My 75 FJ40 build up thread

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The painting is done...:D The roof is done top and bottom. On the bottom the rim was painted white and the fiberglass was coated with Lizard skin ceramic (hoping to keep a little heat and sound out) Forgot to take a pic :frown: The top is done also. Not 100% perfect but close enough (still a few low spot where I joined the two halves)



Front bib also got repainted after the mods...



Rear axle shafts, dipstick tube and cleaned up a Volvo fan...



All the brackets for the exhaust system, wastegate and trans dipstick tube are ready for assembly...



And all the exhaust pipes are back from the welders...





Now that all the painting is done and I've cleaned up the shop to get DD's in the garage for the upcoming winter (also made the :princess: happy with that one), it's full steam ahead to get the engine running. Stay tuned.
 
3 weeks since my last post but with all the winter tires on the cars (4 in total) & the xmas lights installed I'm on the 40 full speed again.

The exhaust is installed for good with all the heat shields. Heat shield where sprayed with Lizard Skin with the hope of keeping some of the heat away from the transmission, t-case and the floors.







The fuel tank, minus the skid plate, is installed for good.



Got a new toy. Knowing that I would need to do a lot of flaring I got myself the Eastwood flaring tool. Here's a shot of the tool and a sample of what it can do.





The fan was a tight fit but I think I made work. Not a lot of clearance between the fan and the water pump pulley but this is as much as I could get.



The plumbing to the radiator is done. Installed a heater bypass to get the engine running.




The fuel system almost done. It was actually done but there's a little section I don't quite like, so I'll go back and fix it before getting some fuel into. Here's a shot of the pre-filter and frame rail pump. The 3/8" ss fuel lines and the modified filler neck.







And finally here are some the work in progress wiring. The Painless harness is less the painless but should be able to make it work.





The plan is to get the engine running next weekend so stay tuned.
 
I found this thread just the other day and read the whole thing. Great workmanship. Too bad we're so far apart. I'd love to see this in person. In the last four years I've become a 6.2/6.5 fan. The only diesel I can afford.

I'm really interested in how this runs for you once you get it on the road, MPG, highway RPMs, and all.

Don
 
Don, I was sure you would have seen my thread by now. We've chatted in the past in other threads about the 6.2/6.5's. Well I'm glad you've found it and enjoyed reading up on my build.

As for distance, you never know. If the stars align and I can swing it financially, in a few years (before the little one gets to old and doesn't want to hang around mom and dad anymore)I hope to take a summer off, hook up the travel trailer to the back of the 40 and drive west to Vancouver. The plan would be to get there through Canada and drive back through the States.

Stay tuned to the thread as the engine should running this weekend. I'll post some video.
 
I am in constant awe of the work you are doing.
Not only for the obvious skill you have but for the work ethic as well.
Keep it up.......
 
Just read the whole thread. Amazing build. Can't wait to see it finally finished. I noticed that I commented on your build 6 years ago!! Time flies.
 
Yes it's been a long build ;) but when you've only got weekend and weeknights to work on it and you have to build up the brownie points with the :princess: it takes a while.

Well I was hoping to post video of the engine running tonight. With the help of a few buddies from the diesel page forums we where able to get it to start and idle properly but giving it anything past 1/4 trottle the IP on the 6.5 would just goes in to full retard and the engine would run really rough blowing a brownish (not black) smoke. We made sure the system was purged of air but nothing help. The engine did sit for over 8 months and we are a little worried that something might be siezed/stiff in the IP. So we are going to let soak for a bit and hope for the best.

Just to finish off the perfect day :frown: the lower radiator hose clamp let go and the entire content of the radiator ended up on the garage floor :mad:

Oh well... this is suppose to be a fun project ;) so back it tomorrow. Stay tuned for a video of it running in the near future... I hope.
 
kcustom73 said:
Don, I was sure you would have seen my thread by now. We've chatted in the past in other threads about the 6.2/6.5's. Well I'm glad you've found it and enjoyed reading up on my build.

As for distance, you never know. If the stars align and I can swing it financially, in a few years (before the little one gets to old and doesn't want to hang around mom and dad anymore)I hope to take a summer off, hook up the travel trailer to the back of the 40 and drive west to Vancouver. The plan would be to get there through Canada and drive back through the States.

Stay tuned to the thread as the engine should running this weekend. I'll post some video.
Click to expand...

It's possible I've read portions of this thread before, but I'm on two GM diesel threads besides Mud. I can easily get sidetracked and forget where I was at just minutes before. When I was still working I was well known to lose my clipboard, and other things, if I was distracted while pulling parts while getting ready to leave for the jobsite.

I definitely remember your avatar, and conversing, but the subject of the conversation is gone. There are many times that something will jog my memory, bringing something to the forfront, but will be unable to place just where that memory comes from.

Anyhow, I'm impressed with your build and hope that someday, someway I'll be able to see it in person.

Don
 
Stephen, it sure a boost to the morale. Know I just to get everything bolted together.

Vae, the video was done with our Sony digital camera in video mode. It does some reall nice pictures and videos.
 
Very inspiring to see all you have done. I've used the Lizard Skin and Monstaliner products on my 55, also. Hopefully they prove to be worthy.

Keep up the good work and enjoy the end results! You have a very unique vehicle that the whole family will enjoy.
 
Had a good break over the Christmas holidays but didn't get much work done on the cruiser. The work I did manage to get done was more a set back then moving ahead.

If anybody tells you that the only difference between a 2wd and 4wd 4l80e gm transmission is the tail housing they are lying. How do I know, by finding out the hard way. If you are looking at the output shaft there is a plug at the 3 o'clock position. In 4wd trannies its a solid plug in the 2wd trannies there's a pinhole to let oil flow to bushing in the tail housing. Guess which one I got... :( At least you can order the 4wd plug (should get it in a week).

I guess I'll be working on something else then the drivetrain this week. Might start working on the axles...
 
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