Duffontap's 9/76 FJ40: From Here to Daily Driver in Two Weeks?

[duffontap]

I'm currently working on recovering my bucket seats and painting the hardware. Here are a couple teasers:



It's really hard to know where to stop with the seat frames. Everything with tub floor contact got thoroughly sandblasted and etched. Parts that won't have ground contact were mostly scuffed, wire brushed, sanded, de-rusted--whatever they seemed to need. Black interior parts are getting Rustoleum Professional Gloss Black and likely clear coat.



I'm now well aware of the fact that I have largely abandoned the near-panicked frame of mind that prompted me to start this thread. It had been a long time since I had been able to devote time to this project and I was just about desperate to get this 40 on the road. After all, it's my daily driver and my wife and I have been sharing our Corolla for more than six months----no mean feat for a family of five with work, grad school and a million other things to get to. My wife has been very understanding and I immensely appreciate her support on this project.

As this thread progressed, I realized that this truck might have more potential than I had given it credit for, and I didn't want to make so many compromises that I would be doing this all again in three years. At the moment, I'm working hard and trying to find the proverbial balance. I want to come out the other end with a truck that is ready to work hard every day like it did when it had toddler-sized holes in the floor, but also one that looks like its owner cares for it. My sincere apologies to those who are disappointed that this job didn't get done on the original schedule. Best, JD

 

[scoutin cruiser]

Better to do it right and cry once than to screw it up and cry twice.

 

[duffontap]

Long Range Fuel Cell

So, in order to turn two weeks into six, I'm thinking about installing a auxiliary tank. I actually have three used ones and they are all different and fasten differently (one is a trail-built one-off that weighs about 100lbs. and the other is the kind that SOR sells but it needs major cleaning). My truck came with this one (below) riding in the cargo area and it looks like my best option. The PO had taken it out to clean it but not everything is still there. Can anyone tell me anything about this tank? It looks like it was once fastened with all-thread running down through sleeves in the tank.







If I'm going to do the tank, now is the best time because I will need to cut into my new quarter panels and I would want to do that before paint. Alternatively, someone just tell me these things are dangerous and I'll bag the idea and use the fuel cells as funky office furniture.

 

[duffontap]

Lots going on . . .

I did a lot more research on my long-range fuel cell, but I wasn't able to confirm anything but that it does not seem to be Con-ferr, or any current model. Looking at my truck, there isn't much left of the original installation so I'm bagging the tank project and moving on.

Rust-oleum Rant:
Lots going on with the interior parts. I would have my bucket seats done but I sprayed the seat sliders with Rust-Oleum Professional. That was a problem. This paint will not harden sufficiently and even after careful prep, scratches and chips too easily. After a week I could still scratch it with a fingernail. I couldn't live with it so I sandblasted everything and I'm re-coating with EP and urethane bc/cc.

I'm reversing my least favorite PO mod: white powder coated instrument bezel, etc.



Pewter colored parts are getting blasted, etched, primed, bc/cc, but I'm just using rattle cans for these small parts.



I'm using the same color FJsnoozer used in his build (thanks!). So much better than the white!



I'm also working on my front and rear heaters. Check out the dog hair in this heater core!



Today I lifted off the tub (just couldn't ignore that voice inside my head screaming STOP!).



I could not believe the buildup on this 4-sp:



And, is it normal for the exhaust to rub on the transmission?



Here's where I left it tonight:



Tomorrow I'm hoping to pull the engine, clean the frame, etch, swap the steering gear, and maybe get started cleaning up the engine and transmission I'm swapping in.

 

[duffontap]

High Pressure Abrasive Blaster

Back when I bought this truck a couple years ago, I had recently come across wet abrasive blasting (I work in Cannon Beach, OR, where they wet blast their rusty fire hydrants) and I was hoping to pick a kit up for the frame if I ever did go that far. Well, I did get that far. This kit is only $60 at Northern Tool, and it showed up late last night:



I've read a lot of reviews and it seems to work really well for basically competent people.

If there is anything I should know--cautions, advice, etc.--fire away.

 

[duffontap]

It works great! New favorite tool.

 

[cbmontgo]

Looking good. Cool blaster.

 

[thecrazygreek]

Can u provide some details on the blaster. Model and part number, abrasive used? I assume soda?
How long did it take for that patch u pictured?

 

[TCSTARK]

Yes, curious minds need more details. Is it a siphon fed system?

Sent from my iPhone using IH8MUD

 

[My wife said no FJ!]

Very nice work

don't know if you decided yet, but with a stock color on the body, I would go with the stock grey for '76 rims...just my 0.02

 

[duffontap]

Can u provide some details on the blaster.

You bet. It's a universal attachment for a power washer:

NorthStar High-Pressure Abrasive Blasting Kit — 3500 Max. PSI | Pressure Washer Hoses| Northern Tool + Equipment

abrasive used? I assume soda?

Playground sand from Home Depot. $3.73 per 50 lb. bag. You have to sift the large chunks out, but it's very coarse and its a kind of sand I don't mind ending up on the lawn and in the flower beds.

How long did it take for that patch u pictured?

20-30 seconds maybe. I'm using a 13hp. 3,700 psi, 4.0 GPM power washer that I borrowed from work.

Yes, curious minds need more details. Is it a siphon fed system?

Sent from my iPhone using IH8MUD

Yes, siphon fed system. The sand is flying up the hose though. You wouldn't want more sand in the water stream than you get I don't think.

don't know if you decided yet, but with a stock color on the body, I would go with the stock grey for '76 rims...just my 0.02

Agreed.

 

[duffontap]

Engine came off this morning. Two broken engine mounts. This is the 5th engine I've pulled out of a '40 and it's the first time I've seen a failed engine mount. Both fronts.



Here is evidence of how bad my steering gear has been leaking. It was like this when I bought it. Always steered a little hard and then I topped it off with gear oil--felt like power steering. That began six months of leaving a small puddle everywhere I parked.



Wet blaster works great. I am not a perfectionist and that will really show, but I'm very happy with how clean my frame and axles are now.



Everything got doused in phosphoric acid, soaked for half hour or so, and then rinsed.



I'm hoping to get some more work done on interior parts after the kids are in bed. If the frame is dry enough, it'll get some primer tomorrow.

 

[bikersmurf]

So, in order to turn two weeks into six, I'm thinking about installing a auxiliary tank. I actually have three used ones and they are all different and fasten differently (one is a trail-built one-off that weighs about 100lbs. and the other is the kind that SOR sells but it needs major cleaning). My truck came with this one (below) riding in the cargo area and it looks like my best option. The PO had taken it out to clean it but not everything is still there. Can anyone tell me anything about this tank? It looks like it was once fastened with all-thread running down through sleeves in the tank.







If I'm going to do the tank, now is the best time because I will need to cut into my new quarter panels and I would want to do that before paint. Alternatively, someone just tell me these things are dangerous and I'll bag the idea and use the fuel cells as funky office furniture.

Looks like a ConFer of Man-A-Free tank... I'm running a similar one now. It's really tough. One day, I'll run some armor along the back edge that sticks about 2.5" below the frame.

 

[duffontap]

Looks like a ConFer of Man-A-Free tank... I'm running a similar one now. It's really tough. One day, I'll run some armor along the back edge that sticks about 2.5" below the frame.

Thanks bikersmurf. I did a lot of image searching and I haven't found any with the all-thread going through the tank. Also, looking at my frame, it looks like a hanger or two was cut with a sawzall to get the tank free. At any rate, I'm going to back burner this part of the project in an effort to get back on the road sooner. Who can afford to fill two tanks at once anyway?

Thanks again.

 

[Leaping Deer]

How many bags of sand did you go through and how long did it take you do do the frame? It looks great.

 

[duffontap]

How many bags of sand did you go through and how long did it take you do do the frame? It looks great.

Thank you. I think I probably spent 90 minutes to 2 hours blasting but I stretched the project out over 3-4 hours or more. I'm amazed at how many angles and surfaces there are on a rolling chassis now that I've done it. More time was spent sifting sand and fiddling. It would go much faster if you had a helper refilling the bucket to keep the sand probe hhmm in dry media.

It took about 400-450 lbs. of playground sand. It probably would have taken less with an official blasting media, but official blasting media is much more expensive and with all the angles I'm positive you couldn't save money that way. Also, this morning I just power washed my driveway clean and spread the sand out in a gravel area in front of our house. The bugger with wet blasting is that you can't just sweep up the sand and reuse it. The benefit is that it's a cheap attachment for the power washer most people already have access to. Most of us don't have easy access to a diesel powered air compressor. ALSO--it's dust free!

 

[duffontap]

The dash on my truck was super ugly when I bought it and not much changed in the two years I daily drove it before tear-down. Actually, nothing changed. Six months after I bought it I drove my Dad into Portland to check out Cross Cut Hardwoods and he asked my why I hadn't washed the dirt off the dash yet. Not sure what I said but I kinda liked the dirt, and besides, I've watched enough Antiques Roadshow to know that you either restore something or leave the patina.

Sadly, I think this is may be the only pic of the interior fully intact--a candid one snapped by one of my students while I was backing out of my work parking space. Behold that white-bezel, non-oem seat, no-headliner glory:



Here's one I snapped during tear-down:



I've repainted the white parts an originalish pewter color. Today, I cleaned and repainted the switch and cable knobs:



Also rolled the chassis out and applied two coats of awesome (a.k.a., Master Coat Silver).







It was warm, breezy and foggy today and this stuff set up hard and fast. I sprayed and rolled. Next comes some AG111 satin black.

 

[snaggletto]

I've been eyeing that same wet blast attachment. I noticed they sell replacement nozzles. What is the condition of your nozzle after you finished with your frame? Keep up the good work.

 

[duffontap]

I've been eyeing that same wet blast attachment. I noticed they sell replacement nozzles. What is the condition of your nozzle after you finished with your frame? Keep up the good work.

Thanks snaggletto. I took a look at the tip and I can't see a difference. It should last a good while. JD

 

[bikersmurf]

Thanks bikersmurf. I did a lot of image searching and I haven't found any with the all-thread going through the tank. Also, looking at my frame, it looks like a hanger or two was cut with a sawzall to get the tank free. At any rate, I'm going to back burner this part of the project in an effort to get back on the road sooner. Who can afford to fill two tanks at once anyway?

Thanks again.

True... Although, 400 mile range is nice. Now I can pick when I fill up which is helpful when prices in is area have been going up and down $0.80 over a week. Filling up once ever month or two is nice.


Your truck is coming along nice, I wish I could make the same progress.