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

[DanS HJ-45]

Glad to see they survived the trip down there.

Glad you like them.

That bumper looks awesome. Take some zip ties and secure the D-rings though, they can rattle loose and fall out if you don't. (yes, experience ) I do the same thing with rocks. The driveway outside our shop (which has a good slope) has all of the chock-rocks all near the driveway and easy to find. Works good, lasts long time.

Dan

 

[Volcano cruiser]

Catching up

I have been stuck lately waiting on the body shop owner to get back from his vacation. My original plan was to have him do most everything except the re-wiring. It is the rainy season here and while waiting for him I got antsy and found found a place where I could get let her stretch her legs a bit, just spin the tires a little really . (see below) All this did was get me really antsy to get this project going already. Later I noticed that while I was spinning around in the creek bed I ended up breaking the exhaust pipe just below the manifold. Given how close the exhaust sits to the front drive shaft I clamped a quick metal patch over the two ends and went looking for a guy who could weld up a a quick fix for me. I decided on the quick fix because as some of you know I have been looking into getting a better engine. I decided to try and get my hands on one of these three, in this order: 15B-FTE, 15BT or 14BT. It turns out that this is a common swap in Malaysia but almost no place else. The engine looks too good to pass up and they are just a little more expensive than the 13BT that I was looking at but much bigger bores and in the case of the 15B-FTE, that beast has 16 valves and comes factory turboed and with an intercooler. As such I didn't want to have a guy redo the exhaust when I am looking for a new engine which may have to shift back or forward an inch or two.
I got a referral from a co-worker on a guy who "knew something about Toyotas" and who wasn't that far from where I live or work. I knew that I was in the right place when I pulled into the shop and the place was small, full of trail rigs and most of all had pros under the hoods of another 40 and a 45 longbed. I really felt at home when all of the mechanics came away from what they were doing and gathered around my rig. Even it's "before" state when to me beauty is still just in the eye of the beholder (mostly me) they all just looked her over and smiled nodding very appreciatively and went back to work. The owner gave me a ride to work and said the car would be ready at the end of the day. When I went back to the shop more trail rigs were parked there and all of their owners were waiting. They all came over introduced themselves shook my hand and asked if I'd like to join their 4x4 off road team/club. As it turns out the owner of the shop is the president and he had called up alot of the other members told them what I was doing to the rig and they all came over to show off their rigs, lend support, introduce themselves. After I told them that I had been looking for something like this for months and that I'd be happy to join up, they dropped the bomb. A couple of them ducked into the office and in Superman style came out dressed in Warn, ARB, OME and Maxxis polos. These guys are the distributors in this country of these products. However since the average guy here isn't interested in 4x4 they really just get the products for club members who want stuff for their rigs. Even better they immediately gave me the "you're with us treatment" i.e, if i ever need parts ask them, the club keeps a stash at the shop and I can now grab what I need from the stash. As I replace stuff I will put the old stuff in the pile . Everybody pays each other a discounted amount for parts that they pull which helps defray the costs of modding their rigs. Apparently there are enough of each make of car represented in the club to make it worth it. At then end I am planning on going on a trail ride with these guys in a little over a month provided they can finish the all of the mechanical stuff on my redo list. Yeah, they offered to do the work, now for an embarrasing fraction of the other guy's estimate. When I asked why, they all said at once they love doing this and can't wait to see my old girl really be able to go out with them and shake her legs. After lots of stories about their dad's cruisers and the cruisers of their youth it was time to go. I asked for the bill and they all laughed, we aren't charging you anything for the repaired exhaust and inspection of the engine, transmission and suspension and the detailed report on what needed to be done to get each area up to speed, " you're with us now".

TEAM EL SALVADOR 4x4 - info. mitroca4x4@gmail.com cel 72606383

Even though I got the news today that the first guy couldn't source the 15B- FTE, it was a very good day. Tomorrow I'm headed over to the parts store to get replacement switch for the headlights and to check with another guy about sourcing the engine. BTW these guys were ecstatic that I wanted to come over during the mechanical rebuilld to work on my two pet bits, rebuilding my axels as well as doing the electrical re-wiring.

 

[highlandcruzer]

Good story John. That does sound like it was a really good day. Having other Cruiser guys support there locally is sure to help your project progress easier. Not mention, it's just plain more fun when you can share your progress with guys that enjoy the hobby as much as you do.


Good luck with the engine swap. I'm eager to see how this turns out. Sounds like you'll have yourself a helluva nice rig!

 

[Volcano cruiser]

Ordered the 30 spline Longfield set today. They should be here in a few days. I am waiting to hear back from Budbilt on their beefed up tie rod and drag link set up. I hope to hear back from them soon I'd like to get the remaining front end bits ordered and in country before I hand things over to the 4x4 mech shop. Again for me this guy is really close to my house and is happy to have me drop by the shop and work along side of him and his crew. The only way that I'm gonna learn about the front end is to be involved in rebuilding it. Aside from the drag link the only bit left is the OME steering stabilizer and shocks. I have to call to see if the ARB guy was able to drive to Guatemala to pick them up. Again it is a small 4x4 scene here and ARB just started up here a month ago so they are still going on parts runs to other countries in the region.
As I mentioned in a post in a separate thread regarding engines, I am trying to source a 15B-FTE to replace my original B engine. Spoke to the salvage guy today. He said that he doesn't have a 15B-FTE here in the country. He felt pretty sure that he could get one but when . They are packing his container now in Japan and he was calling his agent there to see if they could get a 15B in on this shipment. I told him even if he can't I want him to give me a price for one. Assuming that I miss this boat the next container is scheduled to be packed in September to be dockside in El Salvador in October. If I have to wait until then I told him to grab an H55f for me as well. This means that for the next few months the B will get a paint job and a really good tune up and that the H41 tranny that I have will get the maintainance that it has needed for while now. Once the new stuff comes in I'll either sell the old stuff to another club member or crate it and bring it all back to the states for a future resto on another rig.This diesel thing is very addictive, maybe its the fumes early in the morning.

 

[Volcano cruiser]

ALmost forgot I was reading on the Rust Bullet site about how they have all kinds of overseas vendors now. None in Central America yet though. I ordered the combo pack of 4 qts of Automotive grade stuff and 2 quarts of their new black topcoat

http://www.rustbullet.com/ProductCart/pc/viewPrd.asp?idcategory=125&idproduct=426#details

I took a gamble and ordered it still unclear if it was going to be able to be shipped via air here. Fingerd crossed.

 

[beejay42]

Awesome news hooking up with that club!
Good luck with it all.

 

[Volcano cruiser]

Rust Bullet Problem Solved

Well all I can say is thank you to Laurie from Rust Bullet. She worked with Fedex and Salvadoran customs folks to get my shipment of Rust Bullet here by mid September. Apparently I am now a Hazardous Materials Importer. I will now be required to show up at the international airport to receive my Fedex Hazardous Air Cargo shipment in person. Because Laurie was sharp she saved me 200.00 and change by just the airport pick-up alone. Otherwise special truck with special markings, etc, would have been required to haul it to me. I want to thank MS Driver too, reading his Blue Mule Resto thread and his Rust Bullet sourcing saga gave me some ideas on how to skin the cat. I admit that I gave up on it for a while but never completely. As in his case, this was not cheap. Shipping alone cost more the cost of the product itself. I am hoping to defray some of that cost by selling what I don't use to the other guys who are getting their rigs painted in the club.
I'll be travelling for business starting Saturday. Hopefully my rear half doors, Longfields,and OME shocks will be here when I get back and then it's time to hit the garage.
A word about pace. The pace is about to pick up on the build. The guys in the club just informed me that they want me to go out with them to the club's "test track" to get some practice in. Apparently these guys have some place in the mountains where they have mud pits, stream crossing, boulder crossing, hill climbing, etc obstacles all laid out. They get their practice runs in, winching practice in here and then they hit the trails and have competitions with the teams from Guatemala, Honduras,etc. Next competition is in late September hopefully everything will be on and well shaken out by then.

 

[M5driver]

Very nice bumper! And glad to hear you have made your way through the HazMat import jungle I struggled for a long time, but feel it will be worth the pain in the end. Good show!

BTW, is that a CD (Corps Diplomatique/Credentialed Diplomat) plate I see on your rig?

Oh, yeah - it's M 5(five) driver. It refers to my airplane which unfortunately has remained in Scotland while I am here in Malawi . Probably just as well in the long run - no one here to do the annual inspections, and mine needed a new prop this go around. I have someone flying it regularly to make sure everything is as it should be. With 100LL avgas going for $20-$24/gal when it's available, I wouldn't be flying now anyway. Cars are bad enough - duty-paid diesel just hit $7.80/gal and petrol is at $8.15/gal now. According to the gummint, this was a necessary increase to insure we have fuel. Maybe, but at least the lines at the stations have disappeared.

mate!

 

[Volcano cruiser]

Very nice bumper! And glad to hear you have made your way through the HazMat import jungle I struggled for a long time, but feel it will be worth the pain in the end. Good show!

BTW, is that a CD (Corps Diplomatique/Credentialed Diplomat) plate I see on your rig?

Oh, yeah - it's M 5(five) driver. It refers to my airplane which unfortunately has remained in Scotland while I am here in Malawi . Probably just as well in the long run - no one here to do the annual inspections, and mine needed a new prop this go around. I have someone flying it regularly to make sure everything is as it should be. With 100LL avgas going for $20-$24/gal when it's available, I wouldn't be flying now anyway. Cars are bad enough - duty-paid diesel just hit $7.80/gal and petrol is at $8.15/gal now. According to the gummint, this was a necessary increase to insure we have fuel. Maybe, but at least the lines at the stations have disappeared.

mate!

They say that the eyes are first to go, oops M5driver.Yup, dip plates dressing up the old girl as is a Hawkdriver bumper. As to the Rust Bullet deal I'm still in shock that this is only the second day of my concerted effort and the hard part is resolved. Had you not shared the torture that you went through and the resolution I' would have never had any idea of the Hazmat thing as a path to resolving the problem. Thanks again!

 

[Volcano cruiser]

Things are going slow now. I'm waiting for my Longfields set to arrive as well as the knuckle rebuild kit before taking the rig into the 4x4 shop to have them do the mechanical work. I also have ordered up a couple of FJ60 harneses. My plan is to pull the 40 harness and tack it out on a board, line up the 60 harness on a tack board, and use the 60 harness if the 40 harness is as bad as I think. I got a couple of 60 harnesses so that I'd have a donor for extra connectors etc. When this is all over I may still try and rebuild the 40 harness just for fun/ learning experience.
In case I hadn't mentioned it, I have decided to rework the order of attack here.
Stage 1:
Brakes: front discs and rear drums systems will be rebuilt using new parts
Axel: Replacing the stock birfs and inners with the Longfield chromoloy set. Knuckles get rebuilt.
Steering: tie rods, drag links and steering stabilizer all replaced
sus pension: new leafs shocks and body lift
Engine: tune up of the original B engine until I can get a 15B-FTE
Electrical:
replacing wiring harness, new fuse panels, dual battery and power inverter. (hoping that the harnesses get here tomorrow as there is a week long holiday here next week and I would have plenty of time to get the old harness out and the new one in and tested)
I am having the mechanics at the 4x4 club do the work because they are dirt cheap and really understand what I want to do with the rig.
I'll get to the body shop for him to break it all down probably sometime in the fall. I came to this decision once I was able to get an order of Rust Bullet through. It should be here in a few weeks, Once I fill out all of the paperwork to be registered as a Hazardous Materials Importer. By the time the RB gets here all of the other repairs/ mech upgrades should be done. Then time to move this along towards the panel beaters. Man does sourcing the parts take alot of time. I'm waiting on the arrival of the rear half doors and hardware. Again hopefully they get here tomoroow and I can spend the weekend wire wheeling them into submission and grinding down the corners .

 

[Volcano cruiser]

Ok, I spent some time with my wire wheel today. I had ordered a used bezel from a guy and it showed up with a bit of rust. Now it is shiny, steely clean.
Only took pics of the after but I will post it soon. I am also waiting for a shipment of rear half doors to arrive. They also have some rust, which I will wire wheel off and then grind down the square corners so they fit my round cornered door opening. I'll do better and document the rear door prep. Once the rear doors are done I'll be ready for the arrival of the softtop from softopguy. Once I get that kit I will set the footman loops and then Rust bullet the whole deal, the doors and the bezel.

 

[Volcano cruiser]

Center storage bin/arm rest/CB mount

I picked up a CB for trail rides on my last trip back up to the States, mandatory safety requirement for the club. All night before last I was thinking about where I wanted to mount it. It came to me that rather than gettin a tuffy center console, got other priorities now maybe I could make up something decent out of the scrap wood that I had lying around. After sketching out what I wanted to do and taking the measurements I decided that I'd still need a sheet of pine for some parts. I then realized that none of the big stores here sell such and was told that if you want that you have to go to a saw mill about an hour out of town. F**k that I thought and I went back to the drawing board and this is what I came up with a center storage bin/arm rest/CB mount.

To start with there was a cheapo plastic tray that sat in between the driver and the passenger seats. Looks like a PO install and I had been using it to hold car tools etc. since there was nothing else for the moment.

 

[Volcano cruiser]

Next I rounded up my building materials, s**** 3/4 inch pine that I had left over from building a desk top and a s**** of 2x4. I also had some foam and fake leather left over from resurfacing my workout equipment.I went out and bought some wood screws and a hinge to complete the supplies. I am not a carpenter nor a furniture upholsterer, just a regular guy who tries to make do with what is available and tries to have things look decent and be functional at the end. I think that this is simple and will get the job done. I'll post up what I did so that others can see and hopefully come up with some other ideas. This took maybe 8 hours to do including fruitless trips to the store to try to buy the pine stock.

First I clamped the pine stock down as they were going to be the sides of the bin. I cut them down to size per measurements and sanded them.

 

[Volcano cruiser]

Next I took those pieces back out to the rig and re-measured the angle for clearance with the shift levers, etc. Note, Im really glad that I did this as the width of the box measurement changed because when I measured the distance between the seats the first time I was sitting in the seat, with my fat ass compressing the seat and making the space between the seats more narrow than it actually was. You all know the rule measure twice....

 

[Volcano cruiser]

Now time to box in the angle front, back and bottom. As I had used up my scrap from the previous desk project and couldn't buy more pine stock I remembered that I had a piece of old composite that had been used to pack a parts order that I had put into service as a shelf in my portable work bench set up. So more cutting sanding and measuring, driling in pilot holes, screwing in etc..

 

[Volcano cruiser]

More... I fitted the top, being careful to leave some overhang so that I could lift the lid to get at stuff stored inside the bin. My original desire was for a piano hinge, four store later, no go an the hidden hinge.

 

[Volcano cruiser]

Whatever internal debate I had originally between spraying the box and covering it was decided when I had to go with the pressed board pieces. As mentioned earlier I had some left over "pleather" from resurfacing my gym equipment and this was called into service for the job. I'm sure that there are some cool upholsterer's tricks (don't know them) and special tools (don't have them),so I did the best I could with my trusty pistol grip, commercial grade stapler.

 

[Volcano cruiser]

While working on this I decided to kill another bird with the same stone. I have no cupholder to put me coffee in as I drive to work in the morning so I figure that I'd add one into this setup. First I notched out the front of the box with my jigsaw, covered it and then I took the last scrap of 2x4, drew in a space for two cups. I then protractored a nice round arc for the front end of the holder. Cut and sanded it all out. The flat back end of the 2x4 scrap slides into the notch leaving the rounded end outside of the box to hold the cups. Only problem here was that I need a larger hole saw so I'll cut out the actuall holes for the cup this weekend. I put it all together for you guys to see here though. Also it was getting late and I dropped the camera. The result was that I lost the pics of the PITA stuffing the foam into the lid. I was able to get three sections of 6x3.5x2 inch foam pad under the pleather cover for the lid. I wanted my elbow to ride real comfy from now on.

 

[Volcano cruiser]

A little clean up the inside of the rig was overdue. That done it was time to position the CB mount, drill some pilot holes, mount the CB and drop the whole thing in the slot. and do a final check for hand position and comfort. As you can see under the old tray is more evidence that this rig was originally John Deere Green.

 

[Volcano cruiser]

Final fit up. I made sure that there was no interference between the CB/box and cupholder and the stick. It is shown here with the stick in reverse, the farthest back position. Altogether my out of pocket expense for this project was: $3.53. That represents the cost of the foam for the armrests, assorted screws, the hinge and a latch for the lid that I decided not to go with at the end.If you want we can throw in 6.50 for the cost of the larger hole saw bit that I'll buy this weekend to finish the cupholder so grand total $10.03. All in all, it was easy to do, looks decent, is comfortable and gets the job done. The best part I can easily pull it out whenever I want if I decide to go with something else in the future.
John