Build BJ 45 restoration Greece

[Greek Cruiserhead]

Clear!
Feel free to upload pics of your 2022 vintage outcome: this will be not difficult to understand, I gather.

 

[Shown]

I continued the last days buying some parts. New water pumb, brake master cylinder rebuild kit, ball joints for the pto and 4wd and new chassis rubber mounts...

 

[Greek Cruiserhead]

The AISIN water pump is a great addition to your Cruiser.
As I can see, these aftermarket body mounts are for the HiLux: fingers crossed they will do the job right!

 

[Shown]

I rebuild the pto and 4wd shift levers in a machinery with new teflon rings, because the connections were very loose.

 

[Shown]

Some more pictures...

 

[Shown]

As you will see here, the rubber mounts i bought, are for Toyota hilux rn30-50... The dimensions are perfect compared with the factory ones, and found them easily here in Greece. I searched a lot to find the bolt studs that are attached on the handbrake drum, because the threads were damaged and couldn't find them anywhere on the web. Luckily Greek Cruiserhead told me to look at my local Toyota dealer. I couldn't imagine that i could find them there because 40 series were not imported in Greece. But i was surprised when i called the dealer and he told me that the bolts are available....

 

[Greek Cruiserhead]

Shown said:​

"I searched a lot to find the bolt studs that are attached on the handbrake drum, because the threads were damaged and couldn't find them anywhere on the web. Luckily Greek Cruiserhead told me to look at my local Toyota dealer."

Oh mate, this is wisdom I acquired in the Mud!

 

[duncanrm]

Superb work.. I am really enjoying this build. Thanks!

 

[Shown]

I've decided to reinstall the cab and to bring my cruiser inside for the winter, so i can work without being disturbed from the weather.

 

[Shown]

The chassis rubber mounts...

 

[Shown]

I also send the radiator and the starter for rebuild. The radiator had some cut lines and was welded without them. I didn't take photos before (i forgot). The radiator expert welded brand new cells on, and the result is perfect. The starter was working fine, but once it was removed, i preferred to check the internal condition. The electrician that checked it, confirmed that it was in very good condition, and the only thing he had to do after he opened it, was to clean and lubricate the moving parts.

 

[Airdale]

Amazing work! I just read through the whole thread.

I'm curious what you are using when cleaning body and drive train parts, you get them so clean?

 

[Shown]

Amazing work! I just read through the whole thread.

I'm curious what you are using when cleaning body and drive train parts, you get them so clean?

Thanks for your words.
For the final cleaning of the drive train parts, i use petrol with a soft paint brush and removes all the old black oils and carbon.
For the body and chassis things are much more difficult. Firstly i washed them with a cleaner that is ideal for food oils from grill. For The oils that were harder to remove i used nitro thinner. I was surprised from the result. All these require mask for not to breathe them off course. Then i used angle grinder with hard metal brush to remove the most of the rust. Then i used a phosphoric acid based product, to remove the rust from the surfaces that couldn't reach with the grinder. And on the cab, i used a disc like that on the picture. That disc removes the paint without damaging the metal surface..

 

[ceylonfj40nut]

Great build. Very resourceful. What did you use for your brake lines?

 

[Shown]

Great build. Very resourceful. What did you use for your brake lines?

Nice garage... and nice rides... The brakelines are the original repainted, except of two pieces, (one on the front axle and the one that goes from the middle of the car to the rear flexible hose).These two were damaged and i bought new. I found a machinery here in Greece that builds those lines in the length you want, and they attach the side bolts that matches to your need. The flexible hoses are brand new.

 

[Shown]

One year now in the forum i haven't show you my first attempt of rebuilding a vehicle. My parents owned a Hilux RN25 and when they left it for a new pick up, i decided to take action. The plan was not to restore it, as i do now with the cruiser. I wanted to rebuild it and to make something impressive and fun...

 

[Shown]

The past month, I've decided to open the engine top cover to replace the valve stem seals. But i made a mistake trying to replace the seals without removing the cylinder head. I forgot to turn the 1st piston on the right position (full compressed) and the second valve fell in the cylinder.... So i had to remove the cylinder head, something that I didn't intend to do...

 

[Shown]

However i think is better this way because i found out that combustion chambers were all damaged... The hardest thing until now, was to find those chambers. I searched over a month and finally found them in Poland by Terrain Tamer. I couldn't find them anywhere else. I was so desperate that i searched in china (they have them very cheap) but it was very difficult to transfer them. I was surprised that noone else that brings TT parts in Europe has them on their catalogue. The original part was so expensive that i had to sell my liver to buy it (as we say here in Greece when something is so expensive). Very expensive without reason... At least the cylinders inside are in perfect condition.

 

[Shown]

Waiting for the chambers i cleaned the head the valves and the springs, i put them in bags with number so that they will be in the right position on the reassembly. Then i measured the surfaces of the head and the block. The manual says that it must not have a gap bigger than 0,2mm , and luckily it has not...

 

[Shown]

Then i resurfaced the valve seats and the valves.