Builds New here, no idea where to start.

[Nader]

Installed my "Jordanian" door handle. Glad I got the OEM. Aftermarket ones don't have the teeth that grip the latch mechanism doohickey that also has teeth. Took a little wrench gymnastics. Wrenchnastics! This new handle is a game changer for me. No more climbing over the gear selector and transfer case lever like a, uh, a guy who climbs over levers and whatnot. Behold:

 

[Nader]

The dusty and crusty actuating arms and levers benefited from a lubing. I'm really liking TriFlow these days. Been around the block with Kroil, WD-40, PB-Blaster, and home-brew acetone+ATF, but I like this TriFlow best.

For myself, these little projects benefit from a little mental lube. Revisited this Bud Light "Platinum" with its higher alcohol content of 6%. Forgot how bad it tastes, but it has a kick, especially on an empty stomach.

 

[Nader]

Did some more odds'n'ends. Dialed back the 1200 rpm idle and 27° advance (thanks, new timing light!), recrimped a wire or two, and cleaned up the crusty headlight switch. Doused it in CRC electric contact cleaner, then followed by a burst of Tri-Flow. Nice and smooth now both plunging and rotating. Noticed the knob's illuminator bulb was burned, so I ordered the correct mini bayonet-based bulb in a green LED. Cool.

 

[Nader]

But all is not well in Nader's slo-mo rolling restoration. The original faded, brittle and broken plastic cover to the 8274 winch needed to go. I found this fabricator on eBay selling these cool alyoominium covers, so I got one of those. But just my luck, he sends me one with an "M" on it. Why does this always happen to me?

 

[ginmtb]

But all is not well in Nader's slo-mo rolling restoration. The original faded, brittle and broken plastic cover to the 8274 winch needed to go. I found this fabricator on eBay selling these cool alyoominium covers, so I got one of those. But just my luck, he sends me one with an "M" on it. Why does this always happen to me?

View attachment 1439712 View attachment 1439713

Not a simple flip?

 

[Nader]

After getting over the horror of the wrong-lettered winch solenoid cover, I turned my attention to the headlight bezel. Took a while for me to learn that these didn't come with chrome bezels, and that they had a correct orientation.

So I found a crusty white bezel at Stan Mitchell's (people in the PNW might be familiar with his stash). Sanded and painted, but it's still ugly enough to match the rest of the heap. I need to repurpose the chrome bezel. I wonder if the wife will mind. Wonder if she'll even notice...

 

[Nader]

I've commented before how I hate electrical problems. Paradoxically, I enjoy running new wiring. Because it's under my control, and I can use very good materials and techniques. So I dug out some of my materials from previous projects, and set up shop in my living room. No complaints from the better half, because I married well .

I redid the major battery leads including the winch, and used welding cable for that. Got to put my hydraulic crimper to use again, which is always good. I also wired up a set of cheap LED fog lights. Man, say what you want about Chinese stuff, but you get a lot for your money when it comes to these LED lights. These were about $30/pair off Amazon. All machined aluminum and seems pretty stout so far. I did a Youtube video on its installation.

 

[Nader]

Oh, here's the Youtube video.

 

[Flatlanderfj40]

Nice upgrade. Keep checking off the list.

 

[Nader]

First race of the season is next weekend. I keep the car in a shed in the backyard, and have to drive up my hill to get to the driveway to start prepping and loading it into the trailer. I couldn't get the race car up the soggy hill on treadless race tires, you can see I tore up the lawn on the first attempt. So I did what any winch-equipped FJ40 owner would do. Score one for the Landcruiser! (I know I forgot to put a blanket over the cable.)

 

[Nader]

Welp, racing weekend was fun. The car ran great until the last couple of races on Sunday when the throttle was sticking open. I did a bandaid fix with a stronger throttle return spring on the carb linkage, but that didn't last. Had to call it quits a little early. Weber carbs...(side-draft DCOE, not DGV). See hilarious pic of Webers on Weber. Okay, maybe not so hilarious. Amusing? No? Clever? Stupid? Man, tough crowd.

Before I start dissecting the Webers, I want address the exhaust fumes in the cabin I've been suffering in FJ40. I recently bought some Not-Freeborn Red (Subjugated Red?) gaffer's tape to seal off the rust holes, in case that's where the fumes are finding their way into the cabin. Expensive stuff, about $15/roll of what is essentially cloth-backed duct tape.

I think it worked. I was able to drive a few miles without getting a headache and feeling verrrry sleeeeepy.

Man, I think this truck is getting prettier by the week! I should buy more rolls of tape to do the whole car. But at $15/roll, it may end up costing more than a decent re-tub+paint job.

 

[Nader]

Consulted with Torfab, I'm planning on having them help me with restoring this thing once and for all. Regarding the exhaust, the nice worker there looked over my truck and thought there was a muffler leak causing my cabin fume issue.

So I took it to my local muffler shop, with whom I've had generally good experience. There's a new young guy seemingly in charge there, who seems earnest and is a Toyota fan himself. Told me about his mid-80's Toyota truck he's restoring. He seemed to take a special interest in this old FJ40, and said he wants to do up the system himself, "Because it's a classic, and to make it nice."

He checked it out himself, and confirmed that the muffler was split, but on the backside hidden from view. He initially pushed a Magnaflow muffler, which they sell a lot of. I like Magnaflow a lot, I have one on my race car and one of my sporty street cars, but but I rejected it in this application because this truck is loud enough, and I wanted it stock. I wanted a full stainless system, but he couldn't get the muffler in stainless, and said aluminized steel would yield better bends and still have a lifetime warranty. Cheaper, too. So I agreed to that.

Several days later when it was done, he called me to pick it up. Excitedly, I rushed over and had a look. It's all really good, except for where he welded up the forward section of pipe to the old rusty system, just short of the header flange. I was a bit disappointed by this, and his excuse is that the flange wasn't leaking and it was easier to weld up this way. I paid for the work, headed home, and was pleased with the quieter exhaust and lack of poisonous fumes in the cabin. But I still couldn't get over the ugly shortcut he took in welding it up.

At home, I got a closer look, and decided this new system which stopped short of the headers and utilized old rusty pipe was unacceptable. So I took it back, told him how janky it looked, reminded him how he said he'd "Make it nice," and insisted he redo it from the muffler neck forward to include a fresh flange at the header. No additional splices or sleeves. My plan is to restore this 40, including the headers which will eventually be removed and ceramic-coated. I reminded him of this as well.

I was an unhappy customer, but I don't think I was a jerk about it. Have a look. Ignore my stupid finger in the lens (I was mad!). What do you think?

 

[fj40cruisin]

I agree with your decision. I would have him redo it as well. I have learned that you need to babysit the work being done on occasion to make sure it gets done right.

 

[rrv333]

I'd done the exact same thing. You paid for a new exhaust not a 3/4 new exhaust.

 

[Nader]

Thanks for the feedback, fellas. I swear, this kind of auto shop experience has been the norm for me for the last 10 years. It has me wondering if it's possible for one person to be such a magnet for bad service, or if I'm just picky. Has service in general been in a decline for the rest of you?

Because of these experiences, I've gradually learned to do everything myself from welding to machining (I have a small shop at my house), but like I've mentioned before, I just don't feel like I have it me to do more fabrication or another full restoration, hence the farming out of bigger jobs on this one. When it comes time to have work done, I try to seek out experts in their fields. I thought a reasonably well-reputed exhaust shop that does this stuff day in and day out could knock it out without any complications or issues.

Hijacking my own thread, I have some experience building an exhaust. Aside from the headers, I've fabricated a cone exhaust for my race bike, and also the side-dump megaphone exhaust on my race car. There's that Magnaflow I mentioned. I even welded up its flanges! Geez.

 

[Kleatus]

No I don't think you're picky. Good help is becoming a rare commodity. The last time I paid for something was a battery install in the wife's rig while I was working across the country. I came back and they had put one about 3 sizes too small in, because "that's what the computer said" even though the original battery, the hold down and tray said otherwise. I once had a "reputable" exhaust shop put Tek screws through the subframe of my E30 doing exhaust too; that made my blood boil.

No fun having to pay someone to do what you know you can do, but when it's a time thing you gotta be prepared to pay them according to what your time is really worth if you want work that's up to your standards.

Nice work and nice truck - working on a '76 myself. At least you can drive yours!

Using hydraulic crimpers and tri-flo, you must have at least dabbled in the electrical world.

 

[thebigredrocker]

He won't last long doing work like that. Good call making him do it right.

Damn those lights are bright! Cool video. I thought I heard a fusion of Les Claypool and John Wayne Band around the 1 minute mark. Who is that?

Next video needs to be sounds of your race car, race bike and 40.

 

[Nader]

He won't last long doing work like that. Good call making him do it right.

Damn those lights are bright! Cool video. I thought I heard a fusion of Les Claypool and John Wayne Band around the 1 minute mark. Who is that?

Next video needs to be sounds of your race car, race bike and 40.

That's funny, bigredrocker, I was wondering when someone would comment on that music. I wanted background music to the video, no narration as the work is self-explanatory. Wasn't comfortable ripping off someone else's music. So all three tracks (looped) are original songs I cooked up on that Garage Band app that comes with the Macbook. "Ants in my Pants" is a phrase I like, turned into music. Thought it needed some banjo. And also a Michael Jackson tribute. "Supa Baldo" is a tribute to my recently deceased German Shepherd named Baldor, sung by my wife. We say "Damn" a lot, so that made it into the song. That fake stadium track was just us learning how to use the app, and screwing around. So there it is.

As for the bike and car, I do have videos. The bike selfie is on my race KTM 560 SMR, not the Honda (despite what my leathers say). It's a motard, which is why my arms are splayed way off to the sides. The car video was my moment of glory leading a race until I realized I was out of tires at the first hard turn.

 

[Nader]

...I once had a "reputable" exhaust shop put Tek screws through the subframe of my E30 doing exhaust too; that made my blood boil...

Using hydraulic crimpers and tri-flo, you must have at least dabbled in the electrical world.

Hi Kleatus. You and I seem to be neighbors. I also have an e30 (has a Magnaflow, too). Electricity is still a mystery to me, I don't pretend to know anything beyond basic circuitry. Diodes and resistors are above me. But I do enjoy running fresh circuits using marine grade wire, and excellent crimps with solder, then covered in heat shrink. Wired the whole race car from scratch like that. Recently discovered these new marine terminals that have a heat shrink sleeve built in, so I've been using those. Lately been dabbing DeOxit on everything, too. That hydraulic crimper was some of the best $60 I've ever spent at Harbor Freight.

My latest wiring project is this portable air and power box. I gave it its own thread in the "Power Systems" subforum. Still need to clean up the wiring a bit once I'm satisfied with the location of all the components.

Homemade, portable air and power, strong like bear!

 

[Nader]

Okay, I picked up the 40 after the second attempt at an exhaust. Check it out. A big sweeping bend below the frame rails. So if I ever do some real 4-wheeling, I can pinch it shut and be left stranded in the middle of nowhere. Awesome! I'm done with this place. I'll have this fixed some time later when I'm less despondent. At least there's a new flange on there. *Sigh*