Decision Time - Am I Ready For A Frame Off Restoration

[TCSTARK]

Update

Ok gang, I actually got some quality time in with the cruiser.
Here is what I did today:

I attached the replacement smog pump pulley (Thanks tyama!) and slipped on the belts.

I then installed the column bearing bracket. I had to grind the bracket holes to align them with the existing column hardware. Once that was done I was able to secure it with four 1/4" by 1.5" bolts. I test fitted the u-joints on both ends of the dirive shaft. Once I am ready for t permanent install I will use medium thread locker and tack welds.

I drilled 2 half inch holes through the frame to mock up the wdorry bracket. It is secured by four 7/16th bolts (4.5", 3.5" and two 2.5"). I just felt that most of the bolts were too long but I figured that this was tried and tested by Mud Members so I wouldn't question it. (I also saw the same length bolts being used on Jim Smith's thread)

Once I had the power steering box mocked up I test fitted the high/low pressure lines to the pump. I had to manually bend the high pressure line to get the proper fit. I finally cleared the belts and drive shaft so I felt pretty good about it.

I removed the old relay rod and replaced it with new hardware. I slipped the pitman arm on the power steering box and temporarily secured it. I wasn't sure if the pitman arm should move all the way up on the gearbox spline??? I took several pics of this step and hope someone can give me an answer.

Until next time,...

 

[TCSTARK]

More pics

Here are a few pictures of the pitman arm.

 

[TCSTARK]

Update,...

I spent a few hours on Big Blue today and was able to make some good progress. The saginaw conversion is almost complete. I just need to get the weld in place, throw some primer and paint on the parts that need a refresh, and then re-install the fender/bib and front/bumper.

So the plan is to get the power steering done, connect the the trolhole carb and dig into the A/C install. Once I get it all done I will limp on down to the alignment shop and have the cruiser looked at. Then I will take her down to ACC for a tune-up and a thorough inspection before she becomes my daily driver.

Here are a few pictures of my progress.

 

[TCSTARK]

More,...

Here are a few more pictures of my progress.

 

[3doghouse]

Sorry if I missed it, but what AC kit did you decide to go with? Augusta's usually 10 degrees hotter than Atlanta with twice the humidity and no breeze, so I'm interested in how yours works out.

Great work so far!

 

[TCSTARK]

I went with the Vintage Air unit since it is well documented on MUD. I drove to TN and purchased the unit from tpi4x4.com at a lower cost listed from other vendors (plus no shipping helped). I will be installing it shortly after I get the trollhole carb hooked up and new vacuum lines run.

The one thing I was told by Bob at tpi was to insulate the interior the best I could so that I would retain some of the cold air. He mentioned cutting rubber padding/foam and cover as much of the interior as I could. I need to research my approach before I jump into it.

Stay tuned!

 

[TCSTARK]

This week's work

I tinkered with the trollhole carb this past week and got it mocked up on the 40. I quickly realized that I was going to need a set of new gasgets and a OEM choke cable to get it just right.

This leads me to the purchase of items from $OR and their shipping policy. Lesson learned. I won't be doing that again unless absolutely necessary.

I tore out the aftermarket choke cable and replaced it with the new OEM cable. (Removing the gauge cluster was the best approach of installing the nut on the choke pull). I added the gasgets, re-installed the throttle linkage and tightened the carb down. That last nut closest to the cab was a biaaaatch and I almost asked my 4 yr old to do it with her small hands. Thank goodness I got it myself...

Once I got the carb installed I decided I wanted to turn over the cruiser and test her out. Well, it worked on the first shot. Then I decided I wanted to pull her out of the garage and test the power steering. I checked all of the power steering connections, tightened everything up and pulled out of my garage. It was amazing! It was only a short distance at very slow speeds but it worked!!!

I loaned out my car jack, sockets and wrenches to my brother so he could work on his car this past Sunday so I needed something to do on the cruiser. I decided to roll her out of the garage and give the engine, tranny and frame a good cleaning. A little puple power and water did the trick. I would say it is 'less' greasy now.

I set up a few temporary work tables and started to unpack all of the Vintage Air boxes. I am gearing up for this project as it 'may' be the toughest one yet.

I have a list of items I need to knock out:

1. Suspension
a. Replace the two rear shakle pins with greasible pins.
b. Check all bolt torque values.
c. Grease all zirks.
2. Power Steering
a. Cut outter frame scab plate to size and drill out holes.
b. Weld brackets.
c. Locktite all driveshaft connections
d. Grease zirk on Driveshaft bushing bearing.
e. Cut to size and install new vacuum lines.
f. Paint exhaust, frame and gearbox.

 

[TCSTARK]

Project Moving Forward,...

I began the Vintage Air project last night with dismantle of the stock heating system. The original motor, heat valve, blower and plumbing/duct system were removed from the cruiser quite easily. I discovered the PO's hack job on the electrical system where he had integrated a aftermarket radio. I pulled the radio as well...

I installed the compressor bracket and called it a night. Here are a few photos of last night's progress,...

 

[TCSTARK]

More Photos....

Here are a few under-dash photos...

 

[TCSTARK]

Vintage Air Installation

I mounted the condenser and drier units and ran the return line to the compressor. I was about to start the installation of the evaporator unit in the cab but decided to hold off until I got the cab prepped with sound dampening material. I chose 'Quiet Crap' for the sound dampening layer and 'Ensolite' for the thermal layer. I should be receiving them this week... I will post my progress with these two products.

I removed the front seats and brackets as well as the two rear jump seats. I will be giving the inside of the cruiser a deep cleaning so it is ready for the next step.

The one question I have is this,... Is there anything I can do to reduce the amount of gas fumes from the tank while I have access to it?

 

[DSRTRDR]

tighten the lines, make sure you have the evaporator, and possibly get a new gasket for the fuel gauge sender - assuming the tank doesn't leak

 

[Scott68FJ40]

I'm looking forward to your write up about the sound and thermal barrier products. I have spent a lot of time trying to find decent reviews but haven't had much luck. I want to do something along those lines when my FJ40 starts going back together.

 

[TCSTARK]

I'm looking forward to your write up about the sound and thermal barrier products. I have spent a lot of time trying to find decent reviews but haven't had much luck. I want to do something along those lines when my FJ40 starts going back together.

Yeah, I have spent alot of time reading all of the MUD threads, searching the web for reviews and trying to make the heads or tails of all of the products on the market. I finally called Mark from Cruiser Crap, www.cruisercrap.com custom orders, and got schooled on his product. He advised me on how much I would need and gave me some solid pointers for installation. One roll of Quiet Crap, 4 yards of Ensolite and a quality carpet kit with a solid jute backing will be my approach. Not to mention tinted windows,..

Stay tuned,..

 

[Scott68FJ40]

I run open top so the sound isn't much of an issue, but I have always hated when my feet get so hot from the engine / exhaust heat. Of course once summer rolls around here in Arizona it is going to be hot.

 

[TCSTARK]

Sound Dampening

Here's an update:

I received the roll of Quiet Crap (25 sq ft) and sheet of Ensolite (4 yards) on Friday.

I was told that the roll of QC would cover my cruiser but I wasn't quite so sure when I saw how small it was. I proceeded very carfully with my cuts as to not have alot of waste material. I am glad I did that because I barely had enough material to cover the inside firewall.

Since I didn't have enough to cover the doors I decided that I would purchase a small amount of peel and stick to complete the job. I also picked up 25 sq ft of thermal liner that I would add as additional insulation. You can see the difference in material in the pictures. The thermal wrap is very shiny. My daughter said that it looks like a rocket ship and she wanted me to keep it that way. Hmmmm, I'll pass on that. I just ordered the deluxe carpet kit from Cruiser Solutions.

I hope to finish up the thermal wrap and ensolite tonight so I can get back to the installation of the AC evaporator unit.

Here are several pictures of my progress.

 

[TCSTARK]

More Pics

More pics of Big Blue undressed...

 

[TCSTARK]

Wrapped up

Quiet Crap, thermal wrap and ensolite... And a freyed gas intake line. Should I replace that now?

 

[TCSTARK]

More photos

Here is a couple of the ensolite product. I think we can call it wrapping foam with a sticky backing. Just saying...

 

[TCSTARK]

Back to the AC install

Here is where I left off with the AC install. I am glad I took pictures since I almost forgot where I left off. Oh yeah, installation of the evaporator unit.

The photos show the installed condensor unit, drier and compressor. That was a to install.

 

[TCSTARK]

Shhh,... did you hear that?

Sound dampening/thermal barrier has been laid. I am anxious to get the new carpet kit installed so I can provide some feedback on how well this project reduces the noise level of a cruiser.

I have roughly 2 months to get all of the pieces of the cruiser puzzle back together for it's new role as a daily driver. Here is a pic of the cab...

Murphy aka Murphy's Law is also anxious to go cruising.. Maybe I should have put a layer of lizard skin in the rear of the cruiser for any accidents? Well, he has two months to gain control of his bladder or the family lexus will be his vehicle. HA!