My 75 FJ40 build up thread

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I'm so bad at keeping this thread updated, but work hasn't stopped. Got the transmission plugged up and running. The 203 is installed and got the splitcase built up and installed. This took me little while to get done because of the front output oil slinger (forgot to install and had to order a new oil seal to put it in) Also got the twin stick setup installed, just need to paint everything.



Got the rear axle all buttoned up and the rear disk brake installed (raybestos rotors, Monte Carlo calipers and EBC pads). Also got the skid plate re-installed.





Also got the front end put together. Used knuckles & stock birfs from a 60 series, 4Runner calipers, EBC pads. 40 series TRE with starter bushing fix to make them work with the 60 stuff. Also got all the steering set up and installed a Trail gear steering stabilizer.





Got all the power steering lines installed except for the cooler and now I'm waiting for the last of my brake fittings to get the brake system done. The rear driveshaft is done and I'm waiting for my 2 piece front driveshaft after running into issues going with a one piece I'm hoping to take it for a spin around the block soon just to test all the mechanical's and give me a little boost to get it done for the summer.
 
Really got to keep moving on this build if I want to get it on the road this summer. I had a bit of an issue with the 203 reduction box this week and had to tear apart the splitcase and the 203 to figure what was going on. Hadn't noticed when I put it together but there was a little left to be desired on the machining on the new output shaft for the 203 but nothing I was able to take care of. That taken care I got all the shifter's figured out, built, painted & installed. The way the shifter's sit in the picture the 40 is 2wd high.





Also got the my front driveshaft figured out so here are a few pics of the what I came up with but for the full story of the issues I went through take a look at the following thread: https://forum.ih8mud.com/hardcore-corner/795173-drive-shaft-vs-oil-pan.html





Things are really moving now so tuned for regular updates.
 
Quick update. After talking with some of the folks here on MUD I decided to change the front drive shaft setup a bit. Also got the condenser, ps cooler & trans cooler installed and got the bib installed. Don't have much left to do to take for a spin around the block so stay tuned.







 
Well after 6 1/2 years of work I finally got to drive my 40. It was a tight fit to get it out of the garage door (another project for later this summer) but it runs. Here are a few video's of its first initial run (excuse the voice over from my wife :) ).





Here are some other pics of the stuff I did to get it to the video's above.

Brake lines all finished:





The hydroboost/mc/proportioning valve all installed (had a hard getting the booster to work to realize after doing some research that I had a bad booster)



and here are a few pics from yesterday during the first run (big thanks to my buddies Bill and Gord for helping me out yesterday and through out the project)





 
Great build thread! Must have felt good to finally drive it after all these years
 
Thank you for all the good comments folks. Now that I've built up some browny points with the family by going to Disney I can go back to 40 and try and finish it so that I can enjoy it this summer.
 
A quick update since I've been so busy trying to finish it I'm trying not to forget taking pictures of the progress.

With some help from the guys from True North Toyota Land Cruisers and with the sides all prepped I finally got the roof on for good.



The wiring is well on its way with everything in the back hooked up and tested. Also got the filler door installed.





Got loads of other stuff done but need to get pics...hope is still to have it on the road sometime this summer.
 
Once it's done, I'll pay for your diesel to drive that bad boy down my way (yes there will be cold beer here too).
My hope is seeing your truck in my driveway will inspire me to get off my butt and get some work done on mine!

Great job......keep it up....!
 
cool build! mine has taken 2 yrs. and doing it in the driveway has sucked! I thought about doing a diesel with nv4500 203/205 tcase and a new rear-end but I'm trying to keep the budget low! Is that the stock fj40 blue? What do you think of the lizard skin? I'm thinking of going with that or line-x underneath and on the inside for sound and rust protection. What is your wheel base? got mine started the other day that felt awesome! glad yours is running. itd be one heck of a show vehicle. Ive got the truck top and the full top just neither is finished... have you seen? ---http://landcruiserspecialties.com/fiberglass/ a top like that I think would really make a cool full top with the window.
 
freebornred, sorry for the late reply but I've been on summer holiday with the family. It's sad to say but the color is a Jeep color called Cosmo blue. They only used it in 2011/2012 I think. The lizard skin as been good so far. I've drop a lot of stuff on it and so far so good. The only issue I've had is where I applied it on the front door sills and I've chipped the edge. I think it being a narrow edge and only going down one side and not both has left it a little weak.

Wheel base is 117 inches and I'm going to use the 40 as a DD. Probably go to a few shows with it but I'm going to run this rig and get it dirty :)
 
Ok so I know I suck at updating this thread, but I'm spending the time in the shop instead...

So I think I'm done all the fabrication except for one little bracket I need under the dash. Here as some pics of all the things I fabbed up lately, all painted and coated with some Monstaliner I had left. I've had to modify the trans cover and make it into 3 pieces because there was no way I could get the cover on in one piece with all the shifters in place. I've finally figure out what to do for the rear seat and everything is fabbed up (pics will follow next weekend).

First we have some dash trim pieces to replace the bottom dash pads, speaker rings for the doors, glove box door and the new upper dash trim piece that will hold the radio and the trans controller.



Next we have have the gauge bezel, air filternbox cover, rear speaker pods and part of the trans cover



Next we have the second part of the trans cover, the last of the dash trim / gauge panel & the air filter box.



The next two pictures are of the modified trans cover, rear bench box cover and a rear purposed sub-woofer box that I'm going to put in the back of the 40 (used to be big into car stereo and just reused a lot of the stuff I had left over)





I've also installed all the lights on the front of the 40 and the bezel ( I think its in the right direction ;) )



That's it for tonight. Next week is a week of assembly, so I should have some nice pics of the interior coming together.
 
Another quick update...

With all the parts I painted last week, I was able to assemble a lot of things. The rear bench is installed with the seatbelts. I also have a couple of amps installed underneath the bench to power the rear and front speakers. Also have some lockable storage under the bench.







Also got the rear speaker pods installed.



Also got most of the cables going from the bench area loomed, wrapped and routed to the front. With the batteries installed in the back I had to figure out a way to boost the truck if ever needed. Ran a 0 gauge cable from the battery to this post just beside the breather filter.



Also got all my dash trim pieces installed.



That's it for now. I'm hoping to keep up this pace to finally get the 40 done...
 
Looking good
 
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