HJ45 Troopy - Re-Built in Djibouti, Horn of Africa (1 Viewer)

[LAG404]

Hi folks,
am brand new here on ih8mud, but spent many time here as a visitor for the past years.

I am French and recently moved to Djibouti.

Since my arrival, i was is the seach of a 40 series to drive around in my free time and overland in the magnificent teritory of the Horn.

After few beers and sharing my project with newly-made friends, we were on the go to get one. We've spent 4 months rollin' everywhere, from scrapeyards to backyard of guys who kow a guy who know someone... Then, we found the "GOOD" one by a hot day;

(yep, thats an FJ-Cruiser, nothing better to search for a 40's) (note: 50°C = 122°F)

The "Good One" as found, in the middle of nowhere.

So the challenge ws at this time to get it back in town, at the shop. Plus, setting the project and star runing on with orders placement etc etc etc

Desired Specs:
Toyota HJ45 Troopy
QuickSand 4V6 (to match my friend's FJ Cruiser, + i love this color)
1HD-T 12v 4.2 Turbo Diesel
Custom 3 inches exhaust
H55 5 speed manual trans
New or almost new solid axles from 40's or 70's series
OEM or kits to get 4 discs brakes
Aluminum radiator
AC kit
Tan leather or plastic leather interior
Roof Rack
Rooftop Tent

theeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeen i burnt my bank acount in Dubai, UAE

Yeah, give me that one, with that gearbox, yep hum... this how much ? and that ?

Ending up with that one.

(more to come )

 

[LAG404]

Then off to another place...

Yes, please this Japanese firetruck with 8000km on the ODO, i'll take the front axle

and a pair of locking hubs, Aisin please.

Endded the 3 days trip with my pile of junk and some stuff from Ironman4x4 and BFGoodrich Straight to container and shipped !

Time to get back in Djibouti !

For what ? to organise the rescue of the HJ !

My friend found an all wheel drive Renault Kerax truck with a pretty decent auxilary crane. Loading was tough but we succed. 4 hours of Truckoffroading later, the Troopy was about to get offloaded to the shop of my friend.

And then, we start the dismantling of it

More and more.

 

[LAG404]

The idiom was "we will dismantle until we find something great to start with........"

This frame was then bristle blasted. and we started to repaire/reweld the 5 cracks found on it.

I've decided to mig weld some fish plates around the engine block supports and reweld leafsprings eyelets. Without welding the two C shapes of the frame in order to keep the flexibility of this riveted assembly.

DISCLAIMER: i know there is some better ways to achieve some better things. Decisions are made on the basis of Available tools, technologies and spares.

In the meantime, engine was getting a new reinforced clutch straight trom Austalia, Xtreme Outback branded

Engine, tranny, axles, leaf packs, shocks were installed, test fitted, with the body on and of 10.000 times.

 

[LAG404]

After turning, returning, on and off the chassis, it was time to get on the body. Part that i love and hate at the same time... bodywork.

The floor of the rear tub was toasted and already repaired multiple times by stick weld ans some brazing....

I've decided to get rid of it. New sheetmetal. 2.0mm thinck (yes, thats really thick but was the only available).

Some surprises.... cut, weld, grind, antirust, bondo, sanding and off to the next one.

test fitting.

all original panels were bristle blasted in order to break and remove rust while leaving and good grip.

 

[LAG404]

Then, the paint ! After 2 years without painting anything, am almost proud of what i've done here, without booth, in a hot weather.

stick welded plates are ok-ish, sort of a souvenir from its past ownersssss

All insides were done in tinted Raptor lining, all Ext in standard paint, Toyota 4V6.

Then, seats were handed to a local guy to redo them. The tub was back (again) on frame and everything is coming back together !

(i know, shackles are reversed)

 

[LAG404]

Looks progressing huh ? Get back in your shop ! the rest remains to be done !

While the paint is curing, wiring is on the go. I hate wiring, even with a painless loom, i hate it (still not fully done at the time am typing).

this air box was needing a fresh coat...

and off to start the fab of the rack

 

[LAG404]

Here marks the end of the "friend's shop" time; some photos before getting to the house after registration, insurance and tax payement.

roof rack and tent installed, on the road going home to finish little things !

 

[charliemeyer007]

WoW very nice work. In 83 I got a 72 FJ40 with a 76 hardtop. I was red, white and blue. In 85 painted it flat tan - idaho dirt color. Took 3 gallon of the flat paint (no thinning to shoot) 7 coats on the outside 5 on the inside.

 

[Slapshot]

Wow! Quite the transformation.

 

[Chungas Revenge]

Légion étrangère ???

I worked in Dj for one year. Camp Lemonnier Circa: 2003/4.

Great thread…