Builds An FJ40 Named Dusty

[roadstr6]

I am happy to announce that "Dusty", the 1982 FJ40 came back to life this past weekend! I can't wait to get this one tagged, insured and driving around town.

 

[roadstr6]

Koito H4's wired up. 8274 wired up and spooled with fresh synthetic rope and a Factor 55 flat link. Dusty is soon to be a walking, talking man about town.

 

[roadstr6]

I've been having a blast driving Dusty these last few weeks. I've sorted out a few minor issues. I had a driveline vibration beginning at around 50 mph that was solved by adding 2* shims in the rear, and while I was ordering shims from @orangefj45 I went ahead, ordered and installed 4* shims in the front to get my caster corrected. I purchased and installed a trans/ transfer bypass hose from @shipmag and new hood hinge pins from @SMG. The truck runs and drives like new. It's super silent inside, no rattles, and it's so different from any 40 series that I have ever owned or driven. These later trucks are just more refined, quieter and the overall feel is much more like driving a 60 than a 40. I'm beyond stoked with this truck.

 

[shipmag]

I've been having a blast driving Dusty these last few weeks. I've sorted out a few minor issues. I had a driveline vibration beginning at around 50 mph that was solved by adding 2* shims in the rear, and while I was ordering shims from @orangefj45 I went ahead, ordered and installed 4* shims in the front to get my caster corrected. I purchased and installed a trans/ transfer bypass hose from @shipmag and new hood hinge pins from @SMG. The truck runs and drives like new. It's super silent inside, no rattles, and it's so different from any 40 series that I have ever owned or driven. These later trucks are just more refined, quieter and the overall feel is much more like driving a 60 than a 40. I'm beyond stoked with this truck.

View attachment 3476793View attachment 3476794View attachment 3476795View attachment 3476797View attachment 3476799

Thanks for the compliment another happy mudder! Im jealous your rig is awesome!

 

[CBFJ]

Gotta ask- made any visits to Grandpa Cox? I bet he wouldn't believe what his 40 looks like now!

 

[roadstr6]

Gotta ask- made any visits to Grandpa Cox? I bet he wouldn't believe what his 40 looks like now!

Soon. Very soon. I’ve got a couple more little things to do with it before I take it back to Mr. Cox.

 

[Honger]

You've done a fantastic job making this a stunning truck.

 

[roadstr6]

You've done a fantastic job making this a stunning truck.

Thank you sir!

 

[roadstr6]

Relics:

 

[Spike Strip]

Man, got some garage envy goin' on!

 

[open country]

Livin the dream, Dave

 

[roadstr6]

Video Mar 31 2024, 10 54 51 AM.mov

Shared with Dropbox

www.dropbox.com

 

[roadstr6]

I spent springtime driving Dusty as much as I could, running errands and such. The truck make its first real debut at ONSC's Carolina Relic Run in April and it has been an absolute pleasure driving it and enjoying it these last few months. However, Dusty had a bit of trouble back in mid-May on a trip to the hardware store. Truck ran great on the way to Lowes. I came out of the store, fired it up...no issues... and drove out of the parking lot onto the main road. All of a sudden I heard a terrible clackety rattling sound that became worse with acceleration. I could tell the truck was down on power. Oil pressure and temp gauges were steady as always. I limped it very gingerly the six miles home and parked it, where it has sat for almost three months untouched while life has kept me busy with more pressing issues. I finally got a chance to take a look at the truck today. Compression test yields the following results:

1. 150
2. 150
3. 140
4. 80
5. 80
6. 155

I can hear air escaping when I put the compression tester on cylinder 4 and again on 5 when I spin it over. Valve lash is perfect on every valve. No bent pushrods (all seem to spin true in situ (I'll pull them out and check on a flat surface later). No oil loss. Dipstick is full. No leaks (at least no new ones). Coolant is full and clean. Valve cover looks fresh and clean inside. I'm thinking the head gasket blew between cylinders 4 and 5 with no creep into oil or coolant passages whatsoever. My gut tells me that this is not likely. If the break were between cylinders 3 and 4, I could understand that, but 4 and 5? Seems weird. However, it does appear that 4 and 5 are swapping compression back and forth. Maybe the head is cracked? Who knows? Regardless, it looks like the head will have to come off for closer inspection. As sad as that makes me, at least all the manifold hardware is brand new, and the engine compartment is clean enough to eat off of. Shouldn't be too terrible pulling the head. Stay tuned.

 

[izzyandsue]

Dang! I hope it’s as simple as a head gasket, I know a guy with an engine joist….

 

[405]

Gorgeous truck! Mine is also a Dune Beige '82.

 

[roadstr6]

Commencing teardown:

 

[izzyandsue]

That engine bay is cleaner than an operating room.

 

[Almill13]

Slow but steady progress on Dusty. Working on the driver's side and front side of the engine now. Got the manifolds cleaned up and ready to go back in. I used the plasma cutter to remove the exhaust thermoreactor and plugged the holes with pipe plugs. Timing cover re-seal. New water pump. Thermostat housing refresh. Lots of parts removed, cleaned and either painted or powder coated. Moving on to the passenger side next. Lifter cover reseal, desmogged dizzy and new cooling hoses next.View attachment 3335716View attachment 3335717View attachment 3335718View attachment 3335719

Sorry to hear about Dusty running poorly, Hopefully it is just a head gasket replacement and you can be back on the road again. I read through the build thread this morning and your work is top notch, everything looks fresh.

My head gasket on my 71 F engine failed and I've currently got the head off and want to do a refresh and tidy some things up in the engine compartment. What did you use to strip the old paint off of the head and block with and what did you use to repaint it? did you apply it with a brush or spray it?

I'm not too far away from you, I'm in Gastonia. Hopefully I can get my cruiser back up and running soon and we can meet up at an event or trail day.

 

[roadstr6]

Sorry to hear about Dusty running poorly, Hopefully it is just a head gasket replacement and you can be back on the road again. I read through the build thread this morning and your work is top notch, everything looks fresh.

My head gasket on my 71 F engine failed and I've currently got the head off and want to do a refresh and tidy some things up in the engine compartment. What did you use to strip the old paint off of the head and block with and what did you use to repaint it? did you apply it with a brush or spray it?

I'm not too far away from you, I'm in Gastonia. Hopefully I can get my cruiser back up and running soon and we can meet up at an event or trail day.

Thanks for the compliments. I scrubbed the engine block and head with all manner of screwdrivers, pics and wire brushes, initially dry to get the caked on crud, and then by dipping the brushes in mineral spirits and scrubbing. Nothing ground-breaking here. No shortcuts. Just a lot of hard and dirty work over weeks and weeks of time. I finished up by wiping everything down with acetone and spraying with VHT Gloss Black Engine Enamel and top-coating with VHT Gloss Clear coat. Of course, doing this in situ required a lot of taping and masking. I used old towels to keep paint off the engine bay and aluminum foil to cover the odd shaped bits that I didn't want to get paint on. The engine was pretty much a bare long block when I painted it. No accessories. No manifolds, distributor, plug wires, hoses, etc. All that was either refreshed with paint or powder or replaced with new as I built it back. I spent a long time on this...longer than anybody in their right mind would do. The results speak for themselves, but it's probably not worth the effort for an old tractor like this unless you are a complete moron like me.

 

[Almill13]

Thanks for the compliments. I scrubbed the engine block and head with all manner of screwdrivers, pics and wire brushes, initially dry to get the caked on crud, and then by dipping the brushes in mineral spirits and scrubbing. Nothing ground-breaking here. No shortcuts. Just a lot of hard and dirty work over weeks and weeks of time. I finished up by wiping everything down with acetone and spraying with VHT Gloss Black Engine Enamel and top-coating with VHT Gloss Clear coat. Of course, doing this in situ required a lot of taping and masking. I used old towels to keep paint off the engine bay and aluminum foil to cover the odd shaped bits that I didn't want to get paint on. The engine was pretty much a bare long block when I painted it. No accessories. No manifolds, distributor, plug wires, hoses, etc. All that was either refreshed with paint or powder or replaced with new as I built it back. I spent a long time on this...longer than anybody in their right mind would do. The results speak for themselves, but it's probably not worth the effort for an old tractor like this unless you are a complete moron like me.

Aluminum foil sounds like a good trick. I may start chipping away at this process soon and hope the outcome turns out looking as nice as your engine bay.