Australian FJ40 - A possible rebuild thread!

[phils40]

What I haven't been able to work out is the front door seals and how/where they fit. Can anyone post some pics up of their door seals?

The vinyl mat and sound/heat proofing for the floor arrived from Melbourne during the week (Bday present from the wife) but I'm yet to take it out of the packaging. That will be the next job to do - pending the windscreen getting sorted and painted it should be getting put in relatively soon.

A few more pics from today:

 

[phils40]

A set of Hella h4 inserts got delivered today.

Yesterday the window guy installed all of the windows. I'll take a few pics tomorrow.

 

[Strategic1]

Birthdays, fathers day & Christmas represent more parts Looks really good. Cheers

 

[phils40]

Its all coming together! Windows are in and look great; today was putting a bit of black under the wheel arches, the steering column and gear sticks.

The window frame got the last coat of 464, so next weekend i'll start to put things back together!

Im getting excited about it getting back together!

 

[phils40]

The window and doors went on this weekend. Had a few issues with the screws from Toyota on the windshield hinges. Had to the-tap the captive nut inside the windshield.

Next weekend it'll be the apron and then i'll be fixing some dynamat type insulation to the floor.

 

[cult45]

Phil - this is a work of art! You've done so well! Will you clean up the column, gauges cluster, knobs etc?

 

[phils40]

Cheers cult.

Will you clean up the column, gauges cluster, knobs etc?

Yep, started on the door handles etc. this evening. I put the badges, apron, bonnet etc on today:

I gave the floor vinyl a bit of a test run. It seems to have come up short. Ill contact the place where I got it to see if there was an issue. It does say FJ45 on the base - Im wondering whether the 45 is a bit different to the 40?

I also gave the resomat a test. Seems to be pretty easy to install. Cut then peel the sticky backing off and the put in place.

Should of cleaned the floor before taking the picture!

 

[phils40]

The last few weeks have been quite busy with the 40. Roof and associated seals went on yesterday as well as the bumper, bezel, new headlights and touching up the front and rear seats with paint. Today we finished most of the resimat for heat and sound proofing in the cab.

 

[JuanJ]

Hello,

Looking good.

I like those wheels.

Keep up the good work.






Juan

 

[phils40]

Rear and front door seals have been installed, as well as new bailey channel for the front doors... they don't rattle anymore! My father in-law has made a new overhead shelf where the radio and cb will go.

Hopefully finishing up the flooring in the next few days before the auto sparky comes up to check a few things and then the seats go in. The finish line is in sight!!

 

[Strategic1]

Hi Phil, just had the headliner done in my old BJ42 & used marine carpet after I put sound deader material on first makes a huge amount of
difference to the hollow sound the roof used to make, came up a treat. Your rig looks to be going leaps & bounds good job Cheers

 

[phils40]

Hi Phil, just had the headliner done in my old BJ42 & used marine carpet after I put sound deader material on first makes a huge amount of
difference to the hollow sound the roof used to make, came up a treat. Your rig looks to be going leaps & bounds good job Cheers

Cheers - I had the headliner in mine done in marine carpet as well. It came up well. I had a few problems with the door seals after the went in, the doors wouldn't close properly. In the end, we did a bit of 'Chiropractic' type of work on the doors - inserted a small piece of wood between the door and the body and slowly worked it until the doors shut.

Everything is almost finished now! The 40 went for its first drive in over 11 months the other day, down to get some new tyres. It was great to drive it again. Tomorrow work will start on replacing the clutch and at the same time replacing the rear main seal, installing the breather between the transfer case and gearbox and having a general look over.

 

[roscoFJ73]

Great to see someone saving a 40 in Perth. Too many get butchered for half assed V8 transplants that are never finished properly. What happened to the little dog in the 1st pics? Looked just like mine ,she would always photo bomb when it was time for update pics.

 

[phils40]

Cheers @roscoFJ73.

The little dog is Tonic and he's a Staffy. He's still around - everything to do with the 40 was done up at my father-in-laws, so he hasn't had the chance to photobomb any more pics. No doubt in the future he'll have a chance.

 

[Strategic1]

If my rig looks half as good as yours mate I will be a happy man. Excellent job

 

[phils40]

Well, its been a good 6 months since I've posted on this thread. A lot of mechanical work has been done since then. The gearbox and transfer case were rebuilt, new clutch and rear main seal sorted. The front drum brakes were removed and disc brakes added (with 60 series parts) inc new bearings etc. and the old selectro hubs removed and Aisin hubs installed, and steering given a good going over. Photos to come! The plan now is to drive it for a while a good few months anyway. I think the carbs needs a nit of work and the tappets may need adjusting, but nothing major there.

I can't get over the brakes! Steering is tighter too, but the brakes....! I like a learner. jamming the brakes on and almost stalling because of the new clutch!

 

[bwalker16527]

The window and doors went on this weekend. Had a few issues with the screws from Toyota on the windshield hinges. Had to the-tap the captive nut inside the windshield.

Next weekend it'll be the apron and then i'll be fixing some dynamat type insulation to the floor.

View attachment 1333489 View attachment 1333490 View attachment 1333492 View attachment 1333494

Beautiful

 

[Strategic1]

Hi Phil, as said before you have done an excellent job I have Aircon re installed (notice your without) Steering box has just been rebuilt
hoping this will sort out my bump steer problems Just sourced a new heater control box, was a bastard to find! also a second hand fan motor & resistor that works, hoping to have a bit of away time going shooting. Lots of hoping see how it goes Cheers

 

[phils40]

Cheers Strategic - yep i saw your post with the aircon installed. I have the same nippondenso unit - but just the unit, nothing else.

At the moment, I'm enjoying driving it; will have a look at the tappets shortly though.

 

[Strategic1]

Hey mate, posted pics with air con was hoping to see more of your rig? still love that paint job got ripped on mine Now I have the carport will strip it down again in a year or two & redo the whole bleeding lot sigh