Gary's "Just Another Rebuild" 1975FJ40

[gwalt584]

progress

So here's what I got done since my last post.
Somewhere along the line the clutch throw out bearing carrier clips (clutch hub clips) got lost. So I could not stab the tranny to the belling housing, clips ordered and will be in thursday.
So I worked on the motor. Got the intake / exhaust mounted to the block last night.
Since I am adding power steering, I had to relocate the AC Compressor to the passenger side. Nostalgic Air offers a FJ40 mounting kit and the proper compressor.
The kit relocates the alternator just below the OEM alternator bracket and uses a plate and adjustment arm, spaces, links and lots of bolts nuts and washers to mount the alternator and compressor.
I also went with a gear reduction starter for an FJ60, like 87-89 models. I could not believe how much lighter the gear reduction starter is compared to the OEM starter.
Got the water pump and t'stat housing mounted along with the mounting bracket for the GM pump. found out that I had purchased the wrong GM reman pump. so I had to order another one.
So here are the pics of what I done:

 

[gwalt584]

Thanks, Steve I got them ordered. As with any rebuild, I had plenty to do so I just worked on what I could do.
Gary

Gary-

31232-60020 is the clip number...

 

[waiting for time]

Like your build, it gives me a lot of info for my project.
Thanks for the detailled pics.

I will keep tracking this thread.

kind regards,
Michael

 

[gwalt584]

Thanks Michael.
Well, it is time for an update.
Gary

Like your build, it gives me a lot of info for my project.
Thanks for the detailled pics.

I will keep tracking this thread.

kind regards,
Michael

 

[gwalt584]

Time for Update

Well, I got my tub back from the painter last Friday, May 18th. So Saturday moring I was busy getting started.
So here are some pics of the progress:

I came up with a lifting device harness to get the tub off the trailer and on the frame without any help. Well, I did get my wife to hold it to keep it from swinging any. So I rolled the frame out and sat the tub on it without a hitch.

I used the SOR Poly Black soft ride body mount kit. which installed without any problems. all bolts got anti-seize lub. I had to take the rear tail light back off but that was no real problem.

You may notice inside the fender wells that the paint is a little more eggshell looking. My painter used that 3M material that you normally see at the bottom of side body just behind the fenders on some trucks, Toyota uses it on many of their vechicles. It is a stone guard material that you can paint right over.

So here is the tranny hump cover getting a new gasket, it was also from SOR with fitt to a tee and included new mounting bolts

I had to put the new logos on the rear, just to feel good about it.

Also put the OEM ID label, rivited, back on the door post. At least now it has it ID badge back on.

I did make some headway on getting all the wiring harness in, the dash controls in place, the heater model installed along with the blower.

 

[gwalt584]

Bolt and Nut Lub

I decided it would be a good idea (may have read it on some other post on this site, so I can't take credit for the idea) to put some anti-sieze lub in all the nuts on the body. I had a few welded nuts that were stiff so I did have a tap that I chased the threads on the nut before installing the bolt to keep from cross threading the bolt. My wife is an OB-GYN nurse and she had given me some speciman swabs that have a tapered brush on the end. these make a perfect tool to coat the inside of each welded nut with this anti-sieze compound.

 

[Trollhole]

Great clean build. I like your style in doing it all at once.

 

[gwalt584]

Style

Thanks, My wife says that I get obsessed with my projects. But it is fun for me.
Gary

Great clean build. I like your style in doing it all at once.

 

[gwalt584]

Monday Nite Progress

I did spend a couple of hours last night and got the brake booster and master cylinder installed. I converted the front to disk brakes and updated the master cylinder and booster from an 89-95 4Runner. I need to do some touch up on it.
And the carb is just sitting there for fit. I have to rebuild it and clean it up. I have the cruiser addiction!!! CAN YOU TELL!!!
Gary

 

[funk49]

Good lord man, you are making me jealous. What a nicely documented (and carried out) project! I'm looking forward to the progress...you seem to be getting pretty close.

 

[mattcamp]

Your attention to detail is amazing, it is looking great, I thought it looked good in your before pictures, but now, quite impressive. I'll have to check in now and again to see your progress.

 

[gwalt584]

Thanks, it helps to get positive comments about the project. You know it takes patience more than anything else. For example, I had installed the new brake booster, then the master cylinder, found that the ram arm needed some adjustment, off with the brake booster to adjust the ram, back on with the brake booster to find that the pedal arm interferred with the ram so back off with the booster to cut the ram arm off about 1/2" to get the adjustment right. Then I thought I had that fixed, and installed the E brake assembly, well the new brake booster covered one of the studs that went through the firewall and I had to loosen the brake booster to get the nut and washers on the E brake stud.
So last night I was practicing taking stuff on and off.
But Thanks for the comments, it helps.
Gary

Good lord man, you are making me jealous. What a nicely documented (and carried out) project! I'm looking forward to the progress...you seem to be getting pretty close.

Your attention to detail is amazing, it is looking great, I thought it looked good in your before pictures, but now, quite impressive. I'll have to check in now and again to see your progress.

 

[antFJ]

and you said mine was clean! thats going to be nice when its done (also i've definitely visited your thread just never put 2 and 2 together)

 

[gwalt584]

thanks

Well thanks, it certainly taking longer to put it back together than it did to tear it down. I put the radiator in place and forgot the fan shroud, so off it will go when I get back on it.
The top on your rig really looks great. I will have to save some coins and get one.
Thanks
Gary

and you said mine was clean! thats going to be nice when its done (also i've definitely visited your thread just never put 2 and 2 together)

 

[waiting for time]

I find it hard to be patient when building, once you start putting stuff on you want to drive it.
But in your case it will be worth the wait, the truck looks realy nice so far. I hope I can get mine half as good.

Keep up the good work.

Michael

 

[gwalt584]

build

Yes I agree, patience is key, and I have little. Thanks for the positive comments.
Gary

I find it hard to be patient when building, once you start putting stuff on you want to drive it.
But in your case it will be worth the wait, the truck looks realy nice so far. I hope I can get mine half as good.

Keep up the good work.

Michael

 

[gwalt584]

more done

I did get more done this week. Such as:
Fuel tank cleaned and painted and installed.
Radiator installed, with AC coil installed, no lines yet
Pulled radiator off to put fan shroud on that I forgot to put on before radiator install.
Fender Flares installed.
Leather wrap for the old girls steering wheel, nice feel.
Carb rebuilt, found diaphragm bad, ordered one from NAPA, hopefully it will be correct. My carb kit did not have a diaphragm in it. I should have bought a Hygrade kit, 791B, I'm told by Pinhead is the correct kit for my '75 cruiser. I spent most of Saturday, cleaning, reading and trying to do this right. Hopefully, it will run, we will see.

Steering Wheel cover, real important stuff:

Fender Flares installed:

Fuel Tank installed:

Carb rebuilt and installed:

 

[waiting for time]

Hi Gary,

Progress looks great, you've got a lott done this week, I envy you for that,
What are the black spots above the fender flare on the right side and what is the round spot on the other side?

 

[gwalt584]

black plugs

Michael,
I have a two jerry can holders that mount to the side of the truck, so black plugs cover the mounting holes. For now I am not putting them on. so I will just plug the holes and when I want to mount them i just push the plugs out and bolt the jerry can holders to the side.
I need to find two military style cans, the PO kept the cans but left the holders.
Gary

Hi Gary,

Progress looks great, you've got a lott done this week, I envy you for that,
What are the black spots above the fender flare on the right side and what is the round spot on the other side?

 

[waiting for time]

Michael,
I have a two jerry can holders that mount to the side of the truck, so black plugs cover the mounting holes. For now I am not putting them on. so I will just plug the wholes and when I want to mount them i just push the plugs out and bolt the jerry can holders to the side.
I need to find two military style cans, the PO kept the cans but left the holders.
Gary

Can you post a pic.with them, like to see how they are made.
Like your steeringwheel cover btw.

I have one more question, I see that you have the mounting holes for the original spare carrier, can you messure thr distance between the upper and lower bracket?
Center lower bolt hole of upper bracket to center upper bolt hole of lower bracket.
Mine doesn't fit like it should and I am trying to find out what the problem is.

Thanks,