Build My attempt at bringing another FJ40 back to life

[thebigredrocker]

Well I took my manifolds off because I'm pretty sure the are leaking.

Problems: 3/8" course stud is broke off where a 10mm x 1.25 should be.

And, I just broke off a bolt extractor that I knew was bad idea to use.

*edit* I got the broken extractor and the PO's SAE bolt out. What a relief!

 

[thebigredrocker]

I am getting ready to bolt my Intake/Exhaust back up and I don't want to screw it up.

Should I just use lock washers or flat then lock? Both I/E were surfaced together so I won't be needing to grind washers to different heights.

Thoughts?

@65swb45 @73FJ40 @Splangy

 

[65swb45]

Mark

Toyota calls for using a flatwasher only to attach the intake exhaust to the head. I have always thought this was interesting owing to the fact that the F135 In/Ex uses split washers.

 

[thebigredrocker]

My attempt at bringing another cruiser back to life gained some promise late last night. I bolted the newly surfaced manifolds back up and she ran nicely. I probably still need to do some fine tuning though. I am optimistic I'll soon have enough confidence in this rig to take it for a long drive. Right now, it idles at 650rpm and 18 inches of mercury. I backed it out of the garage at midnight and the acceleration stumble seems to be gone. What a relief! I did pull my carb apart again to give it another cleaning prior to my much anticipated test fire. While inside the Aisan I bumped my main jet from a 112 to a 120. Also switched the rubber accel plunger in favor of a leather plunger.

Thanks to @woody for creating a cruiser forum, where someone like myself with zero knowlege can learn how to make a cruiser go again.

I really want to remove that air cleaner bracket and clean it up. Don't want to open a can of worms though(breaking a head bolt) If anyone has experience with head bolts breaking, feel free to reassure me leaving it alone is wise.

 

[65swb45]

I wouldn't worry about the bolt.
I'd worry about breaching the head gasket.

 

[thebigredrocker]

I wouldn't worry about the bolt.
I'd worry about breaching the head gasket.

Exactly the knowledge I was hoping to draw from. I will leave it be. Again, thank you Mark's Offroad for providing guidance, hard to find Teq parts as well as the correct new parts. Your excellence has certainly helped bring another cruiser closer to its former glory.

 

[daner]

Hoping that test ride goes smoothly, good job.

 

[ginmtb]

I wouldn't worry about the bolt.
I'd worry about breaching the head gasket.

Yup I was told the same thing so cleaned it up, taped off the area, and rattlecanned it in place. Looks good enough!

 

[Rigger]

Great thread! Nice work!

 

[thebigredrocker]

I took the ol' girl for a short drive. Running on unleaded dinosaur fuel. Seems to run ok. Upon returning home I fiddled with timing, idle speed screw and idle mix screw. The exhaust pipe is out of whack so I wasn't able to get a complete seal at the collector or flange(not sure of the proper terminology). Definately an improvement

 

[65swb45]

Exactly the knowledge I was hoping to draw from. I will leave it be. Again, thank you Mark's Offroad for providing guidance, hard to find Teq parts as well as the correct new parts. Your excellence has certainly helped bring another cruiser closer to its former glory.

Thanks to encouraging me to dig into another black hole: clutch small parts. I dumped out the last box this morning looking for a brake hose spring. Turns out I have a pretty good stash of clutch return spring brackets after all.

 

[thebigredrocker]

Whoa! That is a cool picture. Thanks for letting us have a peek. Do I see two brake power booster hose supports on the left side of the picture.

I screwed up and didn't ask for a return spring. My 71's clutch slave spring looks like it lived its infancy on a cabin screen door. Shouldn't be too long before I call in another order.

 

[65swb45]

You are thinking of these, two hole brackets, offered with the disc booster. The little ones on the right are stock for the drum brake, only for orienting the check valve.

 

[thebigredrocker]

I also got my hand throttle hooked up in the wee hours last night. It came off an Aussie rig. The cable bracket was not a 90 degree "L" like North American brackets I've seen pictures of. I didn't want to bend or risk weakening the OEM bracket so I built an adapter. I need to improve my bracket but I was itching to go for a drive so I installed it and off I went. I am pleased with my score

 

[Chungas Revenge]

I also got my hand throttle hooked up

Awesome score..!!! My old mule had a "improvised", through the dash HT using an old choke cable and a Rochester 2bl. From your thread it looks like those late nights/wee hours are paying off...

 

[65swb45]

That looks like it'll take some skin off your leg come summertime!

I would mount that without the adapter.

 

[thebigredrocker]

That looks like it'll take some skin off your leg come summertime!

I would mount that without the adapter.

Good point. I may end up bending the Aussie market bracket. I suspect in Oz the bracket was mounted where the dash lip is at a different angle. It does not appear to have been bent up. I just couldn't bring myself to bending it to 90 degrees last night.

I'm 6'1", as is I've got 5" to 5.5" room

Almost time to learn seat repair. A trusted source told me SOR has good quality repair materials.

 

[ginmtb]

Good point. I may end up bending the Aussie market bracket. I suspect in Oz the bracket was mounted where the dash lip is at a different angle. It does not appear to have been bent up. I just couldn't bring myself to bending it to 90 degrees last night.

I'm 6'1", as is I've got 5" to 5.5" room
View attachment 1406005

View attachment 1406006

Almost time to learn seat repair. A trusted source told me SOR has good quality repair materials. View attachment 1406007

Replacing the seat covers is actually not difficult at all. There are some good instructions online. I think I posted a link to the instructions in my thread. I'll try to find it. I got my covers at cruisercorps and am happy with them.

 

[thebigredrocker]

Thanks Gin I'd love to compare samples of C Corps a SOR's materials. I would like to get the best quality foam and vinyl. I'm a picky buggar.

 

[Chungas Revenge]

Thanks Gin I'd love to compare samples of C Corps a SOR's materials.

Any local craftsman IE upholstery shops, in your neck of the woods? I had my front/jump seats rebuilt and recovered/re-foamed for a song.

Well it was a powerful song as I recall.