Dave's 1978 FJ40 long restoration project

[DSB345]

In August I stumbled upon this 1978 FJ40. I decided it was a good candidate for a full nut and bolt restoration so I bought it. I have always wanted one of these since I was went on a 2 week trip across Death Valley with a part time silver miner that worked for my father's company at the age of 15. I was so impressed with the abilities, strength, and endurance of the FJ40 that I knew I wanted one for myself one day. I have learned much from the IH8MUD forum's and fellow members. This will be my first Land Cruiser but not my first 4X4. I will give it my best shot but I will not do it all by myself. Some things are better left to the pros for the level of restoration I plan on doing. I will not cut corners. I plan to attempt to restore this to it's original spec's and looks the way it came off the showroom floor as much as possible. This is a personal challenge. I will only build one like this. So here it goes. I have now joined the crazies. This is what I started with. My name is Dave!

 

[DSB345]

 

[coinoperated40]

Looks like you have a great starting place. She looks to be in above average condition. Speaking from the east coast, that is in GREAT shape.
Shane

 

[DSB345]

I have since stripped apart the FJ40. the body is off the frame, axles separated and now the work begins

 

[DSB345]

I must say that these tools were a life saver to get to this point. I only broke off I body mount and a couple of others through the entire teardown.

 

[DSB345]

I Have since dropped off my front axle to @Mark for a complete overhaul. it was in very bad shape. Housing was welded and needed to be replaced. who ever welded the housing (farmer I bought it from) got weld splatter into the diff.

 

[DSB345]

Thank you!

Looks like you have a great starting place. She looks to be in above average condition. Speaking from the east coast, that is in GREAT shape.
Shane

 

[brian]

looks like a very solid starting point.

 

[DSB345]

All the doors are in amazing condition and still had the plastic on them.

amazing condition

 

[brian]

FYI the weather barrier is no longer available.

 

[DSB345]

Thanks Brian!
Unfortunately, I tried to save them but couldn't. I will have to make some

FYI the weather barrier is no longer available.

 

[78fj40mg]

Great progress Dave! Look forward to seeing more pics of your build, I have a feeling this will be an awesome one!
Have you made a decision on the color yet?

 

[DSB345]

Not yet, Freeborn Red?

Great progress Dave! Look forward to seeing more pics of your build, I have a feeling this will be an awesome one!
Have you made a decision on the color yet?

 

[78fj40mg]

Not yet, Freeborn Red?

That's the one! T-309

 

[65swb45]

I don't know why, but a hunch told me to have Dave bring the front axle in first. He had mentioned the housing had some booger welds on it and I was going to have to supply another housing. Well I didn't turn it over to look at it before I disassembled it. It took me a day to realize why the ring gear had the craziest wear pattern on it I had ever seen!

The booger weld was huge, obviously requiring armor-piercing munitions, and was obviously done with the third still installed.

 

[65swb45]

I spent a few hours pulling carrier studs, chiseling factory welding slag off the replacement housing and transfering over the mounting tab for the front brake line junction before taking it, along with a premium set of dust shields to the powder painter. Once back from the powderpainter I had to chase all the holes before installing new carrier studs.

 

[65swb45]

Yesterday I got as far as installing one birf/spindle/ dustshield combo before having the day run away with an emergency situation involving an adventursome soul taking his 40 to Tierra del Fuego.

Hopefully I will be back at it next week. I've got a stalled rear axle overhaul I've got to get on next.

 

[kcustom73]

DSB, nice 40 to start a project with. Good luck with the build.

 

[coinoperated40]

Not yet, Freeborn Red?

I would think a true restoration would be going with original. That is one of the best colors out there.
My bad for changing mine from red to dune, but all is good.
Keep the pictures coming.
Shane

 

[DSB345]

Thanks

DSB, nice 40 to start a project with. Good luck with the build.