Build Barn Find 1983 FJ45 Troopcarrier

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Another move, showcasing pure historical correctness.
Original exhaust manifold installation.

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That wasn't a new exhaust manifold. He restored the original.:)
 
I've been curious about re-assembling intake/exhaust manifold that way. Was the gasket surface machined/flattened prior?
The 2F is a tricky one. I think the high altitude head design derived from Chevrolet L6 OHV "stovebolt" engine. The manifolds are both on one side of the head with shared ports and shared fixtures. This has a lot of output performance disadvantages but achieve a very important objective it works very well in the cold or at high altitudes.
Could be one of the objectives of the first production of F engines were for US military in the Korea War. Its my guessing why, but surely the F engine and the 2F is very reliable in the cold.
Being said all that there is a heat issue impacting the aluminium intake, especially the bottom area, which is the top of the “hot box”.
There are two expansion attachments on the exhaust manifold being a three piece unit. It suppose to absorb the heat expansion/contraction issues of the exhaust. The shared fixtures are also built with large tolerances.
What you need to see is that both the inlet and the exhaust has a bery similar flange thicknes at the face. Large deviations will lead to blow out. Its very hard to machine both at the same time not only one is cast steel the other is aluminium but they will fall to 4 pieces.
My recommendation is a very slight straight hone on a belt sander of both watching the flange thickness, but most importantly a steel inserted oem gasket to be used. Btw, that is what I just did.
One of the reasons the 2F is not recommended to race is to protect the manifold from very high temperatures.
That is what people forget adding larger Weber’s etc.
In Australia the hot boxes used to fail and used to melt down the inlets therefore aftermarket extractors were quickly installed replacing everything at the exhaust side including the exhausts.
I have heard this happened with mining companies using FJ’s up in the Pilbara. They replaced extractors when the trucks were new. Noone kept the hotboxes.. all went in the bins. Along with the tray long beds replacing flat trays. All went to steel scrap. :eek:
 
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Great stuff. Here is my 78 Aussie FJ-45 2F. Holley Carb. I assume this is what you are referring to regarding the modifications. This rig was west of Sydney and belonged to the National Park Service. BTW, prior to my teardown this setup worked great!
 
KFJ45, that is exactly the case Sir! I have spoken to an old exhaust shop owner in Perth and he admitted throwing the hotbox manifolds out in the bins by the hundreds over the years. And he is happy now that there is no more hot box as he said it was a pain in the arse fixing them. He said it was a three days job taking them to the machinist etc, and rebuild. Those days every 40’ was a work truck, not like today, we try to preserve them, those days they actually if you look around in Sydney every dammed thing was built including the Harbour Bridge 40’s were involved. The whole country was built by these.
So noone cared less about hotboxes when its never cold in Aus!
Btw, my hotbox came off a rural police car somewhere up north at the ebo reserves. And that maybe never once been at the mechanic.!!
 
This has got to be one of the finest restorations of a Troopy I have ever seen, I found this post a little while ago and started looking at all of the Fantastic work you have done on it and came across a post I made here two years ago. I forgot I posted back then and am glad I came across it again. I brought my Troopy over from Perth where Arkana added a third door and a raised roof for the mining company. I started restoring mine a while back and wanted to say your hard and incredible work has inspired me for mine. Cheers mate, Geoff.
 
...and there were this old shed in the back of a family home..
There I found this 1983/01 Troopy with genuine 138,000km (85,700 miles)in the clock. The first and only private owner bought it from South Australia's Forestry Emergency Dept. in 2003. It was parked the following year in 2004 after taking the family with it on a holiday trip to Flinders Chase National Park at Kangaroo Island, SA.
Totally genuine, all complete and featuring a denso knee freezing aircon.
Its 4spd only.
I would like to see the troopy fully restored and I even considered shipping her to reputable restorers however I'm more and more inclined to do it myself.
I'd be happy to hear your opinions even though I'm pretty keen on doing the resto alone, slowly and extremly precisely. Enjoy the first photos and let me know what are your first impressions.. Thanks!

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Dude... Keep as is! Derelict!
 
I can feel the tear welling my eye.

Glad the Troopy made its way to a suitable stewart.

Bravo!

I am not a very moral person per se but koxfarm, its apparent to me that you have a knack for making a lot of ‘right’ decisions.
 
I can feel the tear welling my eye.

Glad the Troopy made its way to a suitable stewart.

Bravo!

I am not a very moral person per se but koxfarm, its apparent to me that you have a knack for making a lot of ‘right’ decisions.
Wooah, thanks for the sweet comments.. my right decisions , sure.. not always but lets say I take the compliments on this girl. She drives like a charm thats in the bank.
How’s in Oregon? I love the trails at the high country..
 
WOW.....What an amazing build
Congrats mate....very inspirational and amazing attention to detail.


The rear seems to be almost ready, need to finish the brake tubes and hoses.

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And one more thing.. the axle shafts and birf were not painted. (?) the RCV gun-drilled shafts come in black. I must admit, those RCV shafts are so nice it is a pity that the axle house is not transparent ;)

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I'm looking into cromos at the moment and was looking at getting RCV's
I noticed you used Nitto axles in the rear.....any reason you didn't stick with RCV's?


That was the load sensing propotional valve LSPV
Toyota was ahead of its time introducing this addition. It is common at trailers and trucks to have a proportional increase of brake force to the load carried by the vehicle. Same apply here.
LSVP topic had been discussed in depths previously on mud.

Where did you get the LSVP from?!
Mine is leaking and was going to replace it
I've been looking everywhere and can't find one - Terrain Tamer don't stock it and neither does Toyota?!


Probably I should've started a new thread for this but..This is my new project here.. I will soon produce 16x7 and 16x8 rims with correct clips and powdercoated black or grey and most of all with a SINGLE WELD!!! The 16x7 outer edge is aligned to body for street legal compliance al least in Australia. 100% factory look and hopefully within the $265 region ea. Photo shows the 16x7 prototype.

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Have you made any rims.....would be very keen to grab a set of 16x7s :)
 
Funny you mention it koxfarm

This nation does have a sort of abundance that is wondrous. And the Portland /Mt. Hood region is so lush; spent most of life in a furnace (California). I love it here, I shall die here. Its home.

We only recently decided to outfit an 8X sofa. They shipped ‘em here real soft in the 90’s, thanks to you Aussies you kind of toughened ‘em back up a bit during the era. The wife and I should be at Heritage in 2020.

One of my enduring motivations for pausing along our planned year long venture across this nation is so that I might stand before certain works of art sort of speak; I have a list already in my head: So we’re stopping there.

If your beloved Troopy is there, I will be quiet and respectful. I will not touch the chrome or turn a latch. Some things, I esteem just take time to admire. I think most people get that way with certain things. I guess that’s what cameras are for.

Anyway, thanks for sharing the wealth. Such a great and fantastic peek.
 
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WOW.....What an amazing build
Congrats mate....very inspirational and amazing attention to detail.
Cheers!





I'm looking into cromos at the moment and was looking at getting RCV's
I noticed you used Nitto axles in the rear.....any reason you didn't stick with RCV's?
I think RCV only had the front axles available as those are a match to the “toyota pickup” at the US, and the rear is semi floating so I had to find another supplier for the rear. Nitro is just as good but they had no gundrilled CV shaft so thats why the mix and match.
I really loved RCV and their packaging is superb too.
I had a friend of mine bought a set of shafts for a 70 series from 4x4World in Aus.. funny wnough the box arrived EMPTY. The shafts poked through the light cardboard and lost in action :)))))
What a mess.. they had to refund and send again. Same with me of the front bumpers. Mines came all damaged of weak packaging. I can gage a business of the wrapping how they respect their product or not.
RCV is definitely an example to follow. Their packaging fit drop from space, nothing will happen to the shafts I recon.



Where did you get the LSVP from?!
Mine is leaking and was going to replace it
I've been looking everywhere and can't find one - Terrain Tamer don't stock it and neither does Toyota?!
I have been hunting parts and cannot remember when but it was a private sale.




Have you made any rims.....would be very keen to grab a set of 16x7s :)
will do a few sets before Chrissy and put it up.
 
Funny you mention it koxfarm

This nation does have a sort of abundance that is wondrous. And the Portland /Mt. Hood region is so lush; spent most of life in a furnace (California). I love it here, I shall die here. Its home.

We only recently decided to outfit an 8X sofa. They shipped ‘em here real soft in the 90’s, thanks to you Aussies you kind of toughened ‘em back up a bit during the era. The wife and I should be at Heritage in 2020.

One of my enduring motivations for pausing along our planned year long venture across this nation is so that I might stand before certain works of art sort of speak; I have a list already in my head: So we’re stopping there.

If your beloved Troopy is there, I will be quiet and respectful. I will not touch the chrome or turn a latch. Some things, I esteem just take time to admire. I think most people get that way with certain things. I guess that’s what cameras are for.

Anyway, thanks for sharing the wealth. Such a great and fantastic peek.
That is so true about admiration of certain items weather a proof of human endeavour or of some important historic provenance. It is good to lnow the story of those and pause for a moment, get connected, get to receive the aura and think about for a second or two.

That is a respectful deed indeed and goes both way as I guess anyone historic or private citizen when they did something of worthy in the average daily worthlessness they did for the respect of future generations, even us, as we stop by and pause.

Its not going to be easy for the kiddies of today surrounded with things that are mostly faux. Others destroying history erasing the respect and leave totally empty space behind. A troopy like this is really a grain of sand but as small and as irrelevant it is, yet can became a vessel to omit a respectable moment for someone interested in. And that is exactly the point of displaying
 
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