..And so it begins.... my BJ40 frame off restoration

[beejay42]

Hi John,
just back from work again.
I spoke to Halls again and they were a lot more helpful.
The same fella I spoke to last time, rekons that the HZJ75 bellhousings they have will be the right fit for your HZ1 and H55- PROVIDED you have the right input shaft (in spline count and length) for the 1HZ.

Price would be AUS $75.00.
I have no idea what postage would cost- no doubt more than the bellhousing itself, but it would seem that you should still be considerably ahead this way.

So, I have tomorrow (sunday) off to sleep in and get a few things done, and then monday free to pick it up (and post?) it if you want.
If you are no't ready to jump on it yet then there is a small chance I could do it later in the week, or if not then the following week should have a lot more opportunities (will have finished this job by then).

Postage we will have to try to figure out- what is best- just go through Auspost, or use some other company?


any way, on a lighter note- gotta share the story- today, Saturdaymad, at work.
Me and my mate who I split jobs with have been working on a big set of offices (3 of them). Moving the client out of three of them into a big building in the city which we have helped to fit out. This last few weeks we have been stripping the old offices, demolishing walls, breaking down hundreds of desks, pulling out miles of data, power, fixing stuff, and finally repainting now, etc, etc...

So, 8am in the morning, really tired, brewing up a coffee, toasting up a couple of cheese and tomato sandwiches, as we do every day.... the usual ritual... and then the smoke alarm goes off
we start running around futilely waving drop sheets and things at the alarm trying to blow the not-even-very-smoky-air away. My friend called '000' trying to cancel the inevitable firetrucks that would be on their way... the big bells start ringing out the front... they say sorry, it is all procedure, the trucks must come... I am still waving the dropsheet as the voice-over starts, 'please evacuate the building'... my mate is pleading, please, we were just trying to have a couple of toasted sandwiches for brekky, can you only send one truck instead of two?... no, sorry there is no way to cancel them... well ok.
So we walk down the front with the bells and all the racket to await the firetrucks, which soon scream around the corner with sirens and lights blazing, full crews in gear jumping out and ready...
they struggle with the alarm to turn it off and then check out how it happened. He looks at our jaffles (toasted sandwiches)-
they are not even burn't! the chief proclaims.
WE KNOW! we agree.
and you have made them in the kitchen just like you should have- he notices.
WE KNOW! again...
anyway, they turned out to be a bunch of great blokes, especially the cheif, who have tried to help us out by writing up the incident in a way where the landlord can easily put it on his insurance with no excess.
The landlord is supposed to be a right royal prick- so we might be in trouble there. If he won't sign on the line, as is to be expected, then my uncle, the primary contractor who we get the work through, will try to put it on his insurance... if that doesn't work, then we will probably have to cough up for some of the most expensive toasted sandwiches in the world
$400.00, per truck, per 15 minutes, charged from when they leave the station untill they get back. $2K minimum.

anyway, had to get that one out, thought it might lighten someones day
At least it was a quiet saturday morning, with not one of the possible hundred or so in the downstairs offices that would have been evacuated as well. Maybe we will have to pay, maybe we will not.
Whatever the case we have all learned something. We will never do these sort of works again unless the alarms have been isolated (as the chief said they should have been for us) and/or unless there is an agreement that we are not liable for any alarm costs.

What a day!
Time to hit the couch with a beer.

Speak to you soon John.

 

[beejay42]

googling a bit of freight costs

Anyone know a rough estimate of the dimensions and weight of a bellhousing?

 

[Tapage]

David,
I'm not even close to being an expert on this so I am going to break it down and say it so even I can make sure that I understand what you are saying. Are you saying that if I had to I could slide a 19 spline H55 input shaft through the clutch cover, clutch disc and into the 21 spline bearing on the 1HZ, that is bolt them up and run them no problem?
Thanks,
John

What I said it's both disc are 275mm .. one 19 splines ( old H55F ) and other 21 splines ( new H55F ) both flywheel must share the same surface of contact ...

But sin't a matter in this case coz you have the right H55F ( newer version )

 

[lostmarbles]

...the old H55F are 19 splines input shaft IIRC and newwers with 1HZ are 21 splines at the input shart ..

But both discs share the same 275mm diameter ..

....Are you saying that if I had to I could slide a 19 spline H55 input shaft through the clutch cover, clutch disc and into the 21 spline bearing on the 1HZ, that is bolt them up and run them no problem?
Thanks,
John

..same fella I spoke to last time, rekons that the HZJ75 bellhousings they have will be the right fit for your HZ1 and H55- PROVIDED you have the right input shaft (in spline count and length) for the 1HZ........

What I said it's both disc are 275mm .. one 19 splines ( old H55F ) and other 21 splines ( new H55F ) both flywheel must share the same surface of contact ... But sin't a matter in this case coz you have the right H55F ( newer version )

Perhaps I can give my interpretation of what David MAY be saying to you John.

I think he is saying that, when using the HZJ75 bellhousing (clutch housing) on your new 1HZ:

• Whatever input shaft is on the H55 transmission doesn't really matter.
• The older H55 transmission has a 19 spline input whereas the newer has a 21 spline.
• But both shaft lengths are the same (regardless of spline count).
• So - the "21-spline-input shaft" (later-model H55) will mate directly into the 1HZ clutch plate you have (and into your little flywheel bearing)
• However if you were to get an early-model H55 (19 spline input) you would just need to use the matching 19-spline clutch plate and you'd be in business once again

Someone please tell me if this interpretation is wrong (especially the part I've highlighted ib large bold type).....I'd hate to be responsible for any misunderstanding here.



PS. And this quote here shows that you have already found an H55 with the 21 spline input - so if my interpetation is correct - it appears you only need the HZJ75 bellhousing now ( $75 + shipping)?

I went to the shop/ salvage yard of another club member today. ...I found 2 different H55fs, each with a a split t case and each with a 21 spline input shaft already on it. ...........John

 

[Volcano cruiser]

Hans,
The price is right and so this will be a go there. We now just need weight and dimensions. If we are lucky we just send it AUS post to U.S.A. (my mailing address is in the U.S.A.) If you can get your guy at Halls to let you at it with a measuring tape and a scale tomorrow and it fits within U.S.P.S. regs (see below) then I can Paypal you the cash by COB tomorrow along with my mailing address. The key to making this work is the size oof the package. Basically the package can't weigh more than 70 pounds and be more than 130 inches in combined length and distance around the thickest part. From my "eyeball"measurement the girth measurement should be easy. The tougher one will be the weight. Here is the lkink:

USPS - Parcel Post

And here is the pertinent section quoted:

Parcel Post

An affordable and reliable option for packages.

Small and large packages, thick envelopes and tubes containing gifts and merchandise can be sent using Parcel Post.

Delivery to every address in the United States-including PO Boxes and military addresses.

Saturday and residential deliveries at no extra cost

Parcel Post packages can weigh up to 70 pounds and measure up to 130 inches in combined length and distance around the thickest part

For discount rates see Parcel Select.

Rates are based on weight, distance, and shape.

A surcharge applies to certain items including packages weighing over 35 pounds (25 pounds for books and printed matter) and certain shapes (e.g. tubes, rolls, and large packages).
Hans,
Thanks again for even trying to help me pull this off. Your a good man.
John

 

[beejay42]

No problem John, we joined about the same time here, both with 'new' rigs, and I've been watching and reading with anticipation your build. It really seems like the H55 is the way to go, so I am more than happy to help get you what you need to get there.
if we go ahead with it, don't worry about the cash until we finalize the postage, then we can figure out the right amount.

However, the more I look into the postage options- it really isn't looking that cheap at all- at least not yet- at least not the way I am searching.
Yesterday with some probably overestimated sizes I was searching for postage from Australia to El Salvador, and today searching for postage from Australia to the US. None of it is very appealing.
I really need to get the exact weight and dimensions to be sure (Halls are not open today), but it would appear now from my rough approximations that postage from here to the US could be anywhere between Aus, $4-500 (or more) Postage to El Salvador seems to be maybe #100-ish more than the US.
I have crawled under the truck and done a rough measurement of my 3B bellhousing- I rekon I could just fit it in 50cm X 50cm X 30cm box (or something close to that). Weight I can only guess, but I am assuming there won't be a lot of change from your 70 Pound limit, so that is what I have been searching for.

Frankly I am really shocked at the prices my queries are returning. Freakin rip off it is!

What are the ballpark figures for time and money you are looking at here?- ie the upper limits to which this is still feasible?
I have been assuming you need this relatively quickly.

Does that US$440 figure from Japan include delivery? What would the final cost of that option, including taxes and such be?
Is the price the dealbreaker on that one, or the time it would take to get there, or both?

Also, how much would it be costing for that parcel post from your US address to your El Salvador address? (ie, at what point/price would it be worth just shipping it straight to you where you are now)

Unless I can figure out a way to find cheaper freight (please help me here anyone that can), it appears that we could most probably get this bellhousing to you a fair bit quicker than the one from Japan, but not necessarily much cheaper in the end- and quite possibly (depending on the full cost of the Japan one) more expensively

I don't know though, maybe someone can point me in the direction of some cheap freighting options.
here is a search page of 'international freight' searching within Australia- which is basically where I have been trying through options.
international freight - Google Search
50cm by 50 cm by 30cm at 30 KG is the very rough approximation I am using- if someone thinks I am way off here please correct me.

(P.S. My location for ease is City: Melbourne, suburb: Preston, State: Victoria, postage code: 3072)

When I talk to Halls tomorrow morning, I will try to see if they have any quick and cheaper freighting options to the US.

Any luck on those ambulance spares? Heard anything back yet from your parts guy? I'd be pestering him if I was you- and attempting to make his efforts in finding one for you worthwhile. Considering the use of the combo in the country, surely there must be a spare one of these things in your country that can be had for the right price... Surely?

Anyway, speak later. Sorry for the $hit prices.
Hans.

 

[beejay42]

Things may not be so grim as I thought.
Just talked to Halls again,
his estimate (which is all he would give me) was 500mm by 500mm (same as mine) by 500mm- then he agreed with me that the last 500mm would probably be more like 3-400mm (ie how deep the bellhousing is. He believed weight would be 20KG.

So I have been playing with a few online quotes again.
Using these dimensions and weight.
Using the online calculator at Interparcel.com.au
it gives me two options to the US.
UPS- Aus $161.92 and DHL Aus $230.33

The UPS one is looking reasonable- and only 1-4 working days- but it is obvious that the exact weight and dimensions are going to be crucial- especially weight.
I played with the same quote to El Salvador but that just goes straight back up to the $5-600 mark.

So, for greater surety,
Just called Halls again, , and he is going to save me the 1.5-2hour round trip and give me a precise weight and measurement- so a firmer price should be just around the corner. Just waiting for his call.

You around today John? I'll just be hanging at home checking in occasionally to see what you wanna do.

 

[beejay42]

Happy days John

Halls just called back.
The bellhousings for the 1HZ are alloy- 5kg's

So, dimensions are 450mm, 500mm, 200mm @5kg.

Just using the last site I posted, interparcel.com.au,
that brings the freight of both DHL and UPS down to approx Aus$150.
I was hoping it would come a bit more down than that, but it seems we are dealing with volume now, not weight- so this seems pretty reasonable to me.
With the new figures I will look into a few more quotes- if you are not happy with that price then don't just leave it to me, maybe follow that google search I posted and play with the figures yourself.

I have plenty of packing material, so that won't be a cost- so all up getting the bellhousing to your US address should cost approximately Aus$225- ( aprox US$189) IF we cannot find a cheaper freighting service.
Not final figures of course, that will only be known once the deed is done.

So, what ya wanna do?
I am going to duck down the street now to do a couple of things, and be back in 45 mins or so-
if you want me to grab it today, I would need to leave here within about 2-3 hours.


Hopefully you check in soon,
Let me know.
Hans.

 

[beejay42]

alright, another update John,
I just called interparcel.com.au to get a bit of a confirmation of the quote.
As I suspected, it seems we are dealing with the volume price now, rather than the weight (ie it goes with whatever brings the highest price)-
so, playing with the size of the end package makes all the difference.
Once it was in my hands and packed would be the only time I could get a definate quote.

I just asked for a quote for 500mm, 500mm by 230mm @ 6KG (allowing 1kg for packaging and a bit of expanded dimensions- which I think will more than cover the packaging allowance, a bit of carboard, some styrofoam and or carpet padding, and tape).
Through DHL, Cost to the US would be Aus $138.20, and cost to El Salvador would be Aus $307.35. Both of them with a 1-4 business day turn around.
So, I guess that means your postage from the US to El Salvador would have to be close to Aus $170 (US $142) to make it worthwhile going direct- OR that the quicker time it would get there would make it worthwhile.
I would need all the details to make the booking online, and then fill out the paperwork, and then if the booking gets put in before midday they will do a same day pick up (from my work).

Hope that helps.

 

[Tapage]

PS. And this quote here shows that you have already found an H55 with the 21 spline input - so if my interpetation is correct - it appears you only need the HZJ75 bellhousing now ( $75 + shipping)?

it's correct .. coz both disc share the same surface and contact with the flywheel.

 

[beejay42]

Flat chat back at work again now, working from darkness through day and well into darkness again.
If you want to do this John, chances are my first opening will be monday again next week. We have to hand the offices over by beginning next week, so we will be flat out every day until then.
This worksite is halfway to Halls4x4, so there is a samll chance if things go well over the next few days that I could take a long lunch and pick it up sooner.
We'll see.

What's news?

 

[Volcano cruiser]

alright, another update John,
I just called interparcel.com.au to get a bit of a confirmation of the quote.
As I suspected, it seems we are dealing with the volume price now, rather than the weight (ie it goes with whatever brings the highest price)-
so, playing with the size of the end package makes all the difference.
Once it was in my hands and packed would be the only time I could get a definate quote.

I just asked for a quote for 500mm, 500mm by 230mm @ 6KG (allowing 1kg for packaging and a bit of expanded dimensions- which I think will more than cover the packaging allowance, a bit of carboard, some styrofoam and or carpet padding, and tape).
Through DHL, Cost to the US would be Aus $138.20, and cost to El Salvador would be Aus $307.35. Both of them with a 1-4 business day turn around.
So, I guess that means your postage from the US to El Salvador would have to be close to Aus $170 (US $142) to make it worthwhile going direct- OR that the quicker time it would get there would make it worthwhile.
I would need all the details to make the booking online, and then fill out the paperwork, and then if the booking gets put in before midday they will do a same day pick up (from my work).

Hope that helps.

Flat chat back at work again now, working from darkness through day and well into darkness again.
If you want to do this John, chances are my first opening will be monday again next week. We have to hand the offices over by beginning next week, so we will be flat out every day until then.
This worksite is halfway to Halls4x4, so there is a samll chance if things go well over the next few days that I could take a long lunch and pick it up sooner.
We'll see.

What's news?

Hans,
Let's go DHL to the U.S. I'll send you a better address for them to recieve the DHL. which if I read above correctly should be approx: 138.20 AUS. This is a great quote and and I don't know how to thank you and the guys at Halls enough. I'll pm you with a new shipping address and you can get me an email address so I can send you the money via Paypal.

In terms of news sorry that I missed the window of opportunity on your day off. I had to run to work yesterday and when I got home yesterday evening my home had been broken into. Iron bars ripped off the building , alarm system wires cut, glass window in pieces all over the floor, cops, security guys, fingerprint powder everywhere etc. etc. Per the investigators this was job pulled off by an odd team, they stole frozen food, tools, liquor, plasma tv , kids game console and ALL OF THE UNDERWEAR, SOCKS AND HOUSE SLIPPERS IN THE HOUSE! I guess they got hungry along the way as they sat in my living room eating YOGURT THAT THEY STOLE FROM MY KITCHEN WHILE THEY WERE PASSING MY STUFF THROUGH THE BROKEN WINDOW
Something scared them off otherwise I wouldn't be responding to you right now as this computer and monitor were pulled apart and on the living room floor ready to go out the window, RIGHT BEHIND MY FAWKING BOXERS????

The bottom line is when I got here they were already gone, it is only stuff, no one got hurt, except maybe some of the thieves as they scaled the scaled the 12 foot+ wall and razor wire and made the 60 foot drop into the jungle ravine that drops off along the side of my house.

I guess when it rains, it pours. Thanks again for going sooo out of your way to help me out . Hans you are a prince, truly.
John

 

[beejay42]

Wow! That sucks.
I am really glad no-one was home, and no-one hurt. Stealing your boxers and eating your yohgurt! what scumbags!

Now we have the go-ahead I'll just see when I can fit Halls in.

And again, no problem John. It is only a little out of my way.

Gotta run to work,
take care,
Hans.

 

[beejay42]

PM'd ya back John.
I'll check in later tonight and before I leave tomorrow.

 

[Volcano cruiser]

Just PM'd ya Hans, hope I'm not completely screwed up on the time difference
John

 

[beejay42]

just pm'd ya John for that all essential phone number- before I hit the sack-
and now I see that light has just come on

I've got a nice freshly cleaned alloy 1HZ bellhousing sitting on the couch, packed and awaiting pickup tomorrow
Just gotta finish off the booking.

 

[beejay42]

Light went off again, maybe it was a glitch.
Gonna go to bed, I'll chase this up in the morning.

 

[Volcano cruiser]

Hans,
all pms responded too. I'm headed in to work now on a holiday to catch up on stuff. I'll check back when I get home.
Thanks,
John

 

[Volcano cruiser]

Ok guys, I'm back. Sorry for no pics recently, one of the things stolen in the burglary was my new digital camera.
Anyone who tells you that doing a refurb/restore is easy needs to be shot. Anyone who tells you that doing one overseas is easy for whatever reason, needs to be shot twice.

UPDATE:
Engine: The 1HZ is in and today's test start went fine, she purrs nice and quiet. I had to replace the starter motor only because it was 24v and I wanted a full 12v system. When I'm all finished I will be holding a sale of all the stuff like that that is accumulating in my garage/den. Unexpected delays here: Couldn't buy the brackets to mount the 1HZ to the chassis, had to be fabbed. The motor mounts that they sold me for the 1HZ were off slightly and had to be returned for the correct ones. Time set back - 3 weeks.

Transmission: The most frustrating piece to this. the R151 that came with the 1HZ was too long. As many know I debated about cutting the cross member and putting it in. I thought long and hard about what was the purpose of this rig. Had it been purely an off road toy and not also my DD I might have done it. But given that I am building this to be both a DD and and an off road touring rig I decided that I wanted to make as few mods to the chassis as possible, especially since the owner of my mechanic shop and the owner of the machine shop each told me separately that they do not possess/import into this country steel of identical strength to that of the chassis such that any alteration could be made to factory specs. As such I decided to go for an H55f.
First, again a hearty thanks to Hans for his wayyy over the top help in locating the correct bellhousing for me and in getting it to me. Locating and getting the bell housing from Aus to me here in Cent Am all told took about three weeks. Second, The owner of a used 4x4 parts place said that he had an H55f for me that he was setting aside. He is a very respected member of the 4x4 community here and a member of my club. I told him fine. I went over to inspect it. Visually it looked like an H55, the version with the vacum pump. However when I tried to shift it, I found only four gears. An argument ensued and I ordered that the top be taken off of it so we could count the gears. There were only 4. To this day he swears that the guy who sold it to him sold it as an H55 and that he was not trying to sucker me. Needless to say either way swindle attempt, failure to know his own merchandise or misplaced trust, he knows that his rep went not just down the c r a p p e r but through the city drainage system and out into the sewage treatment plant. I then looked at two more, each was in worse shape than the previous one. I tried to get access to wrecks from the Red Cross and other fleet vehicles here that use the H55, no go. In the end I decided since the bell housing fits my old H41 as well that I will rebuild it and run it behind the 1HZ until I can either find a good H55 here or can figure out how to get a new H55 shipped here for a reasonable price. The rebuild was easy because thank the lord my original H41 was in excellent shape. We also found out what the problem was that I had shifting just before I put it into the shop for the install. Apparently the C clip, that sits outside of the transmission housing on the front of the input shaft, broke. I still had the small piece of steel that we found in my transmission oil a few months back. It fit just like a jigsaw puzzle. What happened clearly was that the C-clip broke,this allows the input shaft to slide out of alignment making shifting a total crap shoot. This also allowed tranny oil to leak out. You would not believe my face when we went to the dealership and were told that they had no such cm clips in stock and that if I wanted one it would have to be ordered from Japan. The total cost of the part would have been $1.50 but I would have had to have waited close to 50 days for it. I had the machine shop make me one. We got new gaskets etc easily here and now she runs fine, no squeaks, no leaks. All told time set back - 6 weeks


Drive shafts: could'nt buy a replacement output flange for the one that broke a while back so I had a machine shop make one as well as cut / lengthen the drive shafts. Time set back - 2 weeks.

Wire Harness: this had been a perpetual bain of my existence and I was determined to do something about this: I was able to find a wire harness off of a 81 BJ42 that had wrecked and was left for dead. I took it completely apart and cleaned every single inch of it. Sadly, it had connectors for stuff on it the my old harness probably hadn't seen in 20 years. As soon as I had the "new" harness apart I could see fully everything that the PO had cutt out and of the old harness and hidden under tape. The good news is that the wire on the "new harness" was much more supple and intact, i.e., no wacky splices, than I expected. I re-taped and wrapped the new harness and it is now in the rig.

Radiator: Found a shop that does good work. First they took my old rad and repositioned the intake and outlets to fit their placement on the 1HZ. Second they are making me a two sided radiator bracket which will hold the engine rad on the interior and the air condensor above and a 7" by 20" intercooler rad below on the exterior side of the bracket. Note: Today is the all day test drive with the "test rad" in place. If the engine runs cool then the dimensions of the engine rad/mounting bracket and the rest stay the same. If it runs hot then we maybe able to squeeze and additional 2 inches of width on each side bu then we have to start moving things around to make space for a bigger rad which means more delay. As to test conditions for the rad, well for that we are in a good location. I lived in a mountainous tropical country. The high today will be 35C and there are plenty of hills to stress the coolant system on around here plus the ever present disorderly city traffic in Central America. I will advise on results.

 

[beejay42]

Great to hear an update John,
bummer about the H55, welcome back to the world of 4speeds!
At least the bellhousing was still useful!

Hope it goes smoother and quicker from here,
best of luck,
Hans.