MrMoMo
That's not rust, it's Canadian patina...
Ok, so don't let the title be completely misleading... I already own the FJ40, and the BJ60 that everything will be coming out of. I'm not counting the cost of electricity, welding wire, or amortizing the cost of my shop, or paying myself...
*Edit*. This swap has also morphed into a frame off resto... In the spirit of the title, I will keep the costs associated with the swap tracked separately! **
Now, let me also say, that I won't sacrifice something just to say "I did it for free". What I am hoping for is $0 out of pocket to do the swap, I will however do some other stuff at the same time to improve the condition of the 40. I will try to make what I can from what I have, and if I need to buy something to make it work, then that's what happens.
This is the start. My insurance Co. has given the green light, so I can now proceed. Come along for the ride, I'm no expert, there are sure to be a few good laughs along the way...
Will try to keep a running total here, for anyone who wants to reference this, if they feel they would want to tackle a similar project.
The main goal: Have a 3B powered 40.
The short term side goal: blast and paint the frame while I'm in there.
The long term side goal: repair all body damage/rust on the body.
The timeline? Well, let's just say the sooner the better...
The money side thus far; *(swap related)*
$0. 1977 FJ40 (Dec 76)
$0. 1984 BJ60, turbo'd, intercooled, and veggied
$90 New 3B Frame mounts from @Awl_TEQ
$33 New transmission mount from Rock Auto
$10 Old stock (from work) fuel level sender for the veggie tank.
Conversion total $123
The resto costs thus far (including shipping);
$870 - New fenders, quarters & bolt kit, seam sealer from CCOT.
$89 - New body mount kit from Auto Parts Warehouse.
$81 - White monstaliner kit for roof from Magnet Paints.
$44 - New suspension bushings from aftermarketsuspensionparts.com
$150 - Chassis saver and S8 reducer from Magnet Paints
$115 - New rear frame sections - EBay.
$100 - Used rear frame cross section, corner frames, gussets and spring mount. (Fellow Mudder)
$64 - Replacement DS floor panel from Rock Auto.
$55 - Misc parts from Cruiser corps, gaskets, seals etc.
$70 - New aftermarket tail lights from SOR.
$30 - rear frame section sand blasted - local contractor
$200 - frame pickled and galvanized - local contractor
$9 - cold galvanizing for touch ups. - Lowes
$67 - greaseable suspension pin (frame end) from Cruiser Corps.
$30 - metal to re-create rear sill center section.
$51 - 2 new rear corner channels and new upper and lower amby door strikers -CCOT
Resto total = $2026
The progress side thus far;
-Couldn't get the 40 to start, so cranking it out of the woods on the starter... It's a multi-day process...
--> https://forum.ih8mud.com/threads/77-fj40-no-start-troubleshooting-help.807150/#post-9214112
-40 body is off the frame
-2F engine is out
-New fenders and quarters arrived.
-New (used) rear frame cross member section received, repaired and blasted.
-New rear frame sections received and welded on
-Chassis saver paint arrived
-White monstaliner for roof arrived
-Many misc parts (restoration - not swap related) have arrived!
-40 chassis rear end rust repairs are almost completed.
-New drivers side floor pan arrived.
-New Motor mounts arrived from Awl_Teq
-Body has been test fit with engine/trans in place.
-Mounts for veggie tank have been welded to the rear shock cross tube
-Aluminum veggie tank is almost completed.
-Trans crossmember mounts from BJ60 are welded in place
-Engine mounts are welded in place.
-Old 2F is gone, straight traded for a rough '78 FJ45 with driveline.
-60 is fully stripped and the scrap has gone to the scrap yard.
-Frame is back from galvanizing! Needs some clean up and touch up.
-Suspension is re-attached (minus shocks) with new bushings
-Body is temporarily on the frame for disassembly and bracing.
-Roof, side panels, doors and windshield frame are off the tub.
-Bed rot removed from the back edge, replaced with fresh steel
-Rear sill center section has been re-created...
-Rear quarter panels are off, rear corner channels are off
-Firewall is stripped
-Drivers side floor panel and inner rocker are cut and replaced
-Drivers side forward frame mount cut and repaired
-Drivers side floor at heel cut and replaced, along with A pillar base
-Front side of both driver and passenger wheel well cut and replaced
-Rear sill horns fabricated and installed
-Passenger side quarter panel is in place!
*Edit*. This swap has also morphed into a frame off resto... In the spirit of the title, I will keep the costs associated with the swap tracked separately! **
Now, let me also say, that I won't sacrifice something just to say "I did it for free". What I am hoping for is $0 out of pocket to do the swap, I will however do some other stuff at the same time to improve the condition of the 40. I will try to make what I can from what I have, and if I need to buy something to make it work, then that's what happens.
This is the start. My insurance Co. has given the green light, so I can now proceed. Come along for the ride, I'm no expert, there are sure to be a few good laughs along the way...
Will try to keep a running total here, for anyone who wants to reference this, if they feel they would want to tackle a similar project.
The main goal: Have a 3B powered 40.
The short term side goal: blast and paint the frame while I'm in there.
The long term side goal: repair all body damage/rust on the body.
The timeline? Well, let's just say the sooner the better...
The money side thus far; *(swap related)*
$0. 1977 FJ40 (Dec 76)
$0. 1984 BJ60, turbo'd, intercooled, and veggied
$90 New 3B Frame mounts from @Awl_TEQ
$33 New transmission mount from Rock Auto
$10 Old stock (from work) fuel level sender for the veggie tank.
Conversion total $123
The resto costs thus far (including shipping);
$870 - New fenders, quarters & bolt kit, seam sealer from CCOT.
$89 - New body mount kit from Auto Parts Warehouse.
$81 - White monstaliner kit for roof from Magnet Paints.
$44 - New suspension bushings from aftermarketsuspensionparts.com
$150 - Chassis saver and S8 reducer from Magnet Paints
$115 - New rear frame sections - EBay.
$100 - Used rear frame cross section, corner frames, gussets and spring mount. (Fellow Mudder)
$64 - Replacement DS floor panel from Rock Auto.
$55 - Misc parts from Cruiser corps, gaskets, seals etc.
$70 - New aftermarket tail lights from SOR.
$30 - rear frame section sand blasted - local contractor
$200 - frame pickled and galvanized - local contractor
$9 - cold galvanizing for touch ups. - Lowes
$67 - greaseable suspension pin (frame end) from Cruiser Corps.
$30 - metal to re-create rear sill center section.
$51 - 2 new rear corner channels and new upper and lower amby door strikers -CCOT
Resto total = $2026
The progress side thus far;
-Couldn't get the 40 to start, so cranking it out of the woods on the starter... It's a multi-day process...
--> https://forum.ih8mud.com/threads/77-fj40-no-start-troubleshooting-help.807150/#post-9214112
-40 body is off the frame
-2F engine is out
-New fenders and quarters arrived.
-New (used) rear frame cross member section received, repaired and blasted.
-New rear frame sections received and welded on
-Chassis saver paint arrived
-White monstaliner for roof arrived
-Many misc parts (restoration - not swap related) have arrived!
-40 chassis rear end rust repairs are almost completed.
-New drivers side floor pan arrived.
-New Motor mounts arrived from Awl_Teq
-Body has been test fit with engine/trans in place.
-Mounts for veggie tank have been welded to the rear shock cross tube
-Aluminum veggie tank is almost completed.
-Trans crossmember mounts from BJ60 are welded in place
-Engine mounts are welded in place.
-Old 2F is gone, straight traded for a rough '78 FJ45 with driveline.
-60 is fully stripped and the scrap has gone to the scrap yard.
-Frame is back from galvanizing! Needs some clean up and touch up.
-Suspension is re-attached (minus shocks) with new bushings
-Body is temporarily on the frame for disassembly and bracing.
-Roof, side panels, doors and windshield frame are off the tub.
-Bed rot removed from the back edge, replaced with fresh steel
-Rear sill center section has been re-created...
-Rear quarter panels are off, rear corner channels are off
-Firewall is stripped
-Drivers side floor panel and inner rocker are cut and replaced
-Drivers side forward frame mount cut and repaired
-Drivers side floor at heel cut and replaced, along with A pillar base
-Front side of both driver and passenger wheel well cut and replaced
-Rear sill horns fabricated and installed
-Passenger side quarter panel is in place!
Last edited: