My 78 FJ40 Project - HD

[SliderJack]

Intake Patch

I noticed a while ago the intake manifold had some weird goo on it, some type of epoxy or maybe JB weld or something. I wondered if something melted on it but recently I read on the forums that some intakes had a tendency to crack. So maybe a PO had tried to plug a crack with this goo. I’ll have to check it out and maybe have Tim weld it.

 

[SliderJack]

Just when I thought I was done getting dirty. Argh. The trans and driveshafts needed to be cleaned up.

 

[SliderJack]

If June was motor month, July is time to start focusing on the bodywork. So in preparation to start working on the body I decided to get the tub down off its perch and put it on a motorcycle trailer I have. That would allow me to move it around to work on it.

Engine hoist once again to the rescue.

 

[SliderJack]

Well, putting it on a trailer is fine, but hmm, maybe I should goof off and test fit it on the rolling chassis. Wouldn’t that be cool.

Very cool.

The dogs are ready for a ride!

 

[SliderJack]

The bumper is still a work in progress. She’s waiting for her top coat but recently Tim and I added a bull bar to it. I didn’t want the bar so high it obstructed the grill. I think it turned out just right with a good lean back towards the grill—not straight up and down.

 

[SliderJack]

Primer party. Maybe paint this weekend.

 

[SliderJack]

More disassembly. I removed the rest of the parts from the tub including the wiring harness.

I hope to go through the harness when I can, checking connections and wires. I left most of the switches and components attached for now so hopefully I can put it back where it belongs. I took a lot of pictures, I hope enough.

 

[SliderJack]

Test Assembly

Well, with the tub on the chassis I thought I might as well test fit some of the other parts in preparation for the bodywork.

 

[SliderJack]

And I'm officially caught up. I'm a little burnt out at the moment. I little overwelmed.

I'm worried about the body work. I was hoping I could save the fenders, but the passenger side is really thin.

I'll probably give it a go next week. Tonight I'm taking off to see the Foo Fighters at Summerfest in Milwaukee. I have Friday off and maybe I'll finish up the painting and start on the motor.

Thanks for reading. Feel free to let me know if you see something I did wrong.

 

[OrygunCruiser]

nice work man, keep up the pics and info

 

[ElHefe]

You might want to flip those front shackles, they're upside down....

But dang you do nice work.

 

[SliderJack]

You might want to flip those front shackles, they're upside down....

But dang you do nice work.

Thanks for bringing that up. I was going to mention that and discuss it. Something I haven't seen anywhere on the board before is a discussion of the anti-inversion shackles and the power steering box bracket.

I intentionally flipped those shackles. Having them the other way their range of motion is very limited. They first hit on one of the stand-offs for the steering box. I atually went and ground a large portion of the stand-off away so that the shackle had more sweep.

The shackles definitely aren't finished. I'm even considering going with straight shackles in the front.

 

[Snowdogyyz]

Great work! Can't wait to see the finished product!

 

[Blue Ox]

Slider,

Great write up! Excellent photographs and fine looking dog helpers. Having a good fabricator friend is worth a bundle. You're making me happy to keep driving and enjoying my '78, but looking forward to a build down the line.

Thanks for sharing your project. It looks great!

 

[ElHefe]

Slider, I see your point. If the set up as is keeps the springs from inverting, then I think you're good to go. Although you might want to consider adding some additional reinforcement to the other side to even out the constraint of shackle flex. In other words, you don't want all the strain being placed on the one side with less flex.

 

[ElHefe]

And how much did it cost to get those shackles cut, including the materials and hardware?

 

[SliderJack]

Thanks for the comments!

Slider, I see your point. If the set up as is keeps the springs from inverting, then I think you're good to go. Although you might want to consider adding some additional reinforcement to the other side to even out the constraint of shackle flex. In other words, you don't want all the strain being placed on the one side with less flex.

Yeah, I connected just the side of the spring with the shackle and moved it through the arch to see how they would work. I still might cut part of the shackle that makes contact with steering plate. I'll probably fine tune this once I have the motor in and I can flex the suspension.

And how much did it cost to get those shackles cut, including the materials and hardware?

Pretty cheap. Being on a budget I didn't want to buy a set outright but I did buy the grade 8 hardware at the Tractor supply and that was probably $30.

Blue, the dogs always keep me company in the garage. Most of the time they come in the garage and either throw the ball or frisbee at me to tell me enough 40 work already, let's play.

 

[Littl42]

Any updates on this build?

 

[SliderJack]

Any updates on this build?

Hey, thanks for asking! Last month was a bust. Hot weather and lots of work kept me out of the garage. I might get some work done this weekend though.

I need to work on putting the motor together.

 

[SliderJack]

Had some time to work on the motor today.

I treated it with the rust preventative. I wasn't sure if I was going to paint/primer while it was apart but decided to assemble it then paint it because I decided it would probably be better to not have paint on sealing surfaces.

I spent some time running brushes through the oilways and was surprised how much dirt was still in there even after it was washed at the machine shop