- Thread starter
- #121
Yes, those are going into the rubbish bin very soon! We have new leaf springs going in and some shackles that are about half the length of those that are a stronger H shaped design, along with all new bushings.
Builds My Hawaiian 1975 Fj40 Resto-resurrection
- Thread starter Aloha Jen
- Start date
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- Thread starter
- #122
After the first test drive, it became very clear that that brakes were nowhere near safe. Upon further inspection while having the 40 on four jack stands to let the wheels spin freely, the rear tires would keep spinning while applying brakes. The decision was made to do a complete overhaul of the brake system.
Replacing all the soft lines was a given, but some of the brake hard lines were rusty and a little sus looking, so complete replacement of all the hard lines was determined to be necessary.
Brake master cylinder and brake booster had seen better days, so new ones were purchased as well as most other brake components to refresh the system.
Used the fsm as well as this forum to set up the new booster. Tried to match the old boosters push rod length as a starting point. May have to readjust once everything is back on the truck.
Replacing all the soft lines was a given, but some of the brake hard lines were rusty and a little sus looking, so complete replacement of all the hard lines was determined to be necessary.
Brake master cylinder and brake booster had seen better days, so new ones were purchased as well as most other brake components to refresh the system.
Used the fsm as well as this forum to set up the new booster. Tried to match the old boosters push rod length as a starting point. May have to readjust once everything is back on the truck.
- Thread starter
- #123
All the brake hard lines were removed from the 40 and used them as templates to bend up new lines. We decided to use a NiCopp brake line at the recommendation of many on this forum and bought a mid range priced flaring tool that had decent reviews. After a couple test flares with the new flaring tool, we (both of us brake line bending virgins) attempted to start bending some lines!
The NiCoop line proved to be pretty straight forward to flare and was very easy to bend. With a cheap brake line bending tool, a metal pipe and an aerosol can, all the bends and turns were copied from the old lines.
Me trying to be a professional brake bender! I mostly only did some of the tweaking to match the old lines and was on brake nut reminder duties before a line was flared!
The long runs along the firewall and frame proved to be the easiest to make fit. Although the firewall ones have a lot of bends, they seemed to have more leeway to make fit. It was the short lines that needed constant tweaking and much more precise measurements to make fit.
The NiCoop line proved to be pretty straight forward to flare and was very easy to bend. With a cheap brake line bending tool, a metal pipe and an aerosol can, all the bends and turns were copied from the old lines.
Me trying to be a professional brake bender! I mostly only did some of the tweaking to match the old lines and was on brake nut reminder duties before a line was flared!
The long runs along the firewall and frame proved to be the easiest to make fit. Although the firewall ones have a lot of bends, they seemed to have more leeway to make fit. It was the short lines that needed constant tweaking and much more precise measurements to make fit.
1911
chupacabra
This tool makes it easy to get the booster pushrod length perfect:
Amazon product ASIN B079QGXY55
Highly recommended. Don't worry that it says it's for Corvettes; works on Land Cruiser boosters too.
Your flares look good.
- Thread starter
- #125
Thanks, I was trying to to do it all by just carefully measuring. I just ordered from Amazon, will be nice to get it exact!
- Thread starter
- #126
Needed to install the booster and master cylinder in order to test fit the newly bent firewall brake lines. Looks pretty good all back together, but needs to come back off in order to treat/paint the proportioning valve (I think that’s what it’s called) that attaches to the booster. Will also clean up and treat any rust on the firewall before the brake lines go back in.
Ordered some new tires for the 40. Had never purchased tires through Amazon before, but they offered free delivery to my house so I figured I’d try it out. Sure enough, the UPS lady dropped all five 33x10.5xr15 BFG AT tires in front of my garage a few days later!
Also painted up the wheels with a fresh coat of gloss smoke gray. Will have a local tire shop mount the new tires to them soon.
Will be really nice to get rid of the hideous wheel and tire combo the PO put on and get back to the OEM wheel/tire combo with some 40 hubcaps to go with them!
Other then that, still finding plenty of time to enjoy the sunny weather in my other cruisers! Hope you have a good weekend!!
Ordered some new tires for the 40. Had never purchased tires through Amazon before, but they offered free delivery to my house so I figured I’d try it out. Sure enough, the UPS lady dropped all five 33x10.5xr15 BFG AT tires in front of my garage a few days later!
Also painted up the wheels with a fresh coat of gloss smoke gray. Will have a local tire shop mount the new tires to them soon.
Will be really nice to get rid of the hideous wheel and tire combo the PO put on and get back to the OEM wheel/tire combo with some 40 hubcaps to go with them!
Other then that, still finding plenty of time to enjoy the sunny weather in my other cruisers! Hope you have a good weekend!!
- Thread starter
- #127
Can’t believe it’s been over a year since my last update, I really need to try harder to stay up on the build progress.
The whole brake system overhaul was finished up. All new nickel/copper hardlines installed as well as OEM soft brake lines. Rotors were still within acceptable specs so we’re the only things not replaced on the front disc brakes.
The whole brake system overhaul was finished up. All new nickel/copper hardlines installed as well as OEM soft brake lines. Rotors were still within acceptable specs so we’re the only things not replaced on the front disc brakes.
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- Thread starter
- #130
Metal and body work progressing along. New metal was welded in where the structure was compromised, fender supports were beefed up a bit.
Rear quarter panels were in rough shape, PO had patched in a bunch of panels. It really needs a full 3/4 tub replacement, but this isn’t a showroom restorations, so we just cleaned up, strengthened the metal where needed and used body filler to even out as best as possible.
We figured we could get another 10 years easy out of the rear quarters and fenders, before needing to replace the tub. Doing that now is just too much work/time/money for something we just want back on the road for a fun beach cruiser.
Rear quarter panels were in rough shape, PO had patched in a bunch of panels. It really needs a full 3/4 tub replacement, but this isn’t a showroom restorations, so we just cleaned up, strengthened the metal where needed and used body filler to even out as best as possible.
We figured we could get another 10 years easy out of the rear quarters and fenders, before needing to replace the tub. Doing that now is just too much work/time/money for something we just want back on the road for a fun beach cruiser.
- Thread starter
- #134
After assuming that all/most of the mechanical work was done, the discovery of a broken off thermostat bolt snowballed into a bunch of shiny new parts and improvements!
Fresh new alternator from CityRacer.
New housing, thermo and gaskets along with a fun clutch addition.
Trying to understand how it all works
.
Fresh new alternator from CityRacer.
New housing, thermo and gaskets along with a fun clutch addition.
Trying to understand how it all works
. - Thread starter
- #136
With the bodywork complete, my garage was converted to a pretty sweet homemade paint booth. It kind of resemble a Dexter kill room (if you get the reference), but functioned as it should have for a garage paint job. Decided to go with Dune Beige for the final color.
- Thread starter
- #137
I even attempted to paint a few pieces. Did pretty good for my first time, with minimal drips and paint sags.
A few coats of bedliner was also applied. Normally I don’t think I would prefer bedliner on the interior tub, but the PO had done it previously so the decision was made to just recoat it.
First time out in the full sunshine with the new paint.
A few coats of bedliner was also applied. Normally I don’t think I would prefer bedliner on the interior tub, but the PO had done it previously so the decision was made to just recoat it.
First time out in the full sunshine with the new paint.
- Thread starter
- #139
As you can imagine, shipping to Hawaii can be a problem sometimes, especially with big heavy springs. So I ordered from 4 Wheel Parts at there store here on my Island.
- Thread starter
- #140
Hard to believe this is where my cruiser started a few years ago with these hideous front and rear tube bumpers.
The PO had removed the bumper supports to fit these monstrosities, so had to source new/used parts. Brandon from Classic Cruisers in CO found me the side and top bumper supports as well as new chrome carriage bolts. Bumper and front license plate holder is new from Toyota.
The PO had removed the bumper supports to fit these monstrosities, so had to source new/used parts. Brandon from Classic Cruisers in CO found me the side and top bumper supports as well as new chrome carriage bolts. Bumper and front license plate holder is new from Toyota.
