Builds New Alaskan FJ40 intro thread (1 Viewer)

[samatulich]

I fought the timing gear cover gasket for a bit too. Took me 4 attempts to get it. Now one of the 14mm bolts leaks, but not enough for me to tear it down again. Yes, over tightening those lower bolts will destroy the gasket, ask me how I know.
Keep up the good work

 

[Aussie Alaskan]

Many thanks to @FJ907Warrior for providing me with a operational window washer reservoir. After pulling the switch apart for a good cleaning and figuring out my wiring diagram and that the dash was the ground points I finally got it working. Bring on the muddy trails!

Anybody have a spare cap for this reservoir? Or know of a replacement cap that I can make work with same thread and pitch? Currently it's got what appears to be a spray paint lid.

 

[Aussie Alaskan]

Pulled the driver's seat out and cut a piece of 3/4" rubber gym matting to fit. Took about an hour to get it fitted. Took it for a drive afterwards and there is a noticeable decrease in engine and drivetrain noise. Not a huge improvement, but a noticeable one. It also looks pretty nice and will protect the new paint. It also keeps the floor much much cooler.
And the best part is that I got it for free from a jobsite where they were demo-ing the old matting

The only issue I have with the matting is that it raises your feet up 3/4" and so changes the feel of the pedals. Not a big deal, but it's noticeable.

 

[Aussie Alaskan]

Threw on the spare tire carrier and it was a nightmare. All of my mounting points for the brackets and catch were off. Very frustrating after all the time and precision I used to put the capture nuts exactly where I thought they needed to go. Live and learn. Don't trust everything you read on the internet kids...

Anyways, after some adjustment to the bracket, and new mounting holes in the rear for the catch and the support using SS rivet nuts it fits rock solid. I'll just need to patch the old holes and do some repainting, but otherwise it's good to go.

 

[Aussie Alaskan]

Anybody ever mounted a modern stock Tacoma wheel and tire to an unmodified FJ40 spare tire carrier? The back spacing is different and so I'm wondering if I'll need a spacer or not. I'll be using a stock Tacoma 2018 plus wheel with a 235/85R16 tire.

 

[FJ907Warrior]

Pulled the driver's seat out and cut a piece of 3/4" rubber gym matting to fit. Took about an hour to get it fitted. Took it for a drive afterwards and there is a noticeable decrease in engine and drivetrain noise. Not a huge improvement, but a noticeable one. It also looks pretty nice and will protect the new paint. It also keeps the floor much much cooler.
And the best part is that I got it for free from a jobsite where they were demo-ing the old matting

The only issue I have with the matting is that it raises your feet up 3/4" and so changes the feel of the pedals. Not a big deal, but it's noticeable.

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Owooo I like that

 

[Aussie Alaskan]

Made a connection this weekend. Found a guy who has two FJ40s that are full of parts for the taking. A 1972 and a 1979.

I was able to get a set of the shorter rear jump seats that were in like new condition! Amazing find! I also took the rear heater and some very good condition sun visors.

I laid claim to a few other parts as well on the 1979 FJ40 that I'll have to get later.
Factory radio, dash pads and the like. It was a good day!

 

[Aussie Alaskan]

Jump seats installed!

 

[Aussie Alaskan]

Got the spare tire installed.

I ended up needing a 1.5" spacer because of the different backspacing of my stock 2019-2023 Tacoma wheels vs the stock FJ40 wheels.

 

[Aussie Alaskan]

Pulled the rear heater assembly that I scored from a parts rig the other day apart. It was in pretty good shape overall and just needed a bit of rust sanded down and some new paint and the heat exchanger cleaned out.

Painting it with rust remediator paint/primer first, and then over that will be the pewter paint. Should look and function brand new in just a short while.

 

[Aussie Alaskan]

Rear heater installed. Pretty easy installation and refurbishment of the 1979 heater. Works like a charm.

 

[dajojo1]

Getting the bolt holes for the spare tire mount aligned with the sill and sill plate was a bit of a frustration. I used the sill (1/8" thick side walls) and tapped them instead of welding nuts onto the inside of my sill tubing. In hindsight my diy sill was a great idea until it came time to attach anything to it. I ended up having to strip a corner of it off for the sill plate to fit correctly. And then I had to weld my nuts for chassis attachment inside of the tubing. And finally I had to find ways of welding makeshift nuts to the inside of my sill tubing to connect the spare tire mount to.
Anyways, after getting all of that sorted out I sanded (220g) the bed and liberally coated with POR-15 to seal it.
I've also managed to procure a set of brand new Toyota Tacoma 16"x8" wheels and 235/85r16 tires that will work for the time being. It was just too good of a deal to pass up. I want to run 16" wheels for ease of tire sourcing, but just cant quite stomach spending $1600 (after shipping to AK) on a set of City Racer 16" wheels. Plus another $1000 for the tires. These Tacoma wheels are going to be the new semi-permanent shoes on this FJ40, and fit just fine with a set of 1" spacers.
Bonus picture is one I took last night of the Aurora Borealis above my house. Just a reminder that some of us indeed live in "God's Country"

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Thanks for the bonus picture. It brings back memories from the time I lived in Fairbanks. I am enjoying this thread since I have a new to me 77 FJ40.

 

[Aussie Alaskan]

Thanks for the bonus picture. It brings back memories from the time I lived in Fairbanks. I am enjoying this thread since I have a new to me 77 FJ40.

Feel free to share pics of your rig @dajojo1

 

[Aussie Alaskan]

I want to put this older spare tire carrier on the right side of my rig and weld a basket to it. That will hold 2-3 Jerry cans.
But I'm missing the latch portion of the spare tire carrier. Does anybody have an extra latch and catch sitting around that they would part with? Thanks!

Also has anybody ever seen this done or have pictures of the finished product of what I'm trying to do?

 

[Aussie Alaskan]

Began fabrication on my new Jerry can holder.

This frame will bolt onto the factory right hand side spare tire carrier using existing capture nuts and will result in 0 permanent modifications to the factory spare tire carrier.

 

[Aussie Alaskan]

A couple more pics.

 

[RevISK]

That’s badass, simple and efficient.

 

[Aussie Alaskan]

Pulled out my heater box and did a full teardown. Any rust was sanded off and then fresh rust inhibiting paint was applied. The heater core was blown out with pressurized air to remove all the fuzz that was impeding air flow. New SS screws were used to reassemble the unit and bolt it back into the rig.

The difference in heat and defrost air flow is impressive. Before, all the fuzz was blocking 50-75 percent of the airflow, but now it's blowing thru really well and heats up the cab nicely.

 

[Aussie Alaskan]

Updated pics from the Jerry can holder installation.

Using an older style right hand side spare tire carrier I mounted a custom rack/basket to it. Seems to work well enough. Day to day driving isn't what this is for. Eventually I'll be driving this rig down to the States from Alaska and there are places along that drive where gas is scarce and very expensive. The extra gas that I can carry will help take some of the risk of running out in the backwoods of British Columbia out of the equation.

 

[Aussie Alaskan]

I reinforced the top hinge area for the spare tire carrier with a plate of 16 gauge steel. I'll also put some big fender washers there behind each capture nut and then weld it in place. Fingers crossed it will be strong enough to support 70-80 lbs of gas, plus carrier. Should easily be capable of road driving, and probably is strong enough for some trails as well.