aug 16, 2006
Messages
437
Location
Cape Town - South Africa
BJEC69

the diesel motor is going to a friend in Namibia to be put into a farm truck - a 45 series pick-up
 
Joined
Aug 16, 2006
Messages
437
Location
Cape Town - South Africa
Update;-

Minor hiccup - Ive had a problem locating a suitable alternator. The search continues.

Did manage to get the 60 series PS pump on and power steering box clamped in - busy making up brackets and reinforcing back plate.

I have managed to get the tub on - this feels like a big step forward - although there is a slight problem at the rear a part of the rear panel need to be trimmed a bit to fit properly.

Some progress pics

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Joined
Nov 4, 2007
Messages
397
Wow,

That looks really good... I must admit I am surprised that you are putting a 2F where a B belongs. Maybe one of these days I will see it when I go there, for the first time, with my dad, who was born in Uitenhage.
 

Josie'sLandCruiser

Stop calling it a "FJ."
Joined
Feb 4, 2005
Messages
5,252
Location
Seattle, USA
Hi All:

Wow dude! You've been busy!! :eek:

That is quite the complete rebuild! Awesome work! :beer:

Oh, btw - if you need a 2F alternator I have a couple stock Toyota units out in the garage - would be happy to send you one.

Regards,

Alan
 
Joined
Jul 11, 2006
Messages
797
Location
Dallas, TX
I will be in Jhb in 3 weeks, and might be able to bring stuff. However, with the new SAA weight limits and the stuff I am already bringing is in excess, an alternator will definitely put me over.
 
Joined
Jan 12, 2007
Messages
1,645
Location
Houston, TEXAS
Great work - it looks super!!! Would love to hear the story on the rear wheel wells (the before pics were interesting in an unflattering way). Like your remedy though.
:beer:.
 

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