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

[Otterav]

To be exact I broke the instrument cluster down completely. Among my faults is that once I focus on a thing I'm very anal. In this instance I cleaned all the metal and glass, blew dust out of the gears, cleaned the gauge faces, the weatherstripping and then reassembled the cluster.

Hello,
Just a tidbit in regards to your future import to the USA, you will need a speedo that reads in MPH to satisify your registered importer. I would suggest you start the research for a Registered Importer now, since the process can be lengthy and mildy convoluted. Doing the leg work when time is not critical is much less stressful, than when your DEROS is on a fast countdown! Search here on mud for your importing pleasure, I did and it wasn't much of a mystery, just lengthy!
Hola
eric
PS I replaced the instrument cluster in my 1974 FJ with a late model speedo, plug and play so no drama there, and FJ to BJ is also plug and play, ony difference is 12V vs 24V.

 

[Volcano cruiser]

Hello,
Just a tidbit in regards to your future import to the USA, you will need a speedo that reads in MPH to satisify your registered importer. I would suggest you start the research for a Registered Importer now, since the process can be lengthy and mildy convoluted. Doing the leg work when time is not critical is much less stressful, than when your DEROS is on a fast countdown! Search here on mud for your importing pleasure, I did and it wasn't much of a mystery, just lengthy!
Hola
eric
PS I replaced the instrument cluster in my 1974 FJ with a late model speedo, plug and play so no drama there, and FJ to BJ is also plug and play, ony difference is 12V vs 24V.

Eric,
Thanks. I had heard a vague reference to the need for an mph speedo for import purposes now I have something a little more concrete to work from. Actually you point up two searches, one for the mph speedo and the second for a registered importer. Sounds like you've done this before, did you ship from Central or South America to the US? If so can you PM me the info for the importer that you used and whether the experience was good or bad.
Thanks

 

[74fj40]

if you arent going to use those lisence plates, would you possibly be interested in selling them or just one? PM me if you are.

 

[Volcano cruiser]

if you arent going to use those lisence plates, would you possibly be interested in selling them or just one? PM me if you are.

74fj40,
Sorry. When you buy a car here in addition to the title you get the PO registration card and plates but DMV then makes you turn those in in order to get a registration card and plates in your name. Otherwise they would have been nice souvenirs.

 

[Volcano cruiser]

FJ60 v. Mini truck PS

Guys,
I was looking over pics of the various P.S. setups that folks are running. As between the mini truck and 60 series it seems that in each most either buy or fabricate a plate to mount the setup to the frame. and in the 60 series setup there is some modification necessary to the steering shaft due to the gear box being so much farther forward. If I'm right, and please correct me if I'm off as I often am, it seems that most believe the 60 PS to be far superior for combo DD and off road driving. If it is not that much more work, why don't more people go with the 60 PS. If I can get a good price I think I might. Any thoughts?

 

[tlc_4play]

I am in the process of putting the FJ60 power steering onto my 40
Yes you have to either lengthen the original steering shaft, or use the 55 or 60 series intermediate shaft (and/or complete column) as an add on.

 

[Volcano cruiser]

Another Big Day

Today was a really good day. First I got the estimate in from the body shop and it doesn't look like a bad start. I say that because I have already been warned by folks who have restored vehicles here that the estimate is negotiable. As such I plan to give the owner a call in a few days and set up a meeting with him where we can talk turkey. Second, the SOR lift kit arrived today. The leaf springs were by far the largest items that I had shipped and I had fingers crossed that they would make it and not get bounced by some bueraucrat for being an inch too wide or a few centimeters too long. As it turned out no worries they are here and I will go pick them up from the loading dock tommorow. The third is my son is coming down for part of his summer break before he heads to Ft. Lewis for training. I can't wait for him to see the rig in its "before" state and then in the "after" state when he gets back in late August.

 

[Volcano cruiser]

Decisions

Things have been a bit slow of late, a lull in parts deliveries has given me some time to reflect. As most of you know this is a learn by doing build for me. There is alot that I wanted to do myself but as a noob I find myself gravitating to the electrical as it most lends itself to my past DIY projects, PC's ,Laptops and home A/V. As such I decided that I want to tackle the complete re-wire myself. It flows naturally from the work I already started restoring the instrument cluster and frankly it is the one thing about the rig that pisses me off the most about how the PO treated it. Having said that the decision is about timing. Do I send the rig out to the body shop first and have them do the frame off sand and body beat and paint and then put the craptastic wiring back in as is or do I do the rewire first, knowing that they will pull it when they pull the body. If I leave it til later I want them to put the craptasticness back so I can have a go-by, item by item, as I keep hearing that the wiring diagrams for the rig and the Painless kit instructions don't match up and I figure a visual, hands on go-by would be good belt and suspenders. On the other hand I could plunge in and do the wiring now but I don't want to take a chance of all the new work getting damaged by the panel beaters breakdown and re-assembly of the rig. Any suggestions from folks who have done this with reasons would be appreciated.

After much research and discussion with mudders I have decided to go with a 60 steering setup. I decided this for several reasons. One I am having a 4"lift with a plan to run 35s (assuming I can find some here, so far three big tire shops, no,luck) so I need a stronger box and setup than the mini truck. I have my eye on a pretty good size winch (Hawkdriver is fabbing my bumper now with a few mods to make space for it he calls it "sweet") and I kept getting nervous about how far forward the Sagnaw setup was on the frame. Also probably my noobish imagination but it seems to me that if you have a choice why not mount something as important as the gearbox in a more protected/less exposed area if you have the option. Again could just be really wrong on this. Last, except for the steering shaft bit it seems that the full 60 ps setup is easier, I could well be wrong but I'm gonna find out.
That gets to the last bit on steering. While trying to figure out which ps setup to go with I took a good long look at the steering linkage and what looks like an impending knuckle rebuild. I'm definitely going to knock out the steering linkage myself as I will be right there at the pitman arm when I bolt in the gear box. As to the knuckle I'm not sure if I have the tools or the know how for that yet although I can read a manual as good as the next fella and will have the time. If folks are snapping birfields as easy as they say, especially running bigger tires and ps, prudence is starting to tell me to learn now about knuckles and their innards sooner rather than later out on the trail somewhere. If you more experienced guys have a view on the wisdom of this let me know, as I said I am learning as I go and I welcome the advice.
Last, a word about mudders. Thus far advice and assistance from mudders has saved me close to $1,000.00 in this project. Additionally, a couple of mudders from this region contacted me today with ideas on sources for parts in the region, thereby probably saving me bundles in shipping costs as well as invites to hook up to 4x4 clubs in at least three of the neighboring countries when the rig is done. Finding this site was the very best thing I did. It is miles above any other forum I have been on for no BS focussed advice and information exchange and BTW you guys are WAY funnier than the members of the other boards. Thanks.

 

[patches84]

G'day John,

I love my 60 series power steering- vastly prefer it to my factory 40 series power steering.

Also, still have KPH in my troopie in the US, and I've helped import 4 troopies from Australia, and not one of them has had any problems with the speedo. Change to MPH if you want, but I am just this side of certain that you do not need to worry about it.

I imported my troopie in 97, and I had to do the whole compliance thing (which is one of the reasons she has a Vortec). I had to put extra marker lights, US-Spec seat belts and glass and LHD headlamps, but they never mentioned the speedo.

If my experience is any indicator, your import will be very close to mindless. Once the vehicle is 25 years old, you simply tick the right boxes, play nice with the Customs guy, pay the duties, and drive her home with your temporary registration.

Cheers,

Josh

 

[Volcano cruiser]

Update

Update:
I have been travelling for work and not much has been happening on the build. A couple of interesting things did come to pass. In some down time while I was traveling for work I ended up meeting up with highlandcruzer and his Mrs. We checked out a metal fab garage, had lunch and talked cruisers. I got lucky and scored a set of OEM soft top bows and a Eshan skinny top from a mudder who was in on the last group buy but who latter had to sell. That will get here soon. When I got home my left front tire was flat and when I changed it out for the spare it was flat too. Can you say foot pump? This of course settled the which winch question I'm getting the Warn Powerplant winch/air compressor combo, no more foot pump for me. Lastly a co-worker who is getting an Alfa restored took me by the paint and bodsy shop he is using. Another group of guys putting out great work by hand while working on a dirt floor. These guys in turn hooked me up with the head of the local Antique car restoration club. The guy took me on a tour of his private lot, 15 cars, everything from vintage Packard limos, Corvettes, Mustangs, MG, BMW, Caddys, you name it, all tended to by his personal restoration team of metal fab guys and mechanics. They told me to come back anytime and they would take me to see the rest of the collection, another 14 cars at his garage at home. Aside from the cool cars the best thing I got out of this guy was that by just plain dumb luck I had stumbled onto the best LC parts and all around restoration guys in the country. Now if I could just get him to answer the phone so that we can set up a pick up date for the rig.
As to the build, in addition to the flat tire my new custom bumper from HawkDriver was here. I brought it home and it's going on this today and tommorow.

 

[Volcano cruiser]

HawkDriver Bumper install

First I want to say a few words about dealing with Jeremy a.k.a. Hawkdriver. This guy is great. He does great work. He was great to work with. He made sure that he presented all options and configurations. He answered all of my questions thoroughly and clearly knew his business. He kept me informed as to his progress towards completion and worked with me on shipping. Once he completes his move I am definitely getting him to hook up a rear bumper for me.

• The bumper was packed really well by Mrs, Hawkdriver and It arrived her safe and sound. The first order of business was to pull the beat up chrome plated bumper that apparently came as a dealer upgrade package at time of purchase. The only thing that I can say on this is Thank God for WD40. As to be expected every bolt was either rusted tight or frozen solid. After a quick run to the hardware store to pick up some galvanized bolts , paint, etc., I broke open the box . Just as Jeremy promised it as packed very well and with stood some box abuse. The bumper arrived primed and ready for paint. However just as I was about to paint a huge rain storm kicked in making the air really humid. So I called off painting until morning after the air dries out a bit. Here come the pics:

 

[Volcano cruiser]

Here are a few of the way that the bumper arrived. Note the attention to detail in the packing, all hard points were wrapped in cardboard. The entire thing was wrapped in multiple turns of shrink wrap and finally the whole bundle was bathed in packing peanuts. It arrived in Central America without a scratch.

 

[Volcano cruiser]

Now I'm just waiting for the rain to let up and for things to dry out here.

 

[patches84]

That's it?! Common, don't leave us hangin'- what does it look like with the bumper in place?!

Cheers,

Josh

 

[Volcano cruiser]

Stuff

Sorry guys. I got side tracked. A couple of mornings ago The engine wouldn't start. The battery was good it turned over but couldn't get it to catch. I suspected the glow plugs either had given up the ghost or that they weren't getting juice. They were getting juice but three out of the four had kicked the bucket. Those were replaced and for the first time the glow plug controller lit up bright glowing orange...and then the electrical system shorted out. With some help from a friends mechanicwe once again confirmed the POS job the PO did in just maintaining this vehicle let alone taking a little pride in the work that was done to it. I never saw so many wires simply twisted together and then taped over as permanent repairs. Then the taped up stuff was tied together in knots, literally and when some thing stopped working he just pulled the wire from the item and tied it around one of the existing knots. I say all of this because it made it take literally hours to try ti trace a single wire to find the short. We did have a clue when in trying to look for the short in the wire going to the glow plug bar the headlights came on with out being switched on. in the end, since the car is going into to the shop for the frrame off in three weeks I told the mechanic to simply bypass the current wiring, which will be replaced, and just wire me headlights, turn signals and glow plugs.
Just when I was ready to turn back to the bumper I noticed that the spare that I had used to replace the flat front left was splitting between the lugs, literally I could look down the center of the tire and see through to the steel belts.Given that I no longer had a spare that meant a trip to buy tires. Again this was an expense that I had planned to happen two months from now as the rebuild was underway and after the rims had been sanded and repainted. Last night I was at the tire guy and got lucky and was able to score some Toyo Open Country 33X12.50x15R AT's (no one stocks MTs in country, they say that hardly anyone buys them here)
I got the bumper on now but I need to head back to the hardware store for some longer galvanized bolts etc. Pics will go up this afternoon after I mow the lawn

 

[DanS HJ-45]

Tough break about having to buy tires now, but on the plus side: now you've got new tires!

I forgot if I told you, but your hubs were shipped a few weeks ago.

What, a knotted tangle of exposed wiring is a permanent fix for you? I'll bet you feel peas under your mattress too. Just buy some of that liquid electrical tape and smear it all over under there--that'll fix what ails it.

Dan

 

[lostmarbles]

I can't remember the exact details of your BJ40 but my 12V BJ40 takes 8.5V glow plugs.

Make sure those plugs you've put in are not of too high voltage (- in case that was the cause of your wiring failure on their first glow)

(Edit 1/8/08 - Ooops. Error here! I should have said "Watch out that the voltage rating of your plugs isn't too LOW. - Because I believe it is the LOWER voltage plugs that will tend to "glow brighter/faster" and therefore draw more current! Higher voltage plugs will tend to glow less/slower and draw less current.)

Cheers
tom

 

[Volcano cruiser]

Tough break about having to buy tires now, but on the plus side: now you've got new tires!

I forgot if I told you, but your hubs were shipped a few weeks ago.

What, a knotted tangle of exposed wiring is a permanent fix for you? I'll bet you feel peas under your mattress too. Just buy some of that liquid electrical tape and smear it all over under there--that'll fix what ails it.

Dan

Dan,
Good to hear from you and great timing. To make myself feel better I put these on way ahead of schedule. It was quite the learning experience as I am sure that if I had had a better angled rachet wrench this all would have been on in minutes. As it turned out I had to pull the beautiful faces that you did from the mad good looking hubs that you did and did the install in stages. The hubs look really good now but will look outstanding once my wheels get sanded and painted black I will re-take pics of them then. Dan thanks for a really great job. Anyone who has some of your work will attest to the attention to detail and craftmanship.

I can't remember the exact details of your BJ40 but my 12V BJ40 takes 8.5V glow plugs.

Make sure those plugs you've put in are not of too high voltage (- in case that was the cause of your wiring failure on their first glow)

Cheers
tom

Tom,
They are and now that we did the bypass they fire up really quickly, previously I had top hold the wilson switch for almost a minute. Now less than 20 secs.

 

[Volcano cruiser]

Bumper continued

Ok guys, Here are pics of the Hawkdriver bumper installed. I had some trouble only because due to Hawks good measurements I can see that the front triangular pieces ( forgot the name) of my frame are a little twisted on the left side so the bolt holes didn't line up exactly on the top but they are on the bottom. This will get corrected in July when it is in the shop getting the frame worked on. These pics are just initial install pics. Otherwise the install was mad easy. The bumper arrived with a coat of black primer. I cleaned it and then added 4 coats of glossy black to it over a period of four days and then let it cure another two days before bolting it up. I dropped in galvanized bolts, which I hit with some silicon as they went in. Ratcheted everything down nice and tight and it's was on. I will post up final shots of Hawkdriver's work in all its glory after I add the winch and fog lights in a few months. Meanwhile, it has been on the rig less than a week and five guys have stopped me to tell me how sweet it looks and asked where I got it. Hawk, I give you props as promised and they are all in awe of the fact of how mudders support each other, building and buying from each other, shipping and swapping parts etc. Hawk driver thanks, really great work done by a great guy. I'm definitely getting my rear bumper from him once he gets set up again after his move to Alabama.

 

[Volcano cruiser]

O and how do you like my "earthquake brakes" BFrocks in front of my new tires. Things shake at least once a week here and I don't want to wake up and find that my rig has rolled down hill overnight and is making out with the driveway gate.