First Vehicle to work on - FJ40 (1 Viewer)

[dazerb]

Parts have arrived Very satisfying to see how shiny these are. Started to organize everything in trays.

Progress on the frame, split into two pieces. They are not in a too bad condition. Just one place where gets too thin. Smashed out all the tack welded nuts. Most of them were rusty some even partially gone, will use rivet nuts to replace them. I took a piece of paper and drew the frame and each of the whole on it and then marked the places i need a nut. Needs roughly 52 rivet nuts.

After the one part on the frame is fixed its finally off to be blasted and zinc powder coated. Thats what the guys suggested, sounds reasonable to me. Then riveting all together and then powder coating after all. Since we got the frames separated wouldnt it be better to coat the inner parts of the frame rails with the final coating and then do the riveting? As i understand powder coating needs to happen in one go. Or am i wrong?

In the fourth picture i was hitting my knuckle with a small steel part to see how well that color holds onto the knuckle. Im not sure if this is good enough but i suppose once a stone hits that thing there is no more protection on it. Maybe the product i used is s***e after all. Whats your guys impression on that? I hit this thing about 10 times.

Lastly but most importantly my father in law died. Im very happy i took him to the garage just weeks before as ive never invited him prior to that. He was helping me figuring out the rear frame rail situation. Then we had a white table dinner and some beers. We enjoyed it a lot and wanted to do it every couple of weeks since he enjoyed it as he was a handyman himself... Very sad this will never happen again. He wanted to be part of the first ride so i promised to pick him up...

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Condolences! Awesome memory of him in the shop!!

 

[PidgeonGuggolo]

Tools tools tools.

Meant to sound like that song girls girls girls...

Today i can test that differential. Looking forward to do that. Ill upload some more pictures.

 

[PidgeonGuggolo]

And some reinforcement of these brackets (no idea what they are called...). It was very thin metal. So a square was cut out and welded in. They look like new

 

[PidgeonGuggolo]

Alrighty, so this is the gear pattern of the back. The second to last is the underside.

So the backlash (is this really what is pictured in the manual? see images in next post) of that gear is 0.75 as you can see in the next post. Looks like this is much too much according to the manual. And the side play is 0.1 when rotating. See images in next post

 

[PidgeonGuggolo]

And that s***ty tool arrived with a broken glas and the worst part is you cant tighten it properly its loosely dangeling. So i had to wrap it with some tape... awesome stuff. Very much looking forward to your inputs here. As im not sure how to proceed.

It looks like i need to remove these adjusting nuts for the bearing cups anyways and clean them. So that backlash reading was for nothing? See the last two images.

 

[charliemeyer007]

I have seen better patterns. Not sure I like blue, I have only seen yellow. Thickness of the grease in the marking paint could make a difference in the pattern. When using an indicator be sure you are measuring in the line of the axis, if not the reading will be lower than actual play - trigonometry.

 

[pb4ugo]

Backlash is measuring the back and forth of the ring gear with the pinion stationary. The dial indicator should be on the teeth of the ring gear. Look at pic 5-67. If your going that deep in the project, pull the caps and carrier and clean the dirt and rust. Then reassemble and adjust the spanner nuts to the proper backlash, then check your pattern. Are you changing gears or something or are the 3rd members just used units?

 

[45Dougal]

I have seen better patterns. Not sure I like blue, I have only seen yellow. Thickness of the grease in the marking paint could make a difference in the pattern. When using an indicator be sure you are measuring in the line of the axis, if not the reading will be lower than actual play - trigonometry.

Hold on, that's interesting... isn't "Engineers Blue" universally used?

Tbf I haven't used it for 35 years, but I've never seen another coloured product used on a surface plate - is yellow the norm in the US?

 

[charliemeyer007]

I have only seen yellow until now. Looks like this stuff

https://www.amazon.com/Richmond-Gear-5500011-Marking-Compound/dp/B000MISKMU

Prussian Blue and dykem are different.

 

[PidgeonGuggolo]

Backlash is measuring the back and forth of the ring gear with the pinion stationary. The dial indicator should be on the teeth of the ring gear. Look at pic 5-67. If your going that deep in the project, pull the caps and carrier and clean the dirt and rust. Then reassemble and adjust the spanner nuts to the proper backlash, then check your pattern. Are you changing gears or something or are the 3rd members just used units?

Thanks! Will do. I think I need to go that deep because there is rust in a lot of places due to condensation (my guess).

I'm not planning to change gears. They are used and sitting since 40 years.

 

[45Dougal]

I have only seen yellow until now. Looks like this stuff

https://www.amazon.com/Richmond-Gear-5500011-Marking-Compound/dp/B000MISKMU

Prussian Blue and dykem are different.

Always something new to learn

 

[pb4ugo]

If they've not been apart since the factory and the pinions bearings are tight(no wobble), you should be fine just by setting the backlash. B4 removing the carrier set the dial indicator as per the fsm pic, hold the pinion still so it's held stationary and move the ring gear back and forth and check the backlash/freeplay. It shouldn't move much. 0.010" is very minute. When checking to get a good pattern, you or someone else needs to hold the pinion tight but allow it to rotate with resistance and when someone rotates the ring gear with a wrench.

 

[PidgeonGuggolo]

Tiny update.

Got another paste. But it's also blue bit thicker tho. So will do that again soon.

Finished the frame preparation. I hope I can send it this week to be blasted and undercoated. Then finally the cold rivetting will happen.

 

[PidgeonGuggolo]

quick update just because im so excited. I got mail today !

And this weekend my wife and the baby visit friends. So im at the shop 2 days! Weeeeehaaaaa

 

[Chungas Revenge]

Man time in the garage.

 

[PidgeonGuggolo]

Front axle differential is in good condition i seems.

I was blasting the rear axle and that outdoor blaster is always clogging. No idea why. But i got the part done. Now i wonder, there is some places where i could never reach and they are pretty rusty. Would you guys recommend to Ospho the whole thing? I was thinking of brushing the whole thing with ospho but this means i would need to wash and clean it again with mineral spirits. just not sure its necessary. But the places with rust would come back to life again im thinking.

Any advice is greatly appreciated.

And i will use 2k epoxy to prime it and then coat it. Seems like thats way better than the paint i already previously used on the knuckles. Which does chip already... so i must redo the knuckles most likely.

 

[PidgeonGuggolo]

Couldn't finish it... Somehow too much water in the pipes, it always clogged. Probably wet sand and it was raining outside. Because I have two water collectors between my compressor and the sandblaster.

Plan on the diff, just put it back and flush. Is this ok?

Also did some work in the garage itself. Vacuum hose installed and compressor mounted and ready.

These days flew.

 

[PidgeonGuggolo]

Guys today I have finally brought the parts to be blasted and coated. It took such a long time to get here. And so much ahead. But feels like a major milestone was hit. I decided to go for powder coat. The parts underneath will get an additional chip resistance coating. Something rubbery. And everything back to the black it was.

Oddly satisfying to see everything boxed up. But then again putting it into that yard left me a bit worried. I need all the parts back, I told them multiple times

So I got some time now to clean the garage and set it all up. Everything has rust dust on it. So I wipe it all down. Pressure wash the floor again. Probably install a very big bench. And in general I need more storage possibilities.

Exciting days and weeks ahead. They said 6 to 8 weeks waiting time. Let's see.

 

[PidgeonGuggolo]

Hello Hello, longtime no hear Reading through the build threads here. And watching Project wrong way. Good stuff.

I finally got to test my sandblaster. As i waited to hook it up onto my Electricity rack for grounding, and the parts i needed got mixed up so i was waiting for quite some while. Then next thing you know the pressure gauge is not working on this thing. So i decided to just directly route it to the gun and deal with the reseller at a later stage.

It works like a charm since i got the new compressor. Initially i had water inside the system but since some days its really great fun to use the sandblaster tools.

Aaand i got to upgrade the shop with some nice heavy duty racks. I have so much space now. And it also looks cleaner.

On the car i only had a few things done. Im starting to paint the parts of the axles and organising everything to get them done. Unfortunately i didnt clog the wholes on the axles so i have a lot of sand in them and after i tried to clean one it had this rusty coating. Ive never seen that. It took about 1 minute and it turned all orange. I was blowing it dry but still, didnt help. Do i need to blast over this again? Or can i just ignore that and use degreaser and then paint? I plan to use zinc, epoxy primer with a PUR topcoat.

Well there is progress but everything takes its time. Just hatched chicken and now they want a house .

 

[Chungas Revenge]

That is such a nice shop.