A South African BJ40 rebuild into a FJ40

[tlc_4play]

New Overhead Console

During this past week I made and upholstered an overhead console for the 40. This will be home for the VHF radio, two speakers for the radio/mp3 player and also serve as storage for camera, binoculars, sunglasses etc.

It is made from 6mm marine ply, upholstered on the outside with foam and black vinyl. The inside is carpeted with carpet tiles so that the stored items dont rattle around.

It is attached to the front windscreen frame with 6 x self tapping screws and the side hooks over the inner section of the roof channel.

 

[aircrew]

Did I read that right, Diesel to gas????

Can I have your old engine!!???

 

[dallasryan]

What did you do with the Engine? Any change you want to donate it to my project vehicle if i pay for shipping?

 

[tlc_4play]

I've had a few past bad experiences with diesel trucks so they are one of my pet hates - especially the old ones, that are not really strong or economical for that matter, so I pulled out the perfectly running (albeit a bit smokey) "B" diesel donk (3Ltr - 55KW wouldn't pull the skin off a custard) and replaced it with the silky smooth 2F. during the rebuild I also added 60's power steering, lockers, and other candy.

Sorry guys but the Diesel donk has already been promised to a friend in Namibia.


Widscreen Wiper Problem

Driving home on Friday in one of the infamous African thunderstorms (2" of rain in 1hr) and the windscreen wipers died on me AAARRGGHH .
one home I discovered that there was no 12V to the power supply wire to the motor, so I hot wired a 12V wire from fuse to motor terminal, but, now the wipers are only one speed and Ive checked everything, even to the point of swopping the two motor brush connections (which gives the motor its 2 speeds) but I still end up with only one speed. However the return to park function still works.

So it would appear as if one of the brushes in the motor is toast - now to get a new or working used windscreen wiper motor.

 

[tlc_4play]

I had the windows tinted with security film yesterday.

In Africa there is a severe problem with Smash n Grab robberies from vehicles, this film is 135 microns thick and prevents the thieves from gaining access from a smashed window and also offers a UV exclusion tint at the same time.

 

[tlc_4play]

You guys have probably read my other thread about the overheating problem I had in the Kalahari this last December
this problem turned out to be as a result of the wrong size fan being on the 2F engine that I got from a friend in Namibia - and when I rebuilt the motor and replaced the fan and viscous coupling I assumed (assumption is the mother of all fekkups) that these were the correct size for the 2F - big mistake
As a result of continually running it to overheating in the desert the engine developed a knock.
I dropped the sump and checked the mains and big ends - although they were not in great condition they were not bad enough for them to knock - so the diagnosis of the knock was my worst fear - piston slap (knock)
So I have now commenced tearing down and removing the body panels to remove the motor to replace pistons and rings.

I'll keep you posted




But onto something a lot more positive;-

After completing the rebuild of the BJ into an FJ, I mentioned that I didn't know what I was going to do with all this extra time that I now have on my hands and, , , , I would really like to start a rebuild on another 40 - but because finding a 40 series is like rocking horse sh1t in Africa, it would be extremely difficult.

Well good news - I have bought another one - a 1983 FJ40 LX - I am presently arranging to get it to my son's place in Sydney Australia.

Here are some pics of what it currently looks like - Parked in Sydney Aus
Once its here in South Africa
I'll start a new rebuild thread - this one is gonna be a soft top, colour the same as the ICON

 

[Teebag]

Congrats Keith

 

[M5driver]

Sweeeeet, Keith!

Glutton.

 

[tlc_4play]

As I ruled out bearing knock as the noise that had developed as a result of continually driving the truck whilst overheating in the Kalahari desert in December.

This morning I pulled the motor and cogbox out of Kermit in preparation for pulling the motor down to locate what should be the source of the knock - piston slap. This is one hell of job to do on your own, phew ~ working on this truck is lot more difficult since my son emigrated to Aussie. But fortunately the motor is now on the garage floor and will have to wait until I get back from a two week business trip to (-2deg C) Germany [Berlin] and Italy [Rome], before I strip it down
(We South Africans are not built for the cold)

 

[M5driver]

(We South Africans are not built for the cold)

Keith, I understand this! Those of us from Arizona are not cold adapted, either. You could come "warm up" in DC - it's been running around -6C here. After Malawi, this is COLD!!!! When I go outside, I look like the Michelin man and feel like an ice cube

You should do more business in Oz

 

[tlc_4play]

Dan

Funny you should say that - I'm off to Aussie for a two week business trip in mid March

The amount of traveling I do ~ my wife reckons I'm a temporary resident ! !

 

[M5driver]

Safe travels!

 

[Hobbs]

Yep, this right here is what I'm talking about... This is one of those threads that makes me drool....

Very nice work!!!

 

[tlc_4play]

Pulled Kermits motor apart

Those of you that have been following this thread will know that I picked up an engine knock from continually driving the truck to overheating in the Kalahari Desert in December.

Before I went to Europe I pulled the motor and cogbox out in preparation for pull down and rebuild.

Well. Yesterday I pulled the motor apart and sh1t did I get a shock.:whoops:

I lighted sanded the top of the cylinders with abrasive tape to prevent the possibilty of the rings snagging. Wasted my time

The 1st piston I removed was no 6, the second compression ring was broken into about 10 pieces.
The 2nd piston I removed was no 1, the second compression ring was broken into about 15 pieces
The 3rd piston I removed was no 5, the second compression ring was broken into about 8 pieces
The 4th piston I removed was no 2, the second compression ring was broken into about 6 pieces
The 5th piston I removed was no 4, the first (top) compression ring was broken into 3 pieces, and the second compression ring was broken into about 15 pieces, and the piston had 4 score marks down its side (but no damage to cylinder)
The 6th and last piston I removed was no 3, the second compression ring was broken into about 4 pieces

My assumption is as follows;
the fact that I was constantly driving the truck in 45deg ambient temps in the desert, to the point of overheating, then waiting for it to cool down then continuing on further until it overheated again, and this continued for over 500km, has accounted for the broken rings and no 4 was the first piston to break its rings (but:- assumption is the mother of all fekkups)

BTW - when I rebuilt the motor - the pistons were Yota original, but the rings were from Terrain Tamer - Aussie.

I would be very interested to hear any and all other theories on the causes of ring breakage especially when it is only the 2nd compression ring.

 

[tlc_4play]

Well I cant believe its taken me nearly two months to rebuild the 2F.

If you followed the thread you will know it was severely overheated in the Kalahari desert in December that resulted in a broken rings (that were also incorrect - but thats another story)

Work done on rebuild;-
Honed cylinders
New Pistons
New Rings
Reground the crankshaft
New Main bearings
New Big end bearings
New Cam Bearings
New Oil Pump
Skimmed head
Re-seated all valves
New oil seals and gaskets
Alternator re-wound and output upgraded from 35Amp to 75Amp

Here is the finished item - it gets put back in on Saturday morning, so Kermit should be back on the road by Monday, Tuesday the latest

 

[tommckenna6]

Wow...that is a first class rig!

How many months/years do you think in total you have spent on Kermit?

 

[tlc_4play]

Thanks.

Last year I started the tear down in late February 2008 and I had Kermit completely rebuilt in Mid October 2008 so that was 8 months.
Then I removed the cooked motor after our Kalahari Expedition in Late February 2009 and I will have him back on the road by middle of next week, so that is another 2 months.

The total rebuild (motor was done twice) has taken 10 months.

 

[tlc_4play]

Awaiting heart transplant

This is the present state of Kermit as he anxiously awaits his heart transplant

 

[tlc_4play]

Well at last ! ! ! !

Kermit is running again, a special thanks to those that helped me drop the motor in - you know who you are

sorry for the poor quality pics but it was already evening by the time I got all the tools packed away

 

[tlc_4play]

The Next Project

Now that Kermit is running and back on the road again, I need to start preparing myself for the next rebuild

I bought this in Sydney Australia in January, together with another 2 x 40's the container should have shipped out of Sydney for South Africa last week Friday.

It is a 1983 FJ40 LX with factory power steering and 5 speed cogbox.

Once it gets here and work starts - I will put up another rebuild thread