Dang - You move FAST!!!! Puts me to shame.
Good project - and having a 'helper' is nice too.
Good project - and having a 'helper' is nice too.
Any FJ40s in Milwaukee/Madison area?
- Thread starter SliderJack
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- #42
I don't know, probably going to slow down fast now...
Taking stuff apart is the easy part!
Now I need to figure out where the money is going to come for the new parts! 
I ceramic coated my header. However I did have the man-a-fre 6 in 1 iirc. Duct tape the knuckles and breathers on the axles, and blast the crap out of em. I did.
Scott
- Thread starter
- #45
Still chugging along. Didn't find much time this week to work on it, but I did spend some time wire brushing the frame. I got a couple pounds of scale and rust off it. Still hoping to sandblast it at least in parts.
I unbolted the leaf springs but haven't coaxed the bolts out yet. Need to flip the frame and work on the underside. Need to work on the axles.
I picked up an old used air compressor. Plan on wiring a 220 volt outlet in the garage and get it going this weekend. Hope this 60 gallon compressor will be better at sand blasting. Picked up a used welder too. Infrastructure...
Took the rear drums off. PO replaced pads but the wheel cylinders were still pretty dirty. Adjusters didn't want to move. It wasn't clear if they're seized or if the pads are binding. Need to take a closer look at those when I work on the rear axle.
Took the oil pan off last night. Doesn't seem to be much of a ridge on the cylinder walls. Need to stamp the con rods and finish breaking down the motor. Going to try and talk to a couple machine shops this week or beginning of the year and get the motor work started.
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- #46
Forgot to mention some a-hole hit my FJ Cruiser in the parking lot this week and left... Tail light, rear quarter glass, bumper, and rear quarter is pushed in. Sigh... There goes at least $500 out the door that I could have spent on the 40. 
Forgot to mention some a-hole hit my FJ Cruiser in the parking lot this week and left... Tail light, rear quarter glass, bumper, and rear quarter is pushed in. Sigh... There goes at least $500 out the door that I could have spent on the 40.
Ouch! Wheres the consideration. Its christmas after all. Great work on the frame, looks awesome.
- Thread starter
- #48
Thanks! Yeah, pretty sad about the FJ Cruiser but it could have been a lot worse.
Thank goodness for my big selection of duct tape from my track days.
Got some good things accomplished this weekend. I had separated the intake and exhaust Friday night.
I got the suspension separated and the frame flipped. Hopefully those are the last of the stubborn bolts!
I wire brushed the bottom of the frame and got all the scale off. Lots to do on the frame yet. Need to drill out all the broken bolts, need to sand blast, and need to address some rot and for some reason the PO welded the rear bumper on.
Spent some time on a side fun project. When I took the motor apart the huge lump the valve cover is just begged to be cleaned up. I cleaned the inside pretty good with my home-made parts washer. Then I spent a few hours clean it up.
Before:
After:
Have to say I love it! I'm not much into chrome but I think it looks great polished. While I'm tempted to paint the motor red I'll probably end up going stock gloss or even semi-gloss black. But this should give it some pop. It was a lot of fun bringing it to life!
Thanks! Yeah, pretty sad about the FJ Cruiser but it could have been a lot worse.
Thank goodness for my big selection of duct tape from my track days.
Got some good things accomplished this weekend. I had separated the intake and exhaust Friday night.
I got the suspension separated and the frame flipped. Hopefully those are the last of the stubborn bolts!
I wire brushed the bottom of the frame and got all the scale off. Lots to do on the frame yet. Need to drill out all the broken bolts, need to sand blast, and need to address some rot and for some reason the PO welded the rear bumper on.
Spent some time on a side fun project. When I took the motor apart the huge lump the valve cover is just begged to be cleaned up. I cleaned the inside pretty good with my home-made parts washer. Then I spent a few hours clean it up.
Before:
After:
Have to say I love it! I'm not much into chrome but I think it looks great polished. While I'm tempted to paint the motor red I'll probably end up going stock gloss or even semi-gloss black. But this should give it some pop. It was a lot of fun bringing it to life!
Wow. That looks like it was coated by the powder coater. Nice work!
Nice tape job! Sorry about the crash though. People obviously suck.
I can't believe you polished that. I'd be thrilled with just cleaning the grime off mine.
I can't believe you polished that. I'd be thrilled with just cleaning the grime off mine.
- Thread starter
- #51
Thanks.
I'm still chugging along. I did get the suspension and axles separated from the frame. (Yes, I'll need new shackles and bolts.
) I flipped the frame and ground down the under side. There are two spots on both sides of the frame that are rotted a little. The two pieces of the frame separated a bit by rusting. I'll need to work these a bit and weld them. Overall the frame is pretty good. I still ned to figure out why the PO welded the frame bolts of the rear bumper though. The rear bumper is permanent mounted. I spent some time tearing the motor completely down. Good thing. There was no ridge on the cylinder walls, and little ring pressure either. She was pretty loose. All the pistons slid right out of their cylinders, no mallet required. I haven't checked the pistons over yet, but I noticed right away that at least one of the rings on piston one was in two pieces. Good thing I took her apart.
The gaskets were rock hard. I felt like a greek sculpter with chisel and mallet in hand. The oil pan gasket was a rock and I still need to work on the rear main. The head gasket, yikes. I haven't done a lot of these but this was bad. I wonder if it was aftermarket or a cheap gasket. It was baked on the block and the head.
But after a few hours of working on the block and head they cleaned up fairly well. Still need to work more but probably wasting my time since they might need to be milled anyway.
Still I'm really glad I spent some time with them. I'm trying to do as much as I can myself and I'll have a machine shop check my work. I want intimate knowledge of the truck. That way too I find things myself. I have had some problems in the past with mechanics wanting to do more work than was needed so I'll feel better knowing first hand how the part is.
A good example is the exhaust ports on the head.
The exhaust ports did not clean up well. They exhaust manifold wasn't making a good seal, lots of blow by and it looks like there was some rusting on the head. Maybe this will need to be milled to be cleaned up.
Lifters are pitted a bit.
Need to see if I can reuse/regrind the cam and lifters or source a new one.This week I hope to inspect the crank and the rest of the rotating assembly. I might even try and statically balance the pistons and rods.
I'm also going to take out the valves and clean up a bit. I wonder if I can devise a spring tester.
Happy New Year!
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- Thread starter
- #52
Thanks!
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- #53
Still plugging away.
Getting excited about the warmer weather. Anxious to lay down some paint on parts and start putting things back together. I feel bad every time I tear something apart it just seems I'm getting farther and farther away from completion, most stuff to put back together and more parts needed.
Front axle is a good example. I was hesitant to tear into it, but the seals definitely need to be replaced and I feel I know so much more about how everything works having torn it apart.
The bearings look pretty good. Truck has a little over 100K on it. Do the bearing usually last past that or best to replace?
The washers on both sides were scored pretty well though. Not sure exactly what caused this. I guess I'll look closer at the wheel bearings and this washer tonight.
I got all my new JIS fasteners for the truck. I'm anxious to order some stuff this week. Hell Creek 2.5", knuckle rebuild kit. Engine stuff. Radiator. I'm anxious to get the frame finished up and start putting some paint down on the parts. 50s this week!
Getting excited about the warmer weather. Anxious to lay down some paint on parts and start putting things back together. I feel bad every time I tear something apart it just seems I'm getting farther and farther away from completion, most stuff to put back together and more parts needed.
Front axle is a good example. I was hesitant to tear into it, but the seals definitely need to be replaced and I feel I know so much more about how everything works having torn it apart.
The bearings look pretty good. Truck has a little over 100K on it. Do the bearing usually last past that or best to replace?
The washers on both sides were scored pretty well though. Not sure exactly what caused this. I guess I'll look closer at the wheel bearings and this washer tonight.
I got all my new JIS fasteners for the truck. I'm anxious to order some stuff this week. Hell Creek 2.5", knuckle rebuild kit. Engine stuff. Radiator. I'm anxious to get the frame finished up and start putting some paint down on the parts. 50s this week!
- Thread starter
- #55
I'm still here! Figured I'd post a small update. I've been slowly accumulating parts. Eerything is still in pieces. Frame has been at my buddies waiting for some pieces to be cut so we can finish the custom bumper.
I got my wheels, tires, new leafs, converted to rear disc, shocks, power steering bracket fabed, ps box, pump, shaft, engine gaskets, new seat upholstery, round eyes, carb rebuild, hoses, radiator, rear locker installed, clutch and pressure plate, new tie rods, pitman arm, knuckle rebuild kit and bearings, frame paint, and a lot more I'm sure I'm forgetting.
Engine is still in pieces. Still trying to find a deal on rings and bearings. Need to reassamble the 2f. I should start working on that. Front axle is still torn apart. I've been wanting to treat and paint the axles and frame. Probably wait until warm weather now.
can't wait for reassembly. Lots of other projects going on this winter, but sure would be nice to get her back on the road this summer!
Figured I'd post a small update. I've been slowly accumulating parts. Eerything is still in pieces. Frame has been at my buddies waiting for some pieces to be cut so we can finish the custom bumper. I got my wheels, tires, new leafs, converted to rear disc, shocks, power steering bracket fabed, ps box, pump, shaft, engine gaskets, new seat upholstery, round eyes, carb rebuild, hoses, radiator, rear locker installed, clutch and pressure plate, new tie rods, pitman arm, knuckle rebuild kit and bearings, frame paint, and a lot more I'm sure I'm forgetting.
Engine is still in pieces. Still trying to find a deal on rings and bearings. Need to reassamble the 2f. I should start working on that. Front axle is still torn apart. I've been wanting to treat and paint the axles and frame. Probably wait until warm weather now.
can't wait for reassembly. Lots of other projects going on this winter, but sure would be nice to get her back on the road this summer!
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- #56
Finally starting to make some progress. Warmer weather has me out in the garage and I don't have any band responsibilities to worry about for awhile. Time to get some stuff done on the FJ40!
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- #57
I'm finally making some progress! It's fun to finally start putting things back together. Still a long process with cleaning, primer, paint, dry... I'll probably start a build-up thread in the tech forum once I get the rolling chasis done. I hope to do that soon, then on to the engine, brakes, etc.
- Thread starter
- #58
Humming along. Engine machining is done and parts are in. Hope to start bodywork soon.
- Thread starter
- #59
I made a build thread in the forums.
https://forum.ih8mud.com/40-55-series-tech/602740-my-78-fj40-project-hd.html
https://forum.ih8mud.com/40-55-series-tech/602740-my-78-fj40-project-hd.html
