Build Lake Norman's '79 FJ40 Rebuild

[LakeNorman_FJ40]

OK! Finally got the hardtop and full doors restored and installed!

The top and door fitment is great with the Aqualu tub. It even sits flush to the tub panels which is something I didn't expect based on what I saw in the Aqualu CD-ROM they sent with the tub (it looked like it overlapped the tub).

Very happy with the conversion to a liftback verses the ambulance doors (yes, I know that's unusual for an FJ40 owner to not like ambulance doors). But, the rear outward vision is much better and I get to keep my Aqualu storage tailgate year-round.

The CCOT door panels I chose aren't OEM, but they are durable, match the interior, make the door feel more solid, and they will never rot. Plus they are cheaper than OEM door panels.

Next steps are to rebuild and install the heater as well as install my roof rack! Maybe sometime next year I'll paint the side panels and liftgate to match the truck...

Anyway, for those who are interested in a checklist of most of the things you need to do on a hardtop rebuild, I've included a list.

HARDTOP - Talk about a PITA if you tear this thing ALL the way down to bare metal and start over from scratch, but in the end I think it was worth it.
- separated fiberglass cap from drip rail
- all metal media blasted inside/out
- purchased used windshield channel metal part (where you bolt the top to the winshield)
- repaired rusted section on rear inside rail (where you bolt top to tub)...cut out and replaced w/ new metal
- epoxy primered all parts...then top coated with primer sealer
- replaced every single weatherseal and windowseal with new ones (from both SOR and CoolCruisers...really like CCOT's own seal that fits b/t tub rails and roof top side)
- needed some bodywork to the fiberglass roofcap (3M HighStrength repair filler for a couple holes)
- reattached roofcap to driprail with Sikaflex...used a ton of clecos to clamp driprail to roofcap while Sikaflex set up (several days cure time)
- re-installed ALL of the rivets using SOLID aluminum rivets (ordered a pack of 100+ and a rivet set tool from McMaster-Carr); the driprail rivets (visible from the bottom side) now look just like OEM
- filled the rain gutter area with 3M SeamSealer (from CCOT's)
- fitted the replacement winshield header metal part on the fiberglass top; used Sikaflex to attach to fiberglass; bolted in place using stainless buttonheads
- primed the top with epoxy primer; shot the perimeter of the roofcap with off-white epoxy paint (spray cans...from Lowes...appliance spray paint)
- loosely bolted top, rear header, sides together to fit top to Aqualu tub...tightened it all up once on the FJ40 to identify hole locations in tub rails (to bolt sides to tub) & drilled holes in Aqualu tub
- fitted rear liftback to rear top header...had to play around some with alignment and some washers on the liftgate hinges to get the liftback to sit correctly and seal to the Aqualu tailgate since I converted from ambulance doors
- installed original liftback shocks and latch mechanism
- installed riv-nuts into winshield frame to secure front of top (didn't like Aqualu's solution of a bolt all the way through the winshield frame)
- took FJ40 to local glass shop to have windows reinstalled...rear liftback glass was etched (looks like a previous owner welded near the glass...was full of spatter), so I had them cut a new one to fit

DOORS
- completely stripped down to door shells...then media blasted too
- new stamped metal door bottoms ordered from CCOT
- bottom ~6" of both doors cut off; welded back on new metal bottoms, grinded down the welds smooth
- needed some bodywork (filler) on the doors to completely smooth everything out
- fitted brass bushings into door hinges (from regular e-Bay seller) and new door hinge posts (CCOT)
- expoxy primered and then top coated with primer-sealer
- new weatherstripping around perimeter of door
- new rubber glass channels (updated to early '80s OEM vs. older chrome versions), glass felts, etc.
- installed aluminum CCOT inner door panels...powdercoated black by CCOT in textured finish...similar to bed liner...matches rest of black interior...used tool drawer rubber liner for the vapor barrier b/t door and panel
- new door pulls
- leather straps for door limiters

 

[fj40z]

Truck looks great Drew!

 

[MtnClimber]

Wow. Nice rig. If you don't mind me asking, how much did the rebuild cost you?

 

[71 redwood]

that is a really nice build....I think I am going to start growing canibus an throw the money into my FJ...
I like your rig...good job

 

[antFJ]

great work on the doors.. you can't even tell.

 

[alkarich]

Fantastic rig. Looks incredible.

 

[FJ40-40]

Wow, that looks great! I hope my doors fit that well to my aluminum tub.

 

[Cirbo]

Hey! You are still alive!!

Looks good Dood.....

 

[apeterson]

nice man!!!! real nice!!!! I like how that hard top looks on that tub... I was not going to redo mine but now I am rethinking it...

 

[LakeNorman_FJ40]

Thanks for the compliments guys. It's been a slow labor of love...hopefully inspires others about what you can in your garage & backyard with a basic set of tools (except the Dune Beige paint job & bedliner). It's not to the level of a TLC restoration, but then it's also a fraction of the cost.

FJ40Z - Thanks...and I need to get those front shackles from you at some point!! Your new 80 looks good!

MtnClimber - To be honest, I really don't want to add up the receipts and find out what I've invested. But the full alumnium tub & related parts were ~$7K (including shipping). The complete hardtop restoration will be close to $1K when the paint is done. Add several more thousand for other parts/repairs plus the base cost of the rust-bucket FJ40 I bought and my guess is that I'm below $20K (probably not by much). There are things I could have cut out (i.e., back seat and Rhinoliner would save $1.5K). But my plan is for this truck to be used with my 2 sons as they grow up and ultimately be passed down to them, so anything added or rebuilt is done with specific purpose and/or longevity in mind.

Cirbo - Hey there...yes, still alive but this economy is killing me...no $ for the family cage and I've got to run around in primer!! Things could be much worse, so I don't complain. The green FJ40 you recently complete is incredible...nice job!

AntFJ - Thanks...I was really worried about the cut/replacement sections on the door bottoms fitting and looking correct. The guy who did the welding for me does quality work...plus I put some time into the bodywork on the doors to get it all smoothed out. Almost gave up and converted to canvas sided doors, but glad I did not in the end.

FJ40-40 - If you have one of the newer Aqualu tubs, your doors should fit fine. It's a two person job...one to hold the door in place while the other marks the location on the tub to attach the "L" brackets. The doors should be the last thing you install...after the hard/soft top is fitted to make sure it's located correctly in the door opening.

 

[marks69cruiser]

Beautiful build. Another sweet cruiser for me to draw inspiration from. Thanks. Mark

P.S. Happy Holidays!!!

 

[cruiserjunkie]

That thing is beautiful. Attention to detail makes the differance but makes $ add up quick. Wish I knew the feeling of everything done right so I could just enjoy instead of planning the next project

 

[AKcruiserfreak]

Cool build! So you are going to make your sons duke it out for the Cruiser? Sounds like fun!

TK

 

[jackbrad]

What type of rear bumper are you running?

 

[LakeNorman_FJ40]

Jackbrad: It's a Man-A-Fre rear tire carrier...very well designed and over-built, but pricey...shipping alone to the east coast was $200 via pallet. When I talked to a couple of local fabricators they quoted me similar prices, so by the time I got it powdercoated it wasn't going to be so much cheaper that it would warrant the extra time and effort vs. ordering from MAF. If you have welding skills (or the time to spend learning), this would be a great project.

 

[3doghouse]

...hopefully inspires others about what you can in your garage & backyard with a basic set of tools...

Yes sir it does. Thanks for the motivation!

 

[LakeNorman_FJ40]

Another "excursion" in the FJ40...nothing like a real safari, but the kids enjoyed the trip!

 

[msapers]

Awesome rig! I'm drooling over here.

 

[marks69cruiser]

keep the great pics coming!

 

[LakeNorman_FJ40]

Guess it's time for another update...this build thread is turning into more of a blog of my FJ40's history! Still no time to paint the top yet...the grey is actually starting to grow on me.

Finally installed the NOS Con-Ferr roof rack that's been hanging on my garage wall for 2+ years. It involved a little more than just bolting it on:
- fabricated rack floor from heavy gauge sheet aluminum; secured aluminum by bolting it down w/ 100+ stainless bolts)
- located 8 rain gutter mounts (Quick-N-Easy brand...from Nantahala Outdoor Center...cheapest solution I could find)
- fabricate my own cross-bars from square steel tube (FYI the front one is slightly shorter if you install a full-length rack)
- installed Hi-Lift mounts to use as surf fishing rod holders
- clamped down a water can storage rack
- installed 7" driving lights and Quick-Fist securing straps
- installed Camping Labs small awning

Of course we had to put that rack to good use...actually a 5 day camping trip to North Carolina's Outer Banks prompted the rack installation. It was a LONG (6+ hours), hot (no A\C) drive with all 5 of us in the FJ40. The back seat earned it's stripes as the 3 boys sat and slept on it the whole trip. We were loaded to the gills with ALL of our food and camping gear for a self-contained trip...had to remove food from the shopping bags and find nooks inside the FJ40 to store canned food.


Ferry-boat ride:

Drop-off on island:

Who needs roads?

Really was a bummer...beach was so crowded:

Camp site:

Pic of rack hauling a load of scavenged drift wood for bon fires:

To get back to mainland from here, it's 16 miles back to the ferry drop-off point and (if not at low tide) over 1 hour ferry ride across the sound. Spent time fishing and the boys went swimming / fishing / playing. Temperature was just right...

Really put the truck through it's paces on this trip...~13 hours highway driving...almost 100 miles of beach driving and exploring. We were overloaded with gear from the start...bottomed out the suspension (either a 2.5" or 4" lift???) to the point the tires rubbed the fenders for the first time while beach driving (admittedly too fast). On way back home at night truck started to over heat...just needed a new radiator cap...but that required an overnight stay as Autozone isn't open at 11pm.

In short, it was a great trip. While trying at times w/ limited space and no A/C...but boys loved it and still talk about the trip over 1.5 months later. Really can't beat making memories with this truck...it's definitely part of the family.