Blue Mule resto in Malawi

[Adolf]

Dan, did you fit that Grab Handle afterwards or was it std with that dash? Always thought that those with top dash don't have a Handle. Thinking of doing the same with my 40, because Swambo has real trouble to get in, due to the Heystee lift. Needs something to grab on!

 

[Adolf]

What is the function of the Carb Fan?? Does this unit belong to the smog setup?

 

[M5driver]

I forgot, my fault I have purchased them but haven't collected them yet. Will do so this week and post them :whoops:

Theo, I forgot you had got them for me. I was gonna log on to order. BTW, I owe LCCSA a BIG update - I'll do that this week. While I was really pushing to get the build finished, I found that just keeping MUD up to date was tough. I kept going to sleep waiting for the pix to upload over my "broadband" connection

'n'
Dan

 

[M5driver]

Dan, did you fit that Grab Handle afterwards or was it std with that dash? Always thought that those with top dash don't have a Handle. Thinking of doing the same with my 40, because Swambo has real trouble to get in, due to the Heystee lift. Needs something to grab on!

Adolf,
I fitted that grab handle after SWAMBO nearly went through the bikini top (the 40's, that is - not her personal one ) over some rough terrain in Arizona. She had often commented that the driver at least has the steering wheel to hold onto. I find it's great for getting in and out, even with the small OME lift.

What is the function of the Carb Fan?? Does this unit belong to the smog setup?

I think it is a smog gear item, but I would probably install one if I didn't already have it. It cools the carb when things get hot under there and keeps the fuel from boiling away, prevents vapor lock. The relay for mine failed many years ago, in a place where I could not get a replacement, even in the mail, so I just bypassed the relay and put mine on a toggle switch. If I am stopped for a short time, I switch it on - makes hot starts very easy. Since it is no longer auto shut-off, I don't run the fan if I am going to be shut down for more than about 15 minutes... don't want to walk away with it running, and come back to a flat battery

 

[Adolf]

Thanks for the feedback. Would you mind posting a better pic of that Fan and where exactly is it mounted. Can post here or on LCCSA! Was contemplating to get one as well, except that I was not sure what setup would be needed.

 

[M5driver]

Thank yous

This post is one I have been anticipating for awhile - time for some public acknowledgments:

In no particular order

This forum - I'd never have made it without all the help here
Poser, Degnol, Fast Eddy, Orange45, Coolerman, TEQ, Trollhole, Downey, Pin_Head, BSmith, just to name a few... the wealth of information here is just unbeatable.

Tom "Lost Marbles" from NZ - signed on early and provided huge support, encouragement, and info.

Theo, Keith, JT, Adolf, and all of LCCSA - thanks for helping me stay stuck in, even when things went amazingly awry "Africa is not for sissies"

Chris Bevins here in Lilongwe for his encouragement and grunt labor.

Joe Farina - a good bud from work, always ready to lend a hand.

Our home guards, Gerald and Kennedy, and our gardener, Davis, for their ready help with anything that required heavy lifting

The crew at Nunes Panel Beaters, for sticking this out with me.

Cruiser Dan
SOR - hard to find parts and tech support, even when the call is from Malawi
CCOT - Manny and Gaylon... excellent customer support
CruiserParts - James, for all your help and parts when I needed 'em
Man-a-Fre
JT Outfitters
Cruiser Solutions
Bolt Depot
Northeast Fasteners
NAPA
Northern Tool
Small Parts

Everyone who took the time to read my build thread; everyone who offered advice, sympathy, or took a moment to cheer me on.

Of course, my sister Sue for sending parts and supplies whenever I asked, and for handling the large Rust Bullet purchase and shipping. God bless Texans!
And thank God they survived the hurricane without too much loss.

Finally, my long-suffering who now has HER 40 to again.

Couldn't have done this without any and all of you! I'll keep this thread going until the Blue Mule leaves Malawi for the trip back to the states. Then... well, there are bound to be new adventures.

Dan

 

[M5driver]

Thanks for the feedback. Would you mind posting a better pic of that Fan and where exactly is it mounted. Can post here or on LCCSA! Was contemplating to get one as well, except that I was not sure what setup would be needed.

I'll get you some pix tomorrow

 

[amaurer]

Nooo my favorite thread can't be ending! I demand you tear it down again and start fresh!!

[Looks awesome, nice job!]

 

[jvazquez53]

Nooo my favorite thread can't be ending! I demand you tear it down again and start fresh!!

[Looks awesome, nice job!]

Got to keep us posted on the return trip!!! Sort of a part 2 of this Thread.

 

[M5driver]

Almost perfect... I think my fan clutch is failing, tho - she was starting to heat when we were running slow. Had to turn on the heater to get her back in mid range on the gauge, where she normally runs. When we got home, I checked for resistance from the fan clutch, and it doesn't seem to be much more than when the engine is dead cold. I'll be checking with Toyota here tomorrow to see if they have anything...

Toyota Malawi came thru! Granted, the new OE fan clutch (Toyota/Aisin) cost $425 but they had it! And at least, I won't have to pay the additional $70 VAT.

Got the new fan clutch installed. cleaned everything up, started her up and got it warm - huge difference. The fan is visibly faster - about the same as WP speed, I'd say. Switched off to check resistance - much higher than the old clutch warm. So, went out to run the same route as yesterday... same conditions - temp around 90-92F, light breeze, lots of dust, cumulus clouds building, but still too early for rain, and ran her slow. The temp never climbed above the first white hash mark on the gauge (yesterday it hit the second line before I pulled on the heat to cool it down, then it between mid-scale and the second white line). wanted to do the drive today, so I followed in the Pajero and had a chance to watch the suspension work - looking really good

Gotta get under it and check U-bolt torques and other items this afternoon. If all that is good, then she will be ready for a little harder running this week.

New OE unit; old aftermarket unit.

 

[Adolf]

Dan

Could you post the Part No. of the new clutch please!

Thanks!

 

[M5driver]

Thanks for the feedback. Would you mind posting a better pic of that Fan and where exactly is it mounted. Can post here or on LCCSA! Was contemplating to get one as well, except that I was not sure what setup would be needed.

Adolf - pix of the carb fan and mounting.

My mule is LHD, so the fan is mounted at the louver on the left side, just below the clutch master cylinder.

First two pix are for orientation - over the left fender, and from the front of the 40. Third pic here is the two 6mm cap screws that hold the top of the fan to the louver flange.

 

[M5driver]

Now from underneath. There is a small bracket, black, that bolts to the firewall with 2 6mm cap screws, and the bottom of the fan screws up to that with 2 6mm cap screws. The bracket has captive (welded) nuts for the screws.

So, lying on your back under the left fender, looking up, firewall is on the left, fender inner edge diagonal from the bottom going right, and my speedo cable in the clip.

Second pic shows a little better angle on the bracket where it attaches to the firewall. Third pic is looking up fro the rear of the left fender bottom, fan and outlet tube pointing at the carb in the middle.

SOR's online catalog may have a drawing of the firewall bracket - I just came in from the garage and haven't looked yet.

HTH

Dan

 

[M5driver]

Dan

Could you post the Part No. of the new clutch please!

Thanks!

You bet! 16210-54150, coupling assy. Makes all the difference in the world.

'n' s
Dan

 

[M5driver]

Nooo my favorite thread can't be ending! I demand you tear it down again and start fresh!!

[Looks awesome, nice job!]

Wow! Thanks I think I'll skip the starting over part, tho

Got to keep us posted on the return trip!!! Sort of a part 2 of this Thread.

Jose, no telling what will happen next. I'm just crazy enough to do it again. wants a *J45 pick up... my baby sister's husband's father (that would be what, my father-in-law twice removed? ) has a nice red, 80s FJ40 sitting in his garage in Tucson - it was given to him but he has never driven it... it just sits, collecting dust and cobwebs, and maybe pack rats...

Am I crazy enough to do it again? probably. Would I do it again? Yes. Would I do it again in Malawi? Hmmm... I'd have to think about that. Maybe, but only after making sure I have everything I need, including plenty of Rust Bullet, and a sand blaster and some sort of paint booth/tent and my own painting gear. Think I'll do my next resto somewhere I can get what I need in day or weeks, not months

 

[Adolf]

Thanks for the pics Dan. I got the idea now except for one last question or two.

Does the fan get the cool air through the side vents?
And is it also bolted, besides firewall, to the vent side?? If yes, then there must be another bracket attached permanently to the inside of that panel, which mine does not have then ! Assuming that, because I do not see any outside mounting bolts!

BTW, read through your thread again! Absolutely stunning write up of your resto. Wish I could save the whole fred as a PDF! Other good write up is Keith's on LCCSA! to both of you!

 

[M5driver]

Thanks for the pics Dan. I got the idea now except for one last question or two.

Does the fan get the cool air through the side vents?
And is it also bolted, besides firewall, to the vent side?? If yes, then there must be another bracket attached permanently to the inside of that panel, which mine does not have then ! Assuming that, because I do not see any outside mounting bolts!

Yes, the "cool" air comes in through the left side louver. It is fastened to the side with to help hold it against the louver opening, with foam gasket around the intake. I've included another pic of the upper flange - I would think you could fab something up with a couple captive nuts that would work. Might need a bit of welding, though.

BTW, read through your thread again! Absolutely stunning write up of your resto. Wish I could save the whole fred as a PDF! Other good write up is Keith's on LCCSA! to both of you!

Maybe Keith and I can collaborate on a lavishly illustrated book, and you can buy it for your coffee table

I will start updating my fred on LCCSA tonight. The new Ambo got here fine, so now people can relax a bit.

 

[M5driver]

Culturally relevant comments

All the guys who work for me here have been very interested now that the Blue Mule is mobile again. They all want to look at the engine and I happily accommodate them. By far, the most frequent comment is "no leaks!" That is something of a rarity here.

But my favorite comment came from a guy trying to describe how clean the engine is (was, actually - got a nice coat of dust on it this weekend ) He told the other guy that the engine is so clean if you dropped your meat on it, the meat would get the engine dirty, not the other way around.

 

[Colorado Boy-74-FJ40]

Meat

All the guys who work for me here have been very interested now that the Blue Mule is mobile again. They all want to look at the engine and I happily accommodate them. By far, the most frequent comment is "no leaks!" That is something of a rarity here.

But my favorite comment came from a guy trying to describe how clean the engine is (was, actually - got a nice coat of dust on it this weekend ) He told the other guy that the engine is so clean if you dropped your meat on it, the meat would get the engine dirty, not the other way around.

I would have to be leaning pretty damned far in to the engine bay to get my meat on your engine!.
BTW, where did you say you were going to be assigned next?

 

[fjwagon]

But my favorite comment came from a guy trying to describe how clean the engine is (was, actually - got a nice coat of dust on it this weekend ) He told the other guy that the engine is so clean if you dropped your meat on it, the meat would get the engine dirty, not the other way around.

Too funny