Builds New Alaskan FJ40 intro thread (2 Viewers)

[Aussie Alaskan]

Finally was able to find and purchase a spare tire hook bracket for my Jerry can holder setup. Works like a charm and it holds everything tight with no rattle. I used M8 rivet nuts and SS M8 bolts.

Up here in the Arctic we are beginning to feel the cold embrace of winter with 7.1" of snow on the ground so far.

My heated seats are beginning to shine! So glad I installed those when I redid the seats

 

[Aussie Alaskan]

Pulled the roof off yesterday.

Expected to see quite a bit of rust and rot, but was extremely pleasantly surprised to find minimal surface rust and only a few spots of significant putting.

 

[Aussie Alaskan]

Minimal rust, and some pretty original paint.

 

[Aussie Alaskan]

Almost zero rust underneath the front windshield.

A few spots of some deep pitting, but only a single pinhole after wire wheeling all the red away.

Should I try to level out the pitting with some jbweld or similar? Or just put some rust inhibiting paint on it and call it good?

Open to suggestions here.

 

[samatulich]

I like it. I need to do the same. Pull the top off and evaluate. Keep up the good work.

 

[Aussie Alaskan]

After wire wheeling the drip metal and cleaning all the loose rust from the surface. I painted it with POR-15 rust inhibiting paint. I'll go back over the top of this with some Rustoleum marine grade top coat white paint to match the roof.

I began to sand the fiberglass roof itself. It's got lots of tiny cracks and circles the appeared during the sanding process as well as a large fiberglass patch I had not noticed previously. I doubt I'll stand the patch down all the way and it'll more than likely still be noticeable if someone ever got on a ladder and looked closely enough. Good thing it's basically right on the top of the roof and out of sight for the most part.

 

[Aussie Alaskan]

First coat of paint on the sanded and prepped top.

Also painted the underside of the drip rail. Planning on two coats on everything of the cygnus white.

I'm using Rustoleum marine topside paint, with ACME hardener and got it custom tinted by the local paint place. A bit of acetone to thin it and rolled it on.

 

[Crunkenstien]

First coat of paint on the sanded and prepped top.

Also painted the underside of the drip rail. Planning on two coats on everything of the cygnus white.

I'm using Rustoleum marine topside paint, with ACME hardener and got it custom tinted by the local paint place. A bit of acetone to thin it and rolled it on.

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Dang that looks FRESH!

P.s. been meaning to introduce myself for a little while. I live in Cordova, AK and am in the process of setting up my garage to begin a frame-off on my 40. Really been enjoying your posts and great pictures. I will start documenting it here like you have once everything is ready to commence.

Also, RE: other Alaskan 40s. I know one of the pilots here in town has one, there is a really clean one I always see parked outside of the Guardian Flight facility at the Juneau airport, and there is a house in Petersburg that has 2 being reclaimed by nature in the driveway.

Also, my neighbor has this crazy contraption made from a 60 series.

 

[Aussie Alaskan]

Dang that looks FRESH!

P.s. been meaning to introduce myself for a little while. I live in Cordova, AK and am in the process of setting up my garage to begin a frame-off on my 40. Really been enjoying your posts and great pictures. I will start documenting it here like you have once everything is ready to commence.

Also, RE: other Alaskan 40s. I know one of the pilots here in town has one, there is a really clean one I always see parked outside of the Guardian Flight facility at the Juneau airport, and there is a house in Petersburg that has 2 being reclaimed by nature in the driveway.

Also, my neighbor has this crazy contraption made from a 60 series.

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What is the current condition of your 40? Care to share some pics of it?

Thanks for the encouragement. It's quite a bit of work, but it's been rewarding!

 

[Crunkenstien]

Well the feeling is mutual. Your posts have been helping me feel encouraged to tackle my project. Idk how long I’ll have this airplane hangar to work in, so now’s the time if there ever was one.

Once I get started I will post a full rundown of what the starting condition looks like, but here are a few from this summer, and some pics of the interior from last summer, which hasn’t had any work since then. Sorry I don’t have any engine bay pics handy.

 

[Aussie Alaskan]

Well the feeling is mutual. Your posts have been helping me feel encouraged to tackle my project. Idk how long I’ll have this airplane hangar to work in, so now’s the time if there ever was one.

Once I get started I will post a full rundown of what the starting condition looks like, but here are a few from this summer, and some pics of the interior from last summer, which hasn’t had any work since then. Sorry I don’t have any engine bay pics handy.

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Looks like it's in great shape!

Any previous restoration done before you?

 

[Crunkenstien]

Looks like it's in great shape!

Any previous restoration done before you?

Thanks!

Previous owners put aftermarket headers on it and partially de-smogged it in the process (it's a California model). They also replaced the rear quarterpanel but did a terrible job on the paint and it is rusting through again, and they reupholstered the seats.

I bought it in 2009. Since I've owned it, I have completed the de-smog, had the transmission and transfer case rebuilt, replaced the clutch with a heavy duty one, replaced the cooling system, had the original radiator taken apart, rodded and re-soldered, and rebuilt the rear drum brakes. I've also done loads of small jobs: replaced the rear brake lines with stainless ones, replaced the starter, replaced fuel lines, rebuilt brake master cylinder, installed a piece of exhaust pipe where the PO had used flex pipe to mate the headers to the original exhaust system, replaced the exhaust mount, replaced the weatherstripping, Replaced the front bumper (to one that would accept the winch), replaced the tail lights, and repainted the rear bumper.

Planning to repaint the frame and powertrain with POR15, run a new wiring harness, replace the entire exhaust, rebuild the parking brake, replace the rest of the brake lines, repair rust on the body, paint the body Breathe Green, re-glass and paint the roof, and install a headliner.

 

[Aussie Alaskan]

Thanks!

Previous owners put aftermarket headers on it and partially de-smogged it in the process (it's a California model). They also replaced the rear quarterpanel but did a terrible job on the paint and it is rusting through again, and they reupholstered the seats.

I bought it in 2009. Since I've owned it, I have completed the de-smog, had the transmission and transfer case rebuilt, replaced the clutch with a heavy duty one, replaced the cooling system, had the original radiator taken apart, rodded and re-soldered, and rebuilt the rear drum brakes. I've also done loads of small jobs: replaced the rear brake lines with stainless ones, replaced the starter, replaced fuel lines, rebuilt brake master cylinder, installed a piece of exhaust pipe where the PO had used flex pipe to mate the headers to the original exhaust system, replaced the exhaust mount, replaced the weatherstripping, Replaced the front bumper (to one that would accept the winch), replaced the tail lights, and repainted the rear bumper.

Planning to repaint the frame and powertrain with POR15, run a new wiring harness, replace the entire exhaust, rebuild the parking brake, replace the rest of the brake lines, repair rust on the body, paint the body Breathe Green, re-glass and paint the roof, and install a headliner.

A simple weekends worth of work left to go...

Sounds good man. Look forward to seeing updates.

 

[Aussie Alaskan]

Pulled the carpet out of the roof and installed about 1/8" of cotton padding and then some cream vinyl. The vinyl was spendy ($150) and I'm not sure it was worth DIYing the headliner after it was all said and done. Live and learn I guess. It looks fine, but it didn't cost much less than ordering an new original looking headliner.

Ran a bead of sika flex on the drip rail and set the roof down on it. Then worked my way around the roof rivetting the two together. I'm using SS pop rivets because I'm not a purist and I think it'll look perfectly fine when installed.

Once I'm done with the rivets I'll run another bead of the sika flex over the gap between the roof and the edge of the drip rail. After that cures, maybe I'll do a bit of paint touch-up on the visible edge of the drip rail and it'll be done!

 

[Aussie Alaskan]

Cleaned all the rust off the metal pieces that go above the rear and front doors. Sprayed with rust inhibiting paint and metal etching primer.

Also finished riveting the roof to the drip edge and ran a bead of sika flex around the edge to totally seal it up.

 

[Aussie Alaskan]

Painted the windshield visor with a can of matching OEM paint I got from CCOT and reinstalled it. Looks ok for now, but I may adjust it somewhat for the final install after the whole body gets new paint.

I ordered new roof seals from City Racer and with some help was able to lift the roof back in place after installing the metal pieces over the doors.

Maybe in natural light the roof will look better, but in my dark garage it definitely looks too green. Fingers crossed it just an illusion since I had the paint matched to the Cygnus White original color.

The new headliner really freshens/brightens up the interior and makes the rig really look alot nicer from the inside.

 

[Aussie Alaskan]

Ran the wiring to have a functional dome light finally. Just in time for the dark months of Alaskan winter. I also bought some light blue LED strip lights (12V) and wired them in with the dome light to provide extra interior illumination. I hid these light strips along the inside of the drip edge of the roof. The were self adhered with 3M glue strips, and are totally invisible. They definitely further brighten up the interior.

Finally got around to installing the rear bumperettes. They were a bit mangled and bent, but I persuaded them to straighten up with the help of my 8 lb sledge hammer. Once they were as good as new I sanded away decades of crud and paint and applied some self etching automotive primer and some OEM (ish) grey/silver paint.

 

[Aussie Alaskan]

I'm looking for a set of front seat belt buckles. I've got the belts and retractors installed, but I'm missing the buckles/receptacles.

If anybody has an extra set lying around let me know please.

 

[Chungas Revenge]

Summer…..

 

[Aussie Alaskan]

The PO drilled out extra holes for the front side emblems and so I am patching them and welding them closed. Also tackling some surface rust between the front fenders and the side pieces and then priming with rust inhibiting paint. Looks like this is the first time these pieces have ever been separated and there is no paint between them. Only primer, and rust.

Noticing a leak on my garage floor from the front dif. Got a new seal from JToutfitters and will be installing that tomorrow hopefully.