Build My FJ40 Journey...

[thebigredrocker]

I only know of three. 9/73-12/78 is one with the door hinge on the bottom. 1/79 the hinge moved to the right side. Not sure of the date but pretty sure the hinge moved to the left side with in a year or two after the 1/79 started.

You should be aware that in 73 the tank got smaller and 74 was the first year the tank cover was used. This will not fit a 66 gas tank without doing some mods to widen the cover. A 73-78 gas tank can be made to fit and use a cover but would loose a couple of gallons of capacity.

 

[Trailortrash]

My Jalopy gets a generous 9.8 MPG average. I’ve kept all gas records since I bought it. With the straight 6 sipping fuel like that I don’t believe I can afford to lose fuel capacity so no cover it is! Thank for the feedback.

 

[Trailortrash]

Here is an update on the bodywork/paint. Took over a year to find someone reasonable in price and willing to do the work. I ended up not painting it myself but I think they did a bang up job. You can see in the sides I asked them to not hide the welds from the factory so all the demples are still there. That come at a cost of not every little ding was able to be worked out. I didn’t do the original white (my Jalopy was Pollux orange *shudders*) as the original has a hint of red in it giving it a creamy white color. I opted for 2004-2007 Toyota white. Don’t mind the brown furry creature in the pictures. She feels the need to snuggle everything.

 

[Trailortrash]

And here is the tub about to go out tomorrow...someone a while back mentioned needing bracing for the upper bolt area of the spare tire carrier to the body. I opted to shoddily (my best welding skills) put in two thick steel bars as the back plating for it. Most of the backing plates I looked at online looked quite thin to me. A bit of grinding this evening should make it look questionably decent and the entire interior tub I am having lined with bedliner for ease of cleaning , protection of the metal, and sound dampening.

 

[1969FJ]

View attachment 1763773 View attachment 1763772 View attachment 1763771 View attachment 1763770 View attachment 1763769 Here is an update on the bodywork/paint. Took over a year to find someone reasonable in price and willing to do the work. I ended up not painting it myself but I think they did a bang up job. You can see in the sides I asked them to not hide the welds from the factory so all the demples are still there. That come at a cost of not every little ding was able to be worked out. I didn’t do the original white (my Jalopy was Pollux orange *shudders*) as the original has a hint of red in it giving it a creamy white color. I opted for 2004-2007 Toyota white. Don’t mind the brown furry creature in the pictures. She feels the need to snuggle everything.

I really like the white but I disagree on the Orange from Toyota. To me it was a very nice color and especially with newer style paints , it would look real good. Did you use basecoat/clearcoat or urethane ?

 

[Trailortrash]

So the PO put the new side panels on the jalopy and in doing so looks to me like he replaced the rails on the inside of the tub that the rear quarter panels attach to. It looks to me like he used some square DOM tubing. It’s stout as all get out. Problem is I have to drill through the upper and lower portion of the tubing and I’ll have to through bolt my hard top on. Can anyone show me via pictures how the hard top looks bolted appropriately to the tub? Specifically how the bolts go through the bottom? It’s the only way I can think of to do it. See picture...

 

[Jdc1]

View attachment 1763992 So the PO put the new side panels on the jalopy and in doing so looks to me like he replaced the rails on the inside of the tub that the rear quarter panels attach to. It looks to me like he used some square DOM tubing. It’s stout as all get out. Problem is I have to drill through the upper and lower portion of the tubing and I’ll have to through bolt my hard top on. Can anyone show me via pictures how the hard top looks bolted appropriately to the tub? Specifically how the bolts go through the bottom? It’s the only way I can think of to do it. See picture...

I dont have any pics handy but google "rivnut" . No need to drill both or even tap anything with one of these amazing tools.

 

[thebigredrocker]

The stock rails have a welded nut inside. You position the hardsides on the tub and run a 6mm screw into the rail. Agree with JDC1 rivnuts might be a good option.

 

[thebigredrocker]

No matter what rail fastening sytem you go with, test fit the top prior to drilling. I think it would be wise to include all the various seals in a mock up. The whole shabang...Packing, stake pocket seals, tub lip weatherstrip, lid weatherstrip Would suck to drill rail holes only to later find those holes were slightly off, causing a mis-alignment issue between lid and upper hard side holes. I know it sounds goofy and like overkill. It’s amazing how tight the tolerences become once you throw everything into the mix. Heck, it wouldn’t even hurt to have the front doors weatherstripped and ready for top mockup day.

Heads up on the stake pockets. I found my freshly painted tub had too much paint buildup in the stake pockets. The stakes themselves were also painted. I had to sand inside the pockets and sand paint off the stakes. I needed wiggle room to bolt the top together. Food for thought.

 

[SteveH]

No matter what rail fastening sytem you go with, test fit the top prior to drilling.

x3. Assume nothing about the hard top fitment. Mock it all up completely before every considering paint work.

 

[HelloKitty65]

View attachment 1763773 View attachment 1763772 View attachment 1763771 View attachment 1763770 View attachment 1763769 Here is an update on the bodywork/paint. Took over a year to find someone reasonable in price and willing to do the work. I ended up not painting it myself but I think they did a bang up job. You can see in the sides I asked them to not hide the welds from the factory so all the demples are still there. That come at a cost of not every little ding was able to be worked out. I didn’t do the original white (my Jalopy was Pollux orange *shudders*) as the original has a hint of red in it giving it a creamy white color. I opted for 2004-2007 Toyota white. Don’t mind the brown furry creature in the pictures. She feels the need to snuggle everything.

Who did your body and paint work? I'm in the area and need to get some things done.

 

[Trailortrash]

My cousin suggested I should have the body guys spray bedliner in the rear wheel wells and underside front fenders. Anyone have experience with this? What’s the pros and cons?

 

[1969FJ]

I would completely prime and paint those areas. Then, if I decided to add a liner , the base would be a completely sealed metal. If you put it on bare metal or primer, there is chances of chipping and we all know that is rust.

 

[dad4x4]

The side rail that the hard top bolts to... is there not a piece of flat stock inside of the rail that you can drill and tap? I ask because i replaced both sides of mine with a set from pacol and it is designed to be drilled and tapped...

 

[Trailortrash]

The side rail that the hard top bolts to... is there not a piece of flat stock inside of the rail that you can drill and tap? I ask because i replaced both sides of mine with a set from pacol and it is designed to be drilled and tapped...

I could possibly do that but I suspect my best option is the rivet but method provided the flanges aren’t too thick to effect the mounting of my hardtop.

 

[letterman52]

View attachment 1763778 View attachment 1763777 View attachment 1763776 View attachment 1763775 And here is the tub about to go out tomorrow...someone a while back mentioned needing bracing for the upper bolt area of the spare tire carrier to the body. I opted to shoddily (my best welding skills) put in two thick steel bars as the back plating for it. Most of the backing plates I looked at online looked quite thin to me. A bit of grinding this evening should make it look questionably decent and the entire interior tub I am having lined with bedliner for ease of cleaning , protection of the metal, and sound dampening.

I might have to do the same to the back of where my tire carrier is going. I had wondered about the metal warping there.

 

[thebigredrocker]

Worst case you can punch a larger hole in the packing to negate the rivnut thickness..

Here’s some measurements. These are standard ribbed stainless M6 rivet nuts. I would avoid the low profile rivnuts.

 

[Trailortrash]

Here is an update on the tub...some spots I think I want body reworked but the paint looks good. Single stage urethane. I believe they came from the factory with single stage? The interior of the tub is surprisingly not very dented. I’ve seen some where people must’ve used them as pickups. Spray in liner in the interior of the tub is very nice.

 

[letterman52]

That turned out great. Are you putting the stock heater back in?

 

[Trailortrash]

That turned out great. Are you putting the stock heater back in?

Yep, I am. They both worked when I removed them and the troop heater is just neat.