Builds Aloha from Las Vegas! 77 FJ40 Project

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Any pictures of the rig with the new rims and tires?
 
Now I’m working on adding the electrical accessories for a little creature comfort. I installed a console from CCOT a while back and I’m using it to provide space for the radio, some power outlets, and a spot to put the heated seat switches.
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Yours is one of the only other FJ40 seats I've seen with those old vinyl back seat Velcro pockets. I love the way they look on my reupholstered seats.
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Yours is one of the only other FJ40 seats I've seen with those old vinyl back seat Velcro pockets. I love the way they look on my reupholstered seats.
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Well, this rig came from Utah by way of Nevada…
Maybe the same shop did it?
 
Great work! You've really done some justice on that rig. Lucky thing that the guy who did the metal work did such a nice job.
Thanks. The metal work on the tub is nearly perfect, just need to adjust the body mounts on the big channel as they are off by about 3/8". The guy who did the metal work is a sculpture artist and does some amazing work. Here's some examples from his website:

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Sometimes it’s the little things that are the most rewarding. I found a Check Engine Light that fits perfectly in one of the holes in the dash that are normally just plugged.

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My goal was to have the windshield frame painted and glass in it before the meeting. Achievement unlocked!
Then I started disassembly today for body and paint. Amazing how quickly they come apart when there’s no rusty or stripped fasteners to fight.
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While I had the body off the frame, I went ahead and shot Eastwood internal frame coating inside the channel of the frame and all the cavities of the tub.
Then I set about finishing the underside of the tub. The metal work was really nice, but I had to move one of the wheel well supports about 3/8 of an inch to line it up better with the roll bar mounting spot. Then I welded all of the seat mount nuts in place and replaced a couple of captured nuts for the trans tunnel.
I applied three coats of Spectrum sound deadener to the underside and let it cure for ten days before painting over it in Rustic Green. I went ahead and shot a coat on the firewall while I still had the tub upside down.

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Now I’m finishing up details on the topside of the tub. I was missing three of the threaded plates for the amby door hinges, so I copied the one I had. Also, the weldnuts in the B-pillar where the cab bolts to the bed were covered with new steel so I had to carefully measure and drill to regain access to them.
Then I moved on to the one piece of Swiss cheese left by the blaster. One little patch in the corner of the driver floor and I now have a completely rust-free tub!

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As the saying goes- when life gives you lemons, make lemonade.
I had been planning to go to Rubithon this year with my Tornado Alley Cruisers buddies, but the event got rescheduled due to the record snowfall. That put me out since I can’t get the time off to go on the new dates. We called an audible and made Plan B to go as a group to the Black Hills of South Dakota instead. Just a few days before we were supposed to leave, my co-driver found out he was losing his job. 🤬 On top of that, work really needed me to come in one day that week and I also had a funeral to attend. All signs were telling me I needed to stay home and work on the 40.
With more than a full week at home and a stretch of decent weather, I was able to get all the bodywork done on the tub. I also finished metalwork and body work on some other panels like the gas tank cover, trans tunnel, fenders and a tailgate. All the hinges are smoothed out and have 3 coats of epoxy.
This week, I was back at work but managed to build my paint booth and today I painted the tub! Pretty happy with the paint overall, but managed to get a few runs on the dash. I’ll try the razor blade trick to remove them and buff it out but a complete re-do of such a small area won’t be too much work.

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While the tub is still off the chassis, I decided to knock out a bunch of little projects that are easier to do without the tub in the way.

1. Replaced the parking brake cable with new OEM. The old one seemed fine, but it was the only part of the brake system that I hadn't replaced.
2. Installed new OEM bolts in the rear driveshaft, just for good measure.
3. Drilled out the M8 nuts in the back of the frame so I can bolt on taillight covers.
4. Made a little plate to hook a clutch return spring just above the slave cylinder.


5. Finished wrapping and looming the engine harness on the back of the block.
6. Put heat reflective fiberglass/aluminum tape wrap on the parking brake cable and speedometer cable.

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I got some help from @Flatlanderfj40 and @CrowleyFJ40 today and we nestled the tub back on the chassis. Then a flurry of activity as I started initial reassembly!
The ceiling hoist makes this job so much easier for 3 guys. Hoist the tub, scoot the chassis underneath, and lower the tub back down. Thanks for the help, guys!

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