My 75 FJ40 build up thread

[Shad0wTr0n]

I keep seeing this pop up in the thread and thought I'd add it once more: WOW.
This is such a great and inspiring build. I have lots of plans and ideas for my cruiser but no money or time to do them. Oh well, that just gives me more time to read threads like this and dream up new ideas until I can start work on mine.

Great job and keep it up!!!

 

[kcustom73]

Shadowtron, Thank you for the comments.

Not much to update on as all I'm doing is body work but it looks like I'm on track to get this thing painted before winter hits. I'll post up when I get some good pics to show off.

 

[kcustom73]

Time for an update

I don't update often these days because I'm busy trying to get the 40 painted before winter hits. So what's left to do before paint...

For fab work all I have left to do is:

Rear seat support/battery tray
Tranny cover
Tailgate storage (aqualu tailgate) after it comes back from getting a recessed pocket welded in place for the license plate
door defrost vents (75's didn't come with them but I think they are a nice feature to have).

Once I get all the fab work done, I'll be able to pull the drivetrain and send the tranny and the engine for a rebuild/upgrade. I'll also pull the axles and suspension. Then all I have left to do is separate the frame from the body.

For body work all I have left to do is:

Hardtop (long project in itself)
Hardtop sides (both started)
Windshield frame (almost done)
Hood (not much to do on this one)
Liftgate (only the seam sealer is left)
Both doors (both started)
Bib (almost done)
Cowl/body (almost done)
P-side fender (only a light sanding is needed)
tailgate

I know how much everybody likes pics so here are few of where things are today (not very exciting)

Note: stock light in custom bumper and stock fuel filler (stock door will be used also).

Note: my new to me sandblasting cabinet has been real busy

Note: A pile of parts that ready for paint. Also in the pile, everything I need to rebuild both axles, my rust bullet paint and my OME shocks.

That's it for now but next update should have a whole mess of painted parts in it.

 

[boozewz]

Loving this thread. Keep it up, and more frequent updates!

Cheers

 

[kcustom73]

Quick update - lots of pics

Still progressing. I have a deadline now of early May next year. We ordered ourselves a new travel trailer and the 40 has to be ready to tow.

Right now it looks like the 40 exploded in my garage

Hard top and sides are about 70% ready for paint

Rear axle out and ready to get torn apart for paint, re-gear, disk brakes and maybe some poly performance axles and a locker

The frame showing off the 95% complete bumper and the 6 cage to frame tie-ins.

Rear Aqualu tailgate with storage I added and a recess license plate holder.

Wooden fuel tank mock up. Very similar to most aux tanks sold right now but without the corners chopped off ( I don't have any rear frame gusset because of the beefed up bumper)

Rollcage on it side waiting for me to paint the underside of the legs, so that I can then stand it up and paint the entire cage)

Last one for tonight, the body has been flipped upside down and it is waiting for primer and some black Monstaliner.

That's it for now. The goal is to have all the big pieces painted by the end of October. Should also have some news about the motor. A little change of plans but still going with a GM diesel... more on this later.

 

[cruiserjunkie]

Man l love this build. All the beneifits of long wheel base and none of the draw backs. You been doing this build right from the very begining cannt wait to see it with some paint

 

[78fj40mg]

Awesome build!

 

[Pierps]

So cool!

 

[Chamba]

I love this build. I have to say that the only thing I would change is to put 60 series axles under it before you paint the frame. It would lend itself really well to your longer wheel base.

I am so impressed with the handling improvement on my FJ40 with the wider axles that I wish I had done it long ago.

Josh

 

[Ambrew]

Hey Kevin,

Where are you doing your paint? or are you getting it done?

 

[kcustom73]

I was thinking of shooting it myself. I've got the room and the equipment and I'm not look for a show quality paint job so why not. I've done everything else on this truck so I'm going to give it a try.

I've change my plans for the tranny. I was going to go with a 700R4 auto but because of the change in the motor and my entended use for the cruiser I'm now trying to find a 4l80e.

 

[uglyoinker]

I've got a 4l80e that came out of a 93 Chevy 2500 with 6.5 we picked up for the engine. Because its a 93 it has a stand alone computer and harness for the trans. We're using an nv4500 so the 4l80e is available. We are putting a 6.5 in a 40 and one in a 60 series.

 

[kcustom73]

uglyoinker, thank you for the offer on the 4l80e but I'm going to try and source something locally. I've tried shipping transmission across the border before and it a nightmare.

 

[uglyoinker]

I thought of that as I was posting. Too bad it's such a pain.

 

[Chamba]

Painting it yourself is a great idea. I was nervous when I first painted a car but it turned out great. I've now painted three cars and they've all turned out better than I hoped. Just don't be in a hurry, buy good paint, make sure your compressor is up to the task and get the surface REALLY clean.
Josh

 

[kcustom73]

Josh, thanks for the vote of confidence in doing the paint. I got a really good book a few months back that's given me tons of pointers. I'm little nervous but what the heck, have done everything else on this truck so I might as well try doing the paint. I'll be bying everything from the same place that way I know I've got compatible product. Luckily for me there's a really good paint shop 10 minutes away. I've got a couple of basic HVLP guns and the compressor to push them. I'm hoping on taking a week off in the next few weeks to get her done. Now I just to finish the last few bit of body work.

 

[kcustom73]

A bit of an update

Been so busy working on the 40 that I haven't had time to update in a bit. So here goes.

Change the plan on the drivetrain a little. Decided to upgrade to a GM diesel 6.5 center mount turbo engine. While I was it a decide to change the 700R4 for a 4L80e. Because I will be towing a travel trailer with the 40 I taught the 4L80e would be a better transmission. So right now the engine is being built by the guys at Diesel Depot. Here is the build sheet for the engine.

BASE ENGINE
Remanufactured Rear Turbo Long-block

INTERNAL UPGRADES
Balanced Rotating Assembly
Coated Piston Crowns
ARP Cylinder Head Studs

EXTERNAL UPGRADES
Complete Rear/centermount Turbo Kit (w/ Reman Turbo)
Adjustable Boost Controller
Ceramic Coat Exhaust Manifolds and Turbo Housing
6.5L Turbo Injectors
6.5L Turbo Arctic Injector Pump (Reman)
Fluidampr
Complete Serpentine Kit (early style with pass. Side a.c compressor)

This will give me a lot of potential to turn up the boost safely. I hope to get at around 250HP - 450 ft/lbs with about 8-10 psi. Might get water/methanol or an intercooler if I want more boost.

The 4L80e is with a local shop called Lentech (famous for their Ford AOD) for a stock rebuild.

Also have a local shop building a rear frame fuel tank for me. Went with the standard rear fuel tank but didn't have to chop the corner off so hoping to get at least 25 galllons out of it. While I was at the shop I got them to weld up my recovery point to the rear bumper (they are on the under side of the bumper).

While all of this has been happening I've been busy with getting things ready for paint. All the parts have been prepped (62 parts that will be body color, there's a lot of little brackets) and the first two coats of 2k epoxy primer has been sprayed. Now I need to sand it all down with some 220, then spray down some high build primer and then some 600. Then finally color Everything is Dupont Nasson

Using the cage as a paint rack

Also got 80% of the frame covered in Rust Bullet.

That's it for now. I'll try to update again when I get some color on it

 

[Shad0wTr0n]

When you sand the primer with 600 you could wet sand. It will have a smoother surface to lay the paint down with less of a chance for the "orange peel" effect as well as cut back, if not eliminate, dust in your shop.

Either way you go you're doing some great work, keep it up!

 

[Pierps]

I've never used epoxy primer before, but I've read in a few places that you're not supposed to sand it... That it will just gum up your sandpaper... You might want to look into that first.

I think you're supposed to hit it with a few coats of high build primer before block sanding.

 

[Shad0wTr0n]

Oh yes, you are quite right. I meant for the high build after the spray filler. Sorry for the confusion.