first 1978 FJ40 rebuild...

[lvshust]

finished up the rear wire harness and put it to the heat gun to wrap it in shrink tube... fit like a glove...

double insulated the connections along the way after a quick solder and worked around the OEM side marker light connector not meeting up with my rig... just replaced with bullet connectors instead...

 

[lvshust]

dug into the fuel pump... ,mine was encased in all kinds of muck, took an hour or so to get it cleaned up... disassembled and found the lower oil seal has seen better days...

 

[lvshust]

i tried sourcing a rebuild kit, but we should all know how hard this is. i called up the local checker auto parts and they had a kyosan pump for 41 bucks!

here are some shots side by side...

 

[lvshust]

also came with a gasket that was the same as the one that SOR offers (SOR on left)... also a shot of the old pump insides...

 

[lvshust]

here are the pics... plus final installed pump...

 

[lvshust]

project behind due to this wonderful windshield hinge that i did not notice was FUBARED

as you can see in the photo, the hinge on the top---PO put alot of pressure on this hinge... removed it and bending it back into place, with then have to go BACK to paint...

hinge on the bottom is drivers side and is correct...

 

[lvshust]

fuel tank time-

got some 1/16 rubber sheeting, patterned up some pads in the places where the tank touched the body.

masked the area sprayed some adhesive to both the paint and the rubber then bonded...

was able to find a rubber grommet for the tank plug. will be putting two other grommet plugs in the smaller holes before installing the tank...

 

[lvshust]

more pics...

 

[waiting for time]

fuel tank time-

got some 1/16 rubber sheeting, patterned up some pads in the places where the tank touched the body.

masked the area sprayed some adhesive to both the paint and the rubber then bonded...

was able to find a rubber grommet for the tank plug. will be putting two other grommet plugs in the smaller holes before installing the tank...

I don't think it is wise to put a rubber grommet like that in there.
moisture and dirt can get in and stay underneath the tank bacause of the rim you create with the grommet. Its better to use a closed grommet or non at all.

Nice project btw, subscribed.

 

[lvshust]

I don't think it is wise to put a rubber grommet like that in there.
moisture and dirt can get in and stay underneath the tank bacause of the rim you create with the grommet. Its better to use a closed grommet or non at all.

Nice project btw, subscribed.

hey michael-

thanks... i was going to throw in a plug or make one, but the drain plug extends past the body. are those other two holes there for ventilation? was going to plug those up as well...

 

[lvshust]

tossed in the CCOT repro gas tank... it fits very well and came with the sending unit. the hoses that i ordered with it are absolute crap... i will be buying more of my own... the cover was from SOR used. my original was tore up and could not be salvaged.

also started work on the seat brackets...

i would like to find the rubber for the fuel lines coming up through the floor...

deleted the seat belt chime wire... wont be needing that...

 

[waiting for time]

hey michael-

thanks... i was going to throw in a plug or make one, but the drain plug extends past the body. are those other two holes there for ventilation? was going to plug those up as well...

Don't think they are original but they are in the lowest points so they do serve a purpose.

Looks great inside the tub, very nice work.

 

[victorv]

Just a Question

i have plenty of small projects to keep me busy while the the 40's in the body shop.

i started on the speedo cluster, which is in rougher shape then i expected. rust has made its way on the faces, lots of dirt has collected in the case. needles no longer have cover, and the amp gauge mount is bent and twisted. gaskets are in great shape and glass is also good, but will be resurfacing the four pieces.

repainting all cases with factory colors and re-plating where necessary. new rubber tubing on electrical connections.

original factory application of the numbers and markings on the faces is just not practical, so next best thing... designing an exact copy with Illustrator and having a dry transfer made. make a new gasket then finish off with lubing parts, needle paint and new bulbs and hardware.

Could you please explain me how you did to disassemble the speedo cluster this way. I'm also trying to get the Instrument Cluster restored.

 

[numby]

are those other two holes there for ventilation? was going to plug those up as well...

There are small plugs for those other gas tank well holes. They are fitted from the underside so they can be removed for drainage.

Nice color! Keep up the good work.

 

[lvshust]

thanks numby...

perfect, i got some in case that was it... i will pull the plugs from underneath and throw in the ones you speak of...

 

[lvshust]

seat hardware in, passenger seat in and fenders on!

 

[cruiser enthuiser]

Wow! Your rig is really coming together and looking amazing. Your attention to detail is impressive. I didn't see you mention what color you are painting? I really dig it.

Keep it up!


-Ed

 

[lvshust]

thanks ed...

just went with the 78 sky blue, cygnus white for the top and bezel...

i wish i had the time and the money to do a frame off, but i understand only after this project that you must make concessions if you want to drive it sooner...

part of the nature of the beast i guess...

-p

 

[lvshust]

got the aprons on... they line up just as they were before, with a slight gap... is this the norm?... all other places are perfectly aligned...

 

[lvshust]

also finished the charcoal filter install...