First FJ 40 Build Thread

KTM96

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Aug 17, 2018
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Eau Claire, WI
Well after about 30 years of wanting one of these, in a weak moment of irresponsible decision making, I bought the yellow 67 pictured. I needed a top and many other parts so within a week I bought the 68 as a donor vehicle. Both of these things were rough. After shopping for parts and looking at the price of building a new tub or finding a good one to start with, that became the clear choice. This is going to be a frame off resto. I will have all of the 68 chassis available if anyone is looking for anything. Wish me luck, I will take any and all advice from the hundreds of brilliant builders I've seen on this forum.
 

KTM96

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Eau Claire, WI
Some photos of what I'm starting out with. I already have the 68 nearly down to the tub. I think 80% of the bolts snapped of or had to be torched off. I hate dealing with rusty metal!! (wrong project right!!) I just want to get the rotten bodies off both of these and I'm picking up a rust free tub this weekend. I have to use the cowl from the 68 as the new tub has a bent A-pillar and the 68 dash is complete. I'll use the 3/4 tub that I'm picking up and make one nice tub, which will essentially be a 68. I'm going to use the Chassis from the yellow 67 because its already been converted to a SBC 283. All of the mounting has been sorted out and drive shafts set up and so on. That conversion looks like it may have been done in the 80's So its going get the full going through. I picked up a Chevy LS 5.3 to replace the old 283.

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I have seen the yellow one on CL for a long time. Glad someone picked it up and is going to make something out of it. Good luck with build. :)
 

KTM96

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Eau Claire, WI
Thanks. Turns out I’m not going to use too much of it. Using the drivetrain and chassis but putting an LS in it. Mostly it’s a title
 

Martyt

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Of all things, the bezel is a nice shiny black (and not upside down):) Good luck with the build--will be following!
 

KTM96

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Eau Claire, WI
Well after a month I’m making good progress. I’ve got the donor cruiser pretty well harvested and out of the shop. Got the new cowl attached to the new tub and tearing into the yellow beast. Got the front clip pulled off and the old sbc 283 out. Now to fit the LS motor!!

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KTM96

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Eau Claire, WI
Can anyone tell me what this steering sector is from. I’m trying to identify some of the mods that were done to this thing. The v8 swap looks like it was done in the 70s or 80s. Gonna need some serious massaging to look decent.

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KTM96

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Eau Claire, WI
Some new pics of the latest work. Got the old tub off and test fitted the new rust free one. Installed the LS motor to make sure clearance was good and everything bolted up. Found out that the placement of the motor and tcase mounts was going to necessitate a body lift. Not happy about that. I thought about moving the mounts but that was going to create a driveshaft clearance problem. I did some test fitting and found that I can get away with 2”. I think I can do some crafty things to hide it and make it look alright. The steering shaft is going to require some handy work too so I’ll take any advice on that one too. I’m using a Saginaw steering sector.

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KTM96

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Eau Claire, WI
It’s been a busy few weeks on the FJ project. Got it completely torn down, everything blasted and have the chassis epoxied and painted. It’s nice to be working with rust free parts now and new hardware. Still lots to do but the goal is to drive this thing whene the snow melts. Here’s some new pics. The hood had soo much paint on it the it took five coats of stripper and about and hr of sanding

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Some new pics of the latest work. Got the old tub off and test fitted the new rust free one. Installed the LS motor to make sure clearance was good and everything bolted up. Found out that the placement of the motor and tcase mounts was going to necessitate a body lift. Not happy about that. I thought about moving the mounts but that was going to create a driveshaft clearance problem. I did some test fitting and found that I can get away with 2”. I think I can do some crafty things to hide it and make it look alright. The steering shaft is going to require some handy work too so I’ll take any advice on that one too. I’m using a Saginaw steering sector.

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Check out the build thread of my 40. I did a 2" body lift. I tried to hide it as well, very few notice it. Nice work so far. Thats a saginaw steering box, check out 4x4labs, they have a nice bracket kit for saginaw steering. May want to tap the box for hydro assist as a future option.
 

KTM96

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Joined
Aug 17, 2018
Messages
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Location
Eau Claire, WI
Check out the build thread of my 40. I did a 2" body lift. I tried to hide it as well, very few notice it. Nice work so far. Thats a saginaw steering box, check out 4x4labs, they have a nice bracket kit for saginaw steering. May want to tap the box for hydro assist as a future option.
I'll check that out, always looking for new ideas. Thanks for the comments and advice.
 

KTM96

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Eau Claire, WI
And the work goes on. Figured I’d post some new picks of the progress. Mostly still working on the tub. Got the drivers side structure trued up. It had been rolled and the wheel well and b pillar we’re bent in a couple inches. Got the new panel on and welded up. Now doing some body work to make it all smooth. The reflector is from a 68 apron and I’m finding they are pretty hard to come by. It was covered in nasty red tractor paint that was on the 68 donor. About two hrs with a bead blaster and dremel tool and they are looking like new. Last but not least. New tires to go on fresh painted steelies and hubcaps. Seems premature but I need the wheels to assemble the roller.

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KTM96

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Aug 17, 2018
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Eau Claire, WI
Big question is, white letters in or out. I’m a product of the 80’s so turning them in doesn’t seem right even though it seems to be in fashion now
 

pjohnson

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Your cruiser, your choice. Do what looks good to you.

The only reason I put the letters in is because my FJ40 thrashes around in the rocks. Not good for white letters :lol:
 
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