Big T's 77 FJ40 resto thread

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Big T

Big T

10 Year 15 Year
Joined
Oct 19, 2009
Threads
8
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333
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Work
Hello crew,

I have officially started the restoration of my 1977 olive FJ40. This is my first FJ40 so this will be fun (and take quite a bit of time with a busy work schedule, so bear with me).

The tub was pretty much shot, but the front half was in really good shape. 72K Original miles and the engine runs like a top. It is mechanically perfect.
It has a Weber 42/46 (I think) that I'll want to replace with the OEM Aisin carb (found in a box in the back of the cruiser luckily). I was also able to track down an oem air cleaner.

I started by disassembling the back half of the tub and then taking the fenders to the body shop. The hood is near perfect, and I'll post pictures of each item as I finish body work on them.

Excited to start the project :-)

Here is my brother Dallas (dmaddox on the forums) removing the windshield glass:

2010-10-05_09-54-44_311.jpg


2010-10-05_09-54-10_939.jpg


What is really strange on this cruiser is that all of the body panels were straight and virtually rust free except for the rear half of the tub!?

2010-10-05_09-55-08_225.jpg


Tub removed:

2010-10-05_09-54-56_249.jpg


Stay tuned for more project photos.

In the meantime I have a question for you guys. No one seems to know if this is a stock "build sheet" or "birth certificate" but it has very detailed information on my cruiser and appears to be very stock-like. Thoughts?

2010-10-05_10-19-43_468.jpg


Thanks much and stay tuned! If you have any comments or ideas feel free to share :-)
 
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That sticker is not stock. It looks like an old shipping label. Like the truck was shipped by boat. Notice the POE (Port of Entry) code.

Good luck on the build.

:cheers:
 
The "PIO" sticker shows port installed options. Not sure what the 842 and 880 option codes mean, but it would be options installed at the shipping port where your cruiser was shipped, before it was sent to the dealer. I have seen these on a few cruisers, and if stock means it was there when the vehicle was first sold at the dealer, then this sticker is most likely stock.
 
I have a sticker like that on my 76. Inside the glove box door. Looks stock to me...
Maybe a sticker they placed on imports to smog states like cali, to make sure they had the right gear on board...?

Good start btw... And what are your plans for the rear tub? Pilgrim? Aqualu?
 
dmaddox said:
The sticker looks very stock to me, and why would a ferry or port care about options? I vote stock, as others have seen them too.

Looks good big T - I am excited for the end product. KEEP ON IT and don't let the big picture discourage you...you can get this done.

dallas
Click to expand...

Im with you D. I think its stock as well. and BTW are you supposed to be paying attention to your class? lol

Thanks for all the help also. And just so everybody knows its because of dmaddox that I now have the LC addiction. I guess its what family does. It was a heck of a process getting this FJ back to my house and with some threating e-mails from my loyal brother we made it. Its been a fun experience.

Thomas
 
Didnt get much done on the crusier today. Just a little more sanding on the rear doors. Couple of quick questions for you guys about the tub. Thecrazygreek asked me what my plans are and to be honest im not sure yet. I have spoke with dmaddox a few times about it but still have not come to a conclusion as of yet. It is still a ways out until im ready for one any way but its always good to have the input. Let me know what you guys think. thanks.

Thomas
 
Big T said:
the engine ... is mechanically perfect. It has a Weber 42/46
Click to expand...

Oxymoron.

Big T said:
I'll want to replace (the Weber) with the OEM Aisin carb (found in a box in the back of the cruiser luckily). I was also able to track down an oem air cleaner.
Click to expand...

Excellent. I sent mine to Mark A. at Marks Off Road. It's been perfect and passes CA smog easily after 3 years.

Big T said:
What is really strange on this cruiser is that all of the body panels were straight and virtually rust free except for the rear half of the tub!?
Click to expand...

My recent acquisition (Marvin thread in my .sig) is similar. There's a lot of rust around the rear sill and lower rear quarters, and the bed floor is a mess, but the front floor is like new.

Big T said:
Thecrazygreek asked me what my plans are and to be honest im not sure yet. I have spoke with dmaddox a few times about it but still have not come to a conclusion as of yet. It is still a ways out until im ready for one any way but its always good to have the input. Let me know what you guys think.
Click to expand...

Since you have some time, I'd keep an eye out for a used 1/2 tub from SoCal or AZ. You could get it truck shipped on a pallet for a few hundred. I sold just what you need for $400 when I got my first cruiser.
 
Since you have some time, I'd keep an eye out for a used 1/2 tub from SoCal or AZ. You could get it truck shipped on a pallet for a few hundred. I sold just what you need for $400 when I got my first cruiser.[/QUOTE]

You think that is the way to go rather then new? I understand money wise but what about time and effort wise? I just dont want to get somebody elses headache. Thoughts?

Thomas
 
Big T said:
You think that is the way to go rather then new? I understand money wise but what about time and effort wise? I just dont want to get somebody elses headache. Thoughts?
Click to expand...

I agree you don't want someone else headache, but with the support of the forum people you may stumble across something really nice. I'd be looking for something with original paint. They are out there. You can always fall back on something new.

Craiglook: Craigslist Search is a good way to search multiple craigslist geographical regions at once.
 
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Help required......again!!!! I am getting ready to do the carb swap back to the factory carb. It looks like the PO hacked the fuel lines to make the current carb fit. How are the stock lines supposed to be ran and is there any way to get them pre bent or will I have to make my own?
2010-10-09_10-13-50_709.jpg


Im assuming the rubber fuel lines are not stock?:mad:
2010-10-09_10-11-42_304.jpg
 
you should desmog that engine correctly while you're at it too!! (where those crimped pipes are should be small allen head plugs) coolerman has a great writeup with pictures on the stock fuel lines he bent up (i'm pretty sure) someone else has one too

if you can just buy a used set and clean them up that would be easy to do too
 
antFJ said:
you should desmog that engine correctly while you're at it too!! (where those crimped pipes are should be small allen head plugs) coolerman has a great writeup with pictures on the stock fuel lines he bent up (i'm pretty sure) someone else has one too

if you can just buy a used set and clean them up that would be easy to do too
Click to expand...

Thanks, I was going to ask if there is a fix for that.

Thomas
 
Ok guys another question. My dad and I were able to pick up a 1973 FJ40 that was a resto project for some one else and couldnt finish it. We picked it up for $250.00 bucks and the tub to the firewall is in really good shape. If I go through and cut out the fuel filler portion and swap out the rear hinges for the ambulance doors would I be ok using that for my 77? What other complications am I looking to run into? I just think with a little elbo grease this is going to be a quick and cheap fix rather then getting a brand new tub. Thoughts?

Thomas
 
Sounds like a plan on the tub. The hinge setup will be tricky as those are hidden and you will have to open it up, do your mods, then close it back up. I would also look real close at that rear sill. Stuff could be hiding there, but a good dose of phosphoric acid (poor it in there) should help with any future rust. I would also recomend getting it blasted asap. Will help alot in prep etc.

I'll be keeping an eye on this build... ;)
 
Big T said:
Hello crew,

I have officially started the restoration of my 1977 olive FJ40. This is my first FJ40 so this will be fun (and take quite a bit of time with a busy work schedule, so bear with me).

The tub was pretty much shot, but the front half was in really good shape. 72K Original miles and the engine runs like a top. It is mechanically perfect.
It has a Weber 42/46 (I think) that I'll want to replace with the OEM Aisin carb (found in a box in the back of the cruiser luckily). I was also able to track down an oem air cleaner.

I started by disassembling the back half of the tub and then taking the fenders to the body shop. The hood is near perfect, and I'll post pictures of each item as I finish body work on them.

Excited to start the project :-)

2010-10-05_09-54-30_171.jpg


Here is my brother Dallas (dmaddox on the forums) removing the windshield glass:

2010-10-05_09-54-44_311.jpg


2010-10-05_09-54-10_939.jpg


What is really strange on this cruiser is that all of the body panels were straight and virtually rust free except for the rear half of the tub!?

2010-10-05_09-55-08_225.jpg


Tub removed:

2010-10-05_09-54-56_249.jpg


Stay tuned for more project photos.

In the meantime I have a question for you guys. No one seems to know if this is a stock "build sheet" or "birth certificate" but it has very detailed information on my cruiser and appears to be very stock-like. Thoughts?

2010-10-05_10-19-43_468.jpg


Thanks much and stay tuned! If you have any comments or ideas feel free to share :-)
Click to expand...

Nice work! I'm in the same boat as you with my 1965 Fj40 needing either massive rust repair on the rear tub or a new tub, or donor tub. trying to figure out which one is more feasable..
Also what is involved in cutting out the rear tub? as ive never attemped this.
 
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