Builds Meet "Rusty" - 1978 USA - FJ40

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You need one of these
Conferr center console
I'm liking your updates though. Good job on those boxes.
Yeah, that is cool. I have never seen this console. I might just make one of those myself!

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I found a couple threads with more detail on this. It is made by a Con-Ferr in Burbank California. They are no longer in bussiness.


 
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I joined the 80 club... Picked this up yesterday. 1997 Triple Locked!

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This is the first time I have ever used Rusty (or any FJ40) to pull something. I know this was a pretty light load, but man... he did great. I couldn't even tell there was anything back there. It was super satisfying for me to be using this 40 for something it was designed to do... "work"! I couldn't help but feel that Rusty was pretty happy with it, too. He seemed to derive satisfaction from being productive and getting things done as well.

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I spent about three hours cleaning the inside of the frame rails using a tiny wire brush, sandpaper, a screwdriver, and compressed air. Two things surprised me during the process.

First, I couldn’t believe how much dirt, gravel, and mud had collected inside and along the bottom of the frame rails. The photos don’t do justice to the sheer volume I removed. In fact, the picture of the driveway after I finished was taken after I had already swept and blown it off once—there was twice as much debris as what you see in the photos.

Second, I was pleasantly surprised by how solid the frame remained. Despite being a spot where dirt and mud tend to accumulate, the frame is still in great condition. There’s some light surface rust to address, but overall, it’s impressively sturdy. I think Rusty has led a good life—well-used, but clearly well cared for over the years.

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I began at the front of the frame and methodically worked my way back, clearing each opening by blowing debris toward the rear, where the inner channel ends just before the rear axle. I repeated this process eight to ten times until I was confident all the dirt and debris had been removed.

I also removed the skid plate to get better access to the frame and the cutouts on the inside.

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Next, I plan to thoroughly scrub the entire underside using Scotch-Brite pads, scrub brushes, and plenty of degreaser. I’ll likely need to repeat this process a couple of times to ensure the undercarriage and inner frame rails are spotless (including the trans, transfer case, engine, etc.). Once it’s spotless, I’ll address any remaining surface rust with a wire brush, sandpaper, or steel wool. After another quick scrub, I’ll treat all rust spots with KBS Zinc Oxide converter, rinse everything again, and let it dry for a day or two.

Finally, I’ll apply Coreseal Rust Converter to all rust spots and raw metal, as well as the inside of the frame rails. Then, I'll paint the frame, suspension, and axles with black matte enamel.

I’ll tackle a few surface rust spots on the tub (there is just a couple)—sealing and painting them—then touch up areas where the undercoating has worn thin or come off.

Finally, I’ll clean up the skid plate, paint it, reinstall it, and, for the most part, be done with the work on the underside.

I might spray the inside of the frame and a few other areas with Fluid Film, though I’m still debating it since I’ve heard mixed reviews.

What are you'll's thoughts on Fluidfilm??
 
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I spent a couple of hours scrubbing the rear differential, axle, and back third of the frame. This is definitely going to be a multi-step process, so I plan to divide the undercarriage into thirds. Next, I’ll tackle the middle section, including the transfer case and transmission. I’m sure I’ll need to repeat the entire process at least once more. The first round is to remove fifty years of built-up grease and grime from the underside; the second pass will focus on any spots I missed and all the little nooks and crannies, aiming to get it extremely clean and ready for paint. The photos don’t do it justice, but I’ve included some “after” shots of the axle and “before” shots of the transmission and transfer case. Those should be pretty drastic "after pics" when I am done.

I’ll keep making progress a little each day after work.

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I have the day off, so I spent a couple of hours focusing on the transfer case. Take a look at these before-and-after pictures... WOW!

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