Build My attempt at bringing another FJ40 back to life

[thebigredrocker]

Finally made a little bracket to hold my 10 micron fuel filter. Wanted to use something more fancy than a pipe clamp, this will do for now.

Still need to re-route my PCV hose (I made it too short) so I can pop my valve cover without removing the hose.

 

[Rock40]

Nice work with the AN lines and fittings, great stuff

 

[thebigredrocker]

Yeah I just never put forth the effort to learn how to build my own hardlines lines. I know it's probably something I could learn. I did kinda feel it wasn't right to use modern plumbing, but I had a bunch of leftover Fragola supplies from my first project. I guess I went with what I know how to do. So far, I like the servicable AN filters. I've got a 40 micron stainless mesh filter pre fuel pump and the 10 micron (cellulose) pre carburetor.

My "temporary" mounting solution for the 40 micron.

 

[thebigredrocker]

Windshield glass is on the way so I pulled my frame off and started repairing it. I suppose I've been dreading this repair. No Idea how the PO grenaded the corners.

 

[thebigredrocker]

Welds ground down. Far from perfect.

Debating whether to fill the sunken circled area with tacks or quit while I'm ahead.

 

[Rock40]

Another option would be filling those with a "metal like" filler that's harder than Bondo. I'd recommend JB Water Weld as I've used it in the past with good results for a similar issue.

 

[thebigredrocker]

@Rock40 I like that water weld idea. Much safer route. Have you noticed any different properties from standard JB weld other than color?

 

[waiting for time]

You can braze those holes, gives you a metal connection but not as much heat as welding.

 

[Rock40]

My experience is it sets up very fast (5 minutes) and obviously doesn't care about moisture or anything like that. I just make sure the surface is very clean. It sands nicely after drying for about 24 hours or so.

 

[thebigredrocker]

Not too much to report. Been calling my upholstry guy on a weekly basis now. I hate to bug but I've learned somtimes that's the only way to get action. Hopefully this coming week I'll get news of completion.

Did finally pull the trigger on lower dash pads from FJ40dash dot com. My old pads are almost shot. Due to the fact that FJ40dash pads screw on I decieded to pull my gauge cluster to reach the 3 hard to get at rascals.

Since my cluster was out I decided to paint its bezel and have a peek inside. I didn't want to activate a spendy can of 2K epoxy for just a bezel, so I cleaned up a couple rusty rear heaters to also recieve a coating of Ash Grey Epoxy.

I suppose I've been "cleaning the mini blinds" as 65swb45 might say. If You haven't read Mark A's "mini blind" essay, it's worth a read. Especially for us guys who devote precious time to old Japanese made parts. —>LINK

The last batch of T145 I shot was 1K spraymax, so I'll be curios how the 2K spraymax turns out. It seemed to lay down nicely.

 

[thebigredrocker]

Put the gauge cluster back together. #1 goal, don't mar it up. My hands weren't tough enough to bend the bezel tabs back. So I layed a soft towel on my bench, placed a few layers of duct tape on a 12" flat tip drift and crimped the freshly painted tabs down. Next challenge was re-install the gauge cluster. As much as I dislike dealing with the gauge cluster, it's really pretty slick how it's all one unit.

Upon completion I took some pictures. Got to thinking....the average person might look at my dash and just see "old". I and I'm sure many mud members now have an appreciation for the effort that goes into restoring a 46 year old dash that's sat top off, in the sun and rain half it's life. It's a good feeling to look at my dash and know I've got a fresh Coolerman harness and everything else has been 100% gone through.


Pleased with the 2k epoxy paint. It has a nice sheen and will be durable. I used a different spraymax source this time(66autocolor), this 2k ash gray is slightly darker than the 1K I ordered elsewhere for my seat frames.

 

[thebigredrocker]

Blasted, cleaned, degreased and painted my rims with spraymax 2K epoxy in "hot rod satin black" I'll be curious how it holds up. I didn't use primer.

Fully coated 5 rims twice. 3.5 cans per round, so a total of 7 cans used.

 

[thebigredrocker]

Here's a side by side of the T145 ash gray 2K epoxy next to my 76's heater color.

 

[thebigredrocker]

Figured my wiper motor was needing a rebuild so I gave that a go. Turned out the cable that links the linear gears was seized in the sheath. Cleaned everything up and discovered during the test, I forgot to clean my wiper switch. Now all my switches have officially been gone through and my wipers work.

Not sure how the pivot got tweeked. I think Indygbd is going to hook me up with a good replacement unit.

 

[thebigredrocker]

My driver door got bashed in before I took ownership. Got lucky and found a replacement in good shape. Since I am testing some Cygnus paint on the door I also decided to paint the windshield hinges. They were pretty bad. Had a heck of a tustle with the rusty pins. All is well and some replacement stops will soon get installed. I still need to find some rubber door stop bumpers. Also purchased @SouthBostonFJ40 bushings.

 

[thebigredrocker]

Cleaned up my wing window frame last night and splattered some Cygnus single stage paint on stuff.

Next dilema:
My windshield frame is sitting on a bench awaiting glass and the rebuilt wiper motor. I have to touch up paint the windshield frame with Cygnus in the 2 spots I welded. Now seems like a good time to paint the entire frame. Not sure I want to loose the patina though.

 

[thebigredrocker]

I removed my rollbar to mount the long jump seats in the factory holes. The reupholstered were ready for pickup today so I hustled over to get them.

Cleaned off the wheel well top with rust eating acid, I turned out so nice I decided to continue "cleaning the mini-blinds" @65swb45 So I slathered acid on the tub inside and tub rail. Glad I spent time cleaning before installed the jump seats

I like the Pematex "rust desolver" gel. I used a stiff nylon bristle brush for most off it. A fine/stiff metal bristle was used in heavy rust areas.

Guessing this is how the seat belts mount?

Arctic 50 Dark Grey material

 

[thebigredrocker]

Figured since my rig hasn't moved since winter I should put some tires on.

Went ahead and painted the entire windshield frame in single stage "cygnus".

Air cleaner came off a 74 FJ55. Not sure if I should use it with the 1F. It does have a port I could hook to the 2F valve cover I installed.

Painted a couple sets of Heavy Duty shackles from Mark's Offroad. I think the longer set (5 1/4") will go on the 71 if I keep stock springs.

The 4 1/4" set might end up on my 76 FJ40. It has 2+" OME springs.

 

[thebigredrocker]

Made some progress. My 4yo daughter found me a good luck flower on her short hike today. Pretty cute she came out and wished me good luck

Glad to have a windshield I can see through, a straight drivers door and seats so I can test out the new tires. My wife was a big help with the windshield glass install.

 

[thebigredrocker]

Been needing a wider alternator pulley to fit a newly installed 17mm Toyota belt. Bought a nice old NIPPONDENSO that popped up in classifieds. Cleaned it up, scuffed the pulley with a Scotchbrite. Works great and I was glad to find another good old Made in Japan part.

Before the 71 went to winter storage she blew an oil line. Luckily the oil squirted on the exhaust, causing smoke. Probably drove 200 yards before pulling over. Luckily my cousin was in town, he towed the ol’ girl home. Oil even made it through the trans hump.

Looks like the PO added -4 AN or JIC fittings. I imagine the other end is 1/4 NPT. Made a temporary hose using a chunk of braided fuel line and some Army/Navy fittings that were laying around. Thinking I’ll just leave the fitting as is and build some hydraulic hoses next year. Had to add a couple quarts of oil. Was surprised how quickly oil was pumped out of the tiny crack.