Ground up rebuild 78 FJ40

[78GroundUp]

A friend of mine turned me on to this site and I enjoy all the rigs, info and details.
I have just begun the journey of rebuilding mine. Came on board with me many years ago in the early 90's. It has climbed the hills in Tenn, drove the Dunes in NC, Handled the beach in Daytona, sunk in some mudholes in both VA and FL. Then I got a real job and it decayed, undriven in my yard for the last 4 years or so. Last month i decided it was time. Being new I am just learning this site, and am not completely aware. Learning how to put up pics is still eluding me. But all this will come in time. Thanks again in advance of who ever maintains this site, it is amazing how much info you can find once you get sucked into this.

Found the pic attacements.... Here is the beginnings of the long road ahead.

 

[78GroundUp]

Engine Ran Fine

Engine ran good but I figured it wouldn't be a bad idea to redo since it was there in the garage. Here are some pics of progress of engine.

If anyone has detailed (clean) photos of their engine assembly that would be awesome. Pretty good with lables etc but wouldn't mind the visual (picture book) instructions for proper assembly of mine. I am removing the smog pump and could use any info on reassembly process without one on there.

Can I modify my non-oil cooled 2F to handle an oil cooler? Logic would tell me it would not be hard but never laid eyes on one that has it, so any suggestions would be great.

 

[78GroundUp]

Been working hard, and getting through it.

Thanks to all the mudders who have helped, thought I would post some progress pics just for fun...

Being a complete newbie at automotive restorations I think I am doing pretty good, getting to the hard part.... design. Gonna post some old pics (never here) and where I am today. kind of sequentially I hope...

Please, all comments suggestions, opinons, and harrassment will be taken in stride with pride and considered. Some will be filed and saved, others will be circularly filed and others will be considered/analyzed/ and possibly debated but here goes.

 

[78GroundUp]

progress outside

Worked out 7-8 fender bolts, and got the rear cross member removed FINALLY. New replacements on the front door hoping to take over to my welder to fix rear frame extensions tomorrow then off to sand plast and paint.

I know the debate... to paint or powder? I keep falling back on....you can fix paint but you can't fix powder. Plus the deal I am getting is paint (dumptruck frame paint). Guy who is doing it is doing a side job for me. He normally does this on dump trucks but charging me a side job of 2 bills from start to finish. so I will take it.

Ain't gonna be a show car for me, rather a driver. so it works.

 

[78GroundUp]

progress, still tooling along

Radiators cleaned and soldered.... heater core too.
Flywheel re-surfaced and all new clutch parts sitting in Garage.
Tomorrow will consist of reinforcing garage joists with up supports to dangle engine tranny/tcase assembly.

If time permits, will dismantle both axles, check for wear, grease, re-assemble and paint when/where,what is possible.

Trying to time frame return to get back on axles and install engine then work out the crazy web of removing smog pump.

THis has all been great fun for a novice like myself... Hard, trying at times, but fun. Hate using rattle can on every part, but heck, living on a budget that really can't afford this, but hey, welcome to america, incurring some dept to gain is not uncommon.

THnaks Mudders for the help, and more to come, I am pretty sure.

GroundUp

PS... not sure I like the alumiclast valve cover?? What does anyone think about matching it with the gold brackets?? opinions desired. Cruiser final color will be factory Buffalo Brown... BRING IT ON.

 

[TEQ]

Looking great! Keep posting!

 

[78GroundUp]

Looking great! Keep posting!

Valve cover?? Alumiclast grey or should I go with the gold as seen on Brackets?? Just taking opinions. (these are the hard decisions for me...)

 

[ArkansasLarry]

Looking good and welcome to the madness!

 

[kurtnkegger]

I would stick with the grey, and would change the brackets grey to match...Not a fan of the gold...

You asked......Looking good though!!

 

[Michael Hanson]

Nice job,Id just clean and polish the valve cover. MIke

 

[TEQ]

Valve cover?? Alumiclast grey or should I go with the gold as seen on Brackets?? Just taking opinions. (these are the hard decisions for me...)

I meant the overall project. I like the alumiclast. Not a fan of the gold.

 

[78GroundUp]

progress

Making some progress... been a long a treacherous road so far. For someone like myself never having taken on a project of this magnitude. Vehicular anyways. But I am pretty proud of the progress...

As to the color scheme. I agree, not my favorite either but i figured. For now, it is painted and protected. and will in the near future clean it, and get it back to aluminium color. My desire is greater to here it run again. It has been over ...hmm, I say 6 yeears since it cranked up. Of course being new to all this... I sure hope I did it right???

Thanks for the help, from those of you on here who have assisted. I am sure there will be many more questions to come....

Engine in Yesterday.... Tcase/tranny today.... I like when I stay on plan!

 

[krzyabncanuck]

Watching this now.

 

[fj user]

Great work - you're moving right along. What are your plans for the cruiser?

 

[KY Longhunter]

Subscribed.

 

[TCSTARK]

Subscribed.. Being a novice mechanic myself I can truly appreciate this thread. Keep up the awesome work.

 

[78GroundUp]

Great work - you're moving right along. What are your plans for the cruiser?

Just planning on having a fun daily driver that is not afraid of the dirt/sand, etc. Going to keep it mostly stock. Paint color back to original or close to it. (no not the red/purple) I guess you would call it more of a beach cruiser. Any and all mods will be simplistic keeping in mind the original integrity of the FJ legacy. First things first is to get it back to where it needs to be, then go from there. Here is a pic from original color etc. Enjoy

 

[78 FJ40 Restoration]

Following your tracks

I just read through your story and love your progress. I just started this jouney myself on a '78 FJ that will be my daughters first car. It was painted pink when we bought it 10 years ago and has been a ranch truck that we've affectionately named "Pinky" ever since. Hope we can share some stories and ideas. I just registered for this forum and will be posting my progress and photos soon.

 

[78GroundUp]

I just read through your story and love your progress. I just started this jouney myself on a '78 FJ that will be my daughters first car. It was painted pink when we bought it 10 years ago and has been a ranch truck that we've affectionately named "Pinky" ever since. Hope we can share some stories and ideas. I just registered for this forum and will be posting my progress and photos soon.

Sounds awesome.. .I have enjoyed this immensly. Obviously alot of work and I would be glad to help where I can. I don't have a vast knowledge like some of these other mudders and I rely heavily on them. Of course sometimes you can get a response and sometimes not. Don't ever be afraid to PM me and I will help when and where I can. I spend alot of time searching old threads to get info I need and sometimes that in itself is so convoluted that it becomes frustrating.

I will tell you this... I had a mechanic come over and help with engine internals. I did not want to mess that up. Before you start invest heavily in ziploc bags and a sharpie and mark "EVERYTHING" down to nut and bolt, where it went and what it did. I was not so diligent in some areas and although I did save everything I did not label. I am paying for that now! My memory is good, but I am struggling a bit in the garage finding proper nut and bolts for replacements.... Thread pitch varies so becareful not to muck it up.

Enjoy, I know I have... and like I said, glad to help where I can, and will tell you honestly if I can't.

I look forward to seeing your pics before/during/after.

 

[78GroundUp]

Just progress...

After a couple days off. I started some "fun" stuff. I hated the previous color and while waiting for SS brake lines decided that there was no time like the present to change the color format. MUCH better. Thanks for the tolerance and patience with the HORRID color selection previously.

Was still conflicted about clutch slave cylinder mounting bolts...so I bought a tap. If it was not 10 x 1.5 before, it is now!! tap seemed pretty smooth, no metal flake, and tight when in. --> SO, Just FYI, if any one wants to know it is a 10x ? x 55mm bolt. Inherently when a bolt is at that length it has a 35mm shoulder. IF you ask for a shoulder bolt it is different. Gives you a 12mm shoulder. I just wanted a 55mm bolt, which defaults to 20mm of thread. after a **** ton of research and still not sure that was the "perfect fit" but it is what it is.

Spent a day.5 cleaning, blasting and repainting and started attaching. Thanks for all the support, enjoy.

Feels alot closer, yet still such a long way to go...