Builds My 77/40-6 year project (1 Viewer)

[dad4x4]

here are a few pictures of the frame work and a brand new 4+ brush guard I scored. Pics of the frame aren't detailed and I'm surprised that I have any at all. while the body was off I decided to pull the trans/case, install a new clutch kit, engine and trans mounts, main seal, oil pan gasket and a new oil pump. all OE parts.
FYI, the aluminum radiator is temporary and installed when I first bought the 40 to get it on the road. I have a brand new oem one ready to install.

 

[dad4x4]

I didn't take any good pics of the frame before and after but I coated it in POR gloss black. After the bell housing was re-installed I wanted to get the body back on the frame. So I ordered a new body mount kit from Cool Cruisers and put the body back on the frame. I couldn’t wait to start putting on parts that i’ve been collecting for years.

 

[dad4x4]

This is pretty much how it currently sits. I've tried to get as many parts painted as I can in between work, taking my girls to soccer, karate, dance, cheerleading and church on Wednesday nights, Not a lot of time during the week and the weekends are no different. When the weather is right and I have time, I get as much painted as I can. I spend most of my time getting as many parts prepped for paint as I can so when I get a couple hours in the shop, I can hang panels and start spraying. My doors still require some welding and/or body work which I will be working on all day today. The top has a couple areas that require a patch then will be ready for primer, paint etc. i'll try to remember to take pictures today. Here are a few pics of panels hanging to completely dry. also a couple pics of the bugs that have to ruin everything.

 

[dad4x4]

Been a while and haven't had much time in the shop but had a couple weekends around the holidays to get some stuff done. So I got a few more items painted and all that is left to paint are the front doors, which will have to wait until spring. Now to get this thread current.....
Got the front end put together and lined up. This is the first time seeing it look like a cruiser again since 2013.

Then I got the windshield frame and roll bar installed. The headlights look great, can't wait to see how they work. thanks to @Racer65

 

[dad4x4]

Then The hardtop and rear doors. also installed the running boards.

 

[dad4x4]

looking back at these pictures, I didn't realize how junked up my shop is. I guess this is what happens when I only get an hour or so of shop time at a time. I don't want to waste progress with cleaning....lol
The tires and wheels are next. I'll be replacing them with the stock steelies and 33x10.50's. This is pretty much how it sits now. My plan is to get the intererior complete before spring. The problem I have is I haven't decided on front seats yet. I've read for years on the different set ups out there but still haven't decided. I need a driver seat that has lumber support and one I can adjust. I like the SCAT seats that @GA Architect has and is my favorite so far. Scat also has an adapter bracket that bolts into the stock mounts. No chance the stock seats are going back in so I need to figure this out. Any suggestions are greatly appreciated.

 

[Rainman]

Looks like you're smokin'. I'm in for watching this one finish up.

Let me know when you may be headed up here. I'll get the group to gather up while you're here.

 

[dad4x4]

Will do. I’d like to meet the group. sounds like a good time to me. Thanks Rainey

 

[dad4x4]

It’s been way too long since I have updated this thread and didn’t realize it’s almost been a year...
So I have been hard at it trying to get the 40 back together and be road worthy. I feel like I only get a few hours a week in the shop so I made a list of what needs to be done to stay organized and to prioritize projects which helps to maximize my time. In the spring I got my stock wheels blasted & powder coated and ordered some bfg KO2’s. I was torn between the grey and something closer to white. So I went with a light gray...

 

[dad4x4]

I finally decided on the front seats so I ordered two of Scats elite lumbar seats. They are very comfortable and at 6’4, they provide plenty of leg room too. A friend (@JVZii) gave me the center console and it turned out good too. I had to fab up some brackets to make it all work. It turned out great.

 

[dad4x4]

Next I got busy installing all the glass in the hardtop, doors and windshield. Found that passenger top hinge on the ambulance door wouldn’t work due to having too much play. Must have tried to adjust them 100 times before figuring it out. Luckily I had another that I blasted and painted.
When I dropped off my wheels I also dropped off my rear jump seat frames. I parted out a ‘79 a few years ago but kept the jump seats to use in the ‘77. When my girls come out to the shop this is where they want to be.

 

[dad4x4]

Next, I installed all exterior/interior lights including the cluster. I had the hardest time figuring out why I couldn’t get the turn signals to work. I cleaned every ground I could find, went all through the harness, took the fuse block a part and made sure there wasn’t a contact problem... still no turn signals. All the lights are brand new & OEM. I could get them to click one time but would then stay solid. This took several days to figure out but turns out unless you install a resistor in the circuit there won’t be enough load for the turn signal relay to operate when you install all LED bulbs. So I changed the front driver side bulb back and they all work.

 

[dad4x4]

I started working on the front doors. I thought they were straighter than what they turned out to be...
Since they weren’t rotted out at the bottom I considered them good.

 

[dad4x4]

Got them painted along with the other miscellaneous parts.

 

[dad4x4]

Then got the doors installed along with all the internals. I had a friend (@Wadesters) come by and help install the front and rear door weatherstripping.
Didn’t take any more pics from that weekend but had a few cruiser guys at the house. @JVZii & @Rooster47
Thanks for the help, beer and conversations.

 

[dad4x4]

Replaced the tie rod ends, all brake lines, calipers, rear drums, u-joints and bled the clutch & brake lines, filled up the trans/case and installed a bypass hose last week. I have had the knuckle rebuild on the list for a while but haven’t jumped into that yet. I might get that done this winter...?
Got the fiberglass top on but it is a borrowed one. Mine is still requiring a lot of fiberglass work. That will be my winter project. Right now it is road worthy and ready to enjoy while I knock out the rest of my list of to do’s. I took it out yesterday and finally washed off all the dust that’s been collecting on it for years. Not sure what rear bumper I’ll be going with yet so I may end up installing the stock bumpers until I figure it out.

 

[dad4x4]

It’s been a very long road and I now know how much goes into a full restore. It is very rewarding to see it come together the way I had imagined it. I will never be at the end of the road with this thing as I’m constantly thinking of ways to “upgrade this and try out that”. I have replaced everything I could get my hands on with oem parts so hopefully I will have less problems and feel confident when taking it out. I didn’t do the best job at keeping this thread current or document and take pics of all the work I did but hopefully it is a good read for someone to see a 40 get put back on the road.

 

[Wadesters]

I have watched this build come together. A lot of time and attention to detail. I don’t think it could have come out any better.
I have enjoyed watching the progress in pictures and first hand.
Congratulations for a “fist class” build!

 

[tstepp920]

Got them painted along with the other miscellaneous parts.


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The mobile light stand. Where did you get it?

 

[dad4x4]

The mobile light stand. Where did you get it?

Ha, you are the first to ever mention it. I got it from a friend. I’ll leave it at that. He is on here and it was given to him...
It is a great shop light. I use it all the time.