AA Ron's FJ40 refresh (7 Viewers)

[airon23]

Ok time for an update. I feel like I got a lot of work done this weekend so I wanted to post an update. It's pretty exciting to start seeing more of the garage floor empty rather than full of parts. Those parts are steadily moving back onto the 40.

I got a good chunk done on the Vintage Air install. I've sort of jumped around just a little bit. This is mostly because I didn't have the heater hose, then the alternator possible upgrade, along with the fact that I started in the cab with the actual unit rather than with the engine compartment. I don't remember seeing something saying to start with that, but I got to the point that it was saying to connect to things I hadn't yet installed so I moved on to those things.

Radiator getting ready to go in.

I got all the cooling system hoses connected.

I wrapped and painted the headers to help with some of the heat. Then I got them installed along with the intake manifold, that farthest back bolt though...PITA.

 

[airon23]

It's very rewarding seeing this table once full of parts is down to a relatively small amount of parts and hardware. Perhaps a little light at the end of the tunnel, but I don't want to jinx myself. Getting the interior all back in will be another big step. I think I'm almost ready for that, but I wanted to finish up the AC unit before I put it all back in and then need to take it out again.

 

[airon23]

Finally today I went in the garage not intending to work on anything and take a little bit of a break, but then I saw the roof rack flooring and then just started in on measuring and getting it ready. Then before I knew it I was doing the whole thing. Still needs to be bolted down, and maybe some tiny adjustments, but it's pretty well in.

 

[airon23]

Finalizing some of the smaller items on this vintage air install. I wouldn't say it is a difficult install, but a little tedious and with my additional work getting finished on my engine refresh, it makes for me jumping around a little from task to task. But I'm getting very close to finishing up the install as well as wrapping up things on the motor so that is exciting. Depending on schedule and time to work on this, I could be done in a week maybe two optimistically or maybe even three based on finishing up exhaust, alternator, winch, etc. Ok who are we kidding let's give me like a month and then maybe I'll be done...I hope.

Not much in the way of pictures, but I did get a little bit of headliner material that was wrapped around the winch plate I ordered from CCOT. I wanted to try to use it so I lined the glove box and I think I'll line the center console eventually too.

 

[airon23]

Ok so just as I thought I would jinx myself by saying when I should be done, it happened.
I was all ready to start putting the all the interior back in starting with the gas tank but then come to find after cleaning up the gas tank, there are some pin holes.

I guess this was a blessing in disguise. I'm glad to not have put this back in only to continue smelling the gas fumes and then remove and replace it later. So the good news is I've already ordered a replacement from CCOT, not OEM, but their replica looks pretty good. So once I get that in (should be here Monday) I can start putting things back together on the interior. Exciting stuff.

 

[airon23]

But I didn't let that get me down. No. There was too much still left to do before I can get this thing running once again. So I just kept going. I ended up throwing the same alternator back in for the time being. I figured if/when I want to replace it, it shouldn't be too hard to do that even with everything put back together. So it's just all getting thrown back in there for now. So I have fastened the hoses and radiator in place and have to make some final wire connections for the vintage air unit. But we're in the end game now...

Finally located the correct belt size for the compressor. Should've listened to their recommend, but Napa was pretty much the only place that had what I needed.

 

[airon23]

Last but not least for the night I wanted the radio knobs to somewhat match the style of knobs from the A/C. So call me vane but I swapped out the faceplate and knobs finally. I never liked how the standard faceplate that came with the retro sound was too big and how it looked so I wanted to swap it out eventually so now was the time. I like how it looks much better now. You can tell there is a little cut out on the sides behind the radio, but it doesn't look too bad.

Before:

After:

 

[Ackcruisers]

Ok so just as I thought I would jinx myself by saying when I should be done, it happened.
I was all ready to start putting the all the interior back in starting with the gas tank but then come to find after cleaning up the gas tank, there are some pin holes.
View attachment 2396791 View attachment 2396792

I guess this was a blessing in disguise. I'm glad to not have put this back in only to continue smelling the gas fumes and then remove and replace it later. So the good news is I've already ordered a replacement from CCOT, not OEM, but their replica looks pretty good. So once I get that in (should be here Monday) I can start putting things back together on the interior. Exciting stuff.

Minor set back. Let me know if you’re happy with the CCOT replica tank.

 

[Ackcruisers]

Finalizing some of the smaller items on this vintage air install. I wouldn't say it is a difficult install, but a little tedious and with my additional work getting finished on my engine refresh, it makes for me jumping around a little from task to task. But I'm getting very close to finishing up the install as well as wrapping up things on the motor so that is exciting. Depending on schedule and time to work on this, I could be done in a week maybe two optimistically or maybe even three based on finishing up exhaust, alternator, winch, etc. Ok who are we kidding let's give me like a month and then maybe I'll be done...I hope.

Not much in the way of pictures, but I did get a little bit of headliner material that was wrapped around the winch plate I ordered from CCOT. I wanted to try to use it so I lined the glove box and I think I'll line the center console eventually too.
View attachment 2394229

View attachment 2394230

When you installed the Vintage Air, curious if you relocated the carb cooling fan relay and seat belt buzzer from the inside firewall to the outside of the glove box as instructions suggested.

 

[airon23]

Minor set back. Let me know if you’re happy with the CCOT replica tank.

Will do. If nothing else I'm happy with the turn around time. I ordered it late Thursday night so basically Friday morning and it was already shipped and is supposed to be here by Monday. Pretty quick. I'll shoot some pics and give you my thoughts on what I think of it when I get it installed.

When you installed the Vintage Air, curious if you relocated the carb cooling fan relay and seat belt buzzer from the inside firewall to the outside of the glove box as instructions suggested.

So I've found that almost everything they suggest is just a "you might as well do it" because I've tried to go nah I should be good and then I ended up either making it harder on myself, or having to do steps twice because I didn't listen the first time. The one thing I think I got away with is not cutting the screws off the grill's Toyota emblem completely off like they state and provide squish washers to hold it in place. I did cut down the screw parts but it still screws onto the grill like it's supposed to.
As for the relays and stuff I had to tuck them on the left side of the glove box. It was a PITA to mount it there because the wiring harness doesn't have a lot of wiggle room at that point, but I was able to make it work.
They also want you to cut part of the old mounts that held the relays off to make room for it. Again I tried leaving it be, but it makes it too tight to install the unit itself.

 

[Ackcruisers]

Will do. If nothing else I'm happy with the turn around time. I ordered it late Thursday night so basically Friday morning and it was already shipped and is supposed to be here by Monday. Pretty quick. I'll shoot some pics and give you my thoughts on what I think of it when I get it installed.


So I've found that almost everything they suggest is just a "you might as well do it" because I've tried to go nah I should be good and then I ended up either making it harder on myself, or having to do steps twice because I didn't listen the first time. The one thing I think I got away with is not cutting the screws off the grill's Toyota emblem completely off like they state and provide squish washers to hold it in place. I did cut down the screw parts but it still screws onto the grill like it's supposed to.
As for the relays and stuff I had to tuck them on the left side of the glove box. It was a PITA to mount it there because the wiring harness doesn't have a lot of wiggle room at that point, but I was able to make it work.
They also want you to cut part of the old mounts that held the relays off to make room for it. Again I tried leaving it be, but it makes it too tight to install the unit itself.
View attachment 2396981

Thank you. I have an MTS poly tank in mine that I may yank out when I upgrade transmission this winter to H42. Down shifting to 2nd gear in the 3 speed is an experience not for the faint of heart. The fuel smell I experienced in my situation was two fold: First, the fuel switch sender (Inside tank) that screws into top with gasket, was over tightened. This caused the plastic to raise up at each screw causing the gasket to not seal. Second, the tank had no fuel vapor separator and all EVAP hoses capped with no charcoal canister. With those corrected smell is gone.

My Vintage Air install was also a PITA. I rewired truck with a restored 1975 harness vs the 1976 because that year there was no carb cooling fan relay and seat belt warning light/buzzer. The only modification I made from install instructions was gasket used for firewall plate. Since my truck had no heater blower motor to remove, the holes were not cut and did not want to use silicone they suggested when mounting plate. I also tapped into blower motor B+ wire vs running purple wire to fuse block.

 

[dmaddox]

Very neat! Nice job. I know the feeling of parts and boxes of new things going onto the cruiser instead of tripping over them! Thank you for posting up the pictures!

 

[airon23]

Thank you. I have an MTS poly tank in mine that I may yank out when I upgrade transmission this winter to H42. Down shifting to 2nd gear in the 3 speed is an experience not for the faint of heart. The fuel smell I experienced in my situation was two fold: First, the fuel switch sender (Inside tank) that screws into top with gasket, was over tightened. This caused the plastic to raise up at each screw causing the gasket to not seal. Second, the tank had no fuel vapor separator and all EVAP hoses capped with no charcoal canister. With those corrected smell is gone.

My Vintage Air install was also a PITA. I rewired truck with a restored 1975 harness vs the 1976 because that year there was no carb cooling fan relay and seat belt warning light/buzzer. The only modification I made from install instructions was gasket used for firewall plate. Since my truck had no heater blower motor to remove, the holes were not cut and did not want to use silicone they suggested when mounting plate. I also tapped into blower motor B+ wire vs running purple wire to fuse block.

View attachment 2396989

The CCOT tank even comes with a new sending unit which I will probably use vs. sticking the OEM one in, but we'll see. I have also changed all the hoses for new ones so I'm really hoping not to have any gas fumes in the cab.

Yeah the idea you mentioned with the purple wire is probably a good one, but like I was saying I kept running into things where I was like "I know they say do this but maybe I can modify it or not really do it", then it would bite me later. So by that point I'm just like let's just freaking do it. lol

 

[airon23]

Very neat! Nice job. I know the feeling of parts and boxes of new things going onto the cruiser instead of tripping over them! Thank you for posting up the pictures!

Thanks so much for the comment. It really has come a long way and I've been able to learn so much in the process. I'm a little nervous about all those parts I put on now coming together and actually starting up once again. Wish me luck.

 

[airon23]

I posted some of this on the "What have you done to your Landcruiser this week" thread, but here's some more pics of the progress that has been made this week.
New CCOT gas tank is now in along with those seats I worked so hard on getting recovered. I think the results are awesome but I might be bias.

 

[airon23]

I think the interior is all done now, so it's just about time to get this thing fired up. I have to fill the transmission with gear oil, then put the skid plate on. Then fill radiator and engine up, put some fuel in and we'll see how it goes.

A small thing I did this week too was bought this reflector from @crockett here on mud for this reason. It was a cheap semi stock looking fix to having a hole on the side of the hard top. I know there's still another hole from cb antenna left, but I'll deal with that later.

The hole on that was covered...

 

[airon23]

The latest update is that I've all but finished up with the motor. It is all put back together and got some help again to get the timing done. The hood has been put down for the first time in about 3 months, so that's a big milestone.
So really the only things left are:

• I have to get the exhaust fixed since the new headers don't line up with the existing exhaust pipes.
• Then I have to get the AC unit charged with R134. Once I do this good ol Rusty Smurf should be able to ride again.
• There is the possibility the timing needs to be fixed via vacuum advance/retard since I've removed much of the smog stuff. So I just wonder if the pieces that have been removed were essential to advancing/retarding the timing. I think I'll be able to tell more once I take it on a test drive.
• One last thing we found today when getting it running is the connector for the oil pressure gauge is a little old and worn and we noticed it does not make great connection when pushed all the way on. Maybe @ToyotaMatt sells some of these little slide connectors.

Anyway, I'm way excited to get this thing back on (and off) the road and break in everything. I very much appreciate all the help and encouragement I get from everyone on here. I'll post a video of it running and test drive at some point hopefully soon.

This thread will continue to be updated but probably not as frequent as has been during this refresh. I still plan on doing some small changes like adding the winch, changing diff fluids which hasn't been part of this, cleaning things up on the exterior (following the patina thread guide to refresh some original paint), and possibly some day in the future fixing some rust on panels and rear sill repairs.

 

[airon23]

Question regarding the exhaust work I'm going to have done soon...
@65swb45 mentioned a while ago that if I were to switch to headers, then I should not cut up the OEM exhaust piece but have somewhere do a fix for the exhaust and keep that OEM exhaust pipe because it is worth something. Did I understand this right? Is that a thing, do people need or look for and reuse the OEM exhaust pipe? Seems like an odd request to the muffler shop to say make me this repair but I want to keep the old pipe. I don't think I've seen this item in the classifieds or craigslist, so I just wanted to see if that was really what I should do.

 

[mrboatman]

When you take it to the exhaust/muffler shop just have them run a complete new system from your header flange back and be sure that they know to make the exit or dump at a 45 to the rear corner. then keep your original exhaust system aside or sell it. Also nice work on the your project you did good

 

[40FOX]

Congratulations to Aaron on both winning the ReefMonkey giveaway and on your amazing build!