Builds Build: Rusty Pumpkin Project 74' FJ40

[bdawg23]

Bottom end is coming together! Shop sent me a few photos this week

got a few more parts on order, new engine mounts, new carb, new brake master cylinder, finishing installing most of the new brake lines and I’ve got a few to manually bend.

happy Saturday!

 

[bdawg23]

Look who is back! I’ll go over the work done but wanted to share this for now.

 

[bdawg23]

Question: installing the flywheel, how do you fold up the tabs on the other bolts? With the clutch installed can’t reach the other tabs. Do I need to rotate the crankshaft? Maybe this is more obvious but I’m stumped.

I think it’s coming along nice aside from this little hurdle hoping to get the engine mounted this week!

 

[charliemeyer007]

Long skinny old flat blade screwdriver sharpened like a chisel. Place up against the tab parallel to flat on the bolt - tap with a mallet to get under the tab, then twist to bend it out. Then use a punch to flatten the tap to the bolt.

 

[pb4ugo]

You'll have to turn the crank when you install and tighten the pressure plate bolts too.

 

[bdawg23]

Long skinny old flat blade screwdriver sharpened like a chisel. Place up against the tab parallel to flat on the bolt - tap with a mallet to get under the tab, then twist to bend it out. Then use a punch to flatten the tap to the bolt.

Thank you!

You'll have to turn the crank when you install and tighten the pressure plate bolts too.

For some reason I had a mental note to NOT turn the crank and I was hung up.

Got the tabs punched this morning and reviewing pics for the clutch install next!

 

[bdawg23]

look what dropped in last night!

Decided to go ahead and mount the engine despite needing a few parts to complete the clutch assembly. Clutch parts are on order (it's mostly the two little spring pins that hold the clutch fork to the throwout bearing assembly...grrrr) but I also ordered a new fork boot so freshen it all up.

A few things I discovered along the way:
- the fuel pump inlet valve is now blocked by the oil filter, previously on the F the oil filter was on the driver's side so I'll have to tinker with potentially using a 90 degree bend on the inlet
- I have a few blank holes on the head where the coolant runs by, need to plug these
- need to replace some hardware for the engine mounting bolts, the bolts I have all seem to be the wrong length (too short or too long)
- need to replace some front brake lines before I install the radiator

Lots more but those are top of mind after getting the block back in the engine bay

 

[Augustiron]

Great perseverance.

 

[bdawg23]

Progress has been a slow thing but before my next work trip I received the parts I needed to finish installing the clutch, pressure plate and fork.

I thought I was about to have a working clutch but turns out the old clutch slave cylinder isn’t happy so it will need replaced.

Off to order this part and a few others…

 

[Pighead]

View attachment 3917176

Your oil pressure sender, check that that's really the spot for it. I know it looks like it should be 'cuz that's where the old one went. It fooled me too. I swapped in an early 2F block, 098203, and got no oil out of that hole. Had to get the 2F oil filter mount with the threaded hole for my pressure sender.

 

[bdawg23]

Your oil pressure sender, check that that's really the spot for it. I know it looks like it should be 'cuz that's where the old one went. It fooled me too. I swapped in an early 2F block, 098203, and got no oil out of that hole. Had to get the 2F oil filter mount with the threaded hole for my pressure sender.

I will check, thank you!

 

[bdawg23]

Starting to make a little more progress finally!

 

[bdawg23]

Making some good progress over the last week.

Got the transmission installed. Seems there are some opinions about when to install this (while the motor is out or after the motor is in). Seems like it would be way easier to install while the motor is out. Getting the input shaft aligned was not easy. I ended up buying longer bolts to act as guides which helped a lot.

Next up I was going to install the intake/exhaust manifold but I realized I don't have all the hardware. I need six M12x1.25 studs and two m10x1.25 bolts. I found some stuff at the hardware store that would work but I didn't like it so I ordered the correct parts.

Still a laundry list of stuff to do but it feels like the big items are getting done and the more parts that go from the floor back into the car it makes the garage feel better so its a self fulfilling prophecy at this point.

one of those large items getting off the floor was a new OEM Toyota gas tank. After purchasing the plastic tank and having some fitment issues on my particular install and then reading the FAQs it was clear what my next course of action was: order the oem tank and be done with it.

Here is the engine bay as it stands currently. Where is the wiring harness you ask? It's still removed starring at me. Intimidating me. Giving me nightmares. I'll tackle it eventually!

YouTube Project: I've also been trying to video record the work on this project and I've gotten a few episodes up on the build progress if anyone wants to watch check out the videos here:

 

[knuckle47]

I’ve been wondering how you’re doing. Glad to see your making progress. After all, we’re not that far apart… on the other hand, I have a laundry list of small stuff like…connecting 8 wires, that may take me 4 more days ! Good luck getting this back in great shape

 

[charliemeyer007]

For me its way easier to pull/install the engine/tranny/transfer in on piece. Take the starter off for additional clearance. Assembly bolts (long without heads but slotted for removal is a good trick)

 

[bdawg23]

I’ve been wondering how you’re doing. Glad to see your making progress. After all, we’re not that far apart… on the other hand, I have a laundry list of small stuff like…connecting 8 wires, that may take me 4 more days ! Good luck getting this back in great shape

thanks! Finally, just been staring at it and thinking about all the work that needs done. Plus it’s been so hot and humid, makes it tough to work in the garage. First it was too cold now it’s too hot lol

 

[bdawg23]

For me its way easier to pull/install the engine/tranny/transfer in on piece. Take the starter off for additional clearance. Assembly bolts (long without heads but slotted for removal is a good trick)

If I do this again I’ll def try installing it all as one unit. Thx for the feedback!

 

[knuckle47]

These days, the outdoor weather rules my life. When it’s hot I can deal with it but when you add that humidity… I’m done!.
Never the case before. Vermont winters in the 70’s were more severe with temps frequently at -20 and greater. I would be outside in a flannel shirt. Now fifty years later I check at night to plan the next day.

If I can help you this fall as an extra set of limited hands, let me know. Without saying where….how far from Philadelphia are you?

 

[bdawg23]

These days, the outdoor weather rules my life. When it’s hot I can deal with it but when you add that humidity… I’m done!.
Never the case before. Vermont winters in the 70’s were more severe with temps frequently at -20 and greater. I would be outside in a flannel shirt. Now fifty years later I check at night to plan the next day.

If I can help you this fall as an extra set of limited hands, let me know. Without saying where….how far from Philadelphia are you?

I hear ya! About 3 hours from PHL. Conveniently located in the middle of the nowhere